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I N S T R U CT I O N M A N UA L
GCU Series
Refrigerated Type Compressed Air Dryers
Models: GCU-0.5, GCU-0.75, GCU-1.0, GCU-1.5, GCU-2.0, GCU-2.5, GCU-3.5
F O R M N O . : 5 0 0 3 3 4 3
R E V I S I O N : 0 4 / 2 0 1 5
R E A D A N D U N D E R S TA N D T H I S M A N UA L P R I O R TO O P E R AT I N G O R S E R V I C I N G T H I S P R O D U CT.
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Summary of Contents for SPX Hankison GCU Series
- Page 1 I N S T R U CT I O N M A N UA L GCU Series Refrigerated Type Compressed Air Dryers Models: GCU-0.5, GCU-0.75, GCU-1.0, GCU-1.5, GCU-2.0, GCU-2.5, GCU-3.5 F O R M N O . : 5 0 0 3 3 4 3 R E V I S I O N : 0 4 / 2 0 1 5 R E A D A N D U N D E R S TA N D T H I S M A N UA L P R I O R TO O P E R AT I N G O R S E R V I C I N G T H I S P R O D U CT.
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Page 2: Table Of Contents
CONTENTS GENERAL SAFETY INFORMATION ................1 RECEIVING, MOVING, AND UNPACKING ..............1 1.0 INSTALLATION 1.1 Location ........................2 1.2 Mounting ........................3 1.3 Piping Connections ....................3 1.4 Electrical Connections ....................3 1.5 Moisture Separator ....................3 1.6 EDD Operation ......................3 2.0 OPERATION 2.1 Minimum/Maximum Operating Conditions ............. -
Page 3: General Safety Information
GENERAL SAFETY INFORMATION RECEIVING, MOVING, AND UNPACKING 1. PRESSURIZED DEVICES: A. RECEIVING This equipment is a pressure containing This shipment has been thoroughly checked, packed and device. inspected before leaving our plant. It was received in good condition by the carrier and was so acknowledged. •... -
Page 4: Installation
IMPORTANT: READ PRIOR TO STARTING THIS EQUIPMENT 1.0 INSTALLATION 1.1 Location A. For typical placement in a compressed air system, see drawing. B. Air compressor intake – Locate air compressor so that contaminants potentially harmful to the dryer (e.g. ammonia) are not drawn into the air system. C. -
Page 5: Mounting
1.2 Mounting B. Models 0.5 & 0.75: Separator has a knurled fitting with flexible drain tubing Mount the dryer on a level solid surface. Holes are provided attached. Be sure knurled fitting is tightened by turning in the dryer base to permanently mount the dryer to the counter-clockwise before operating dryer. -
Page 6: Operation
B. The condensate flows through the feed line (1) into NOTE: If there is no power to the control board for the condensate drain and accumulates in the housing a period of two weeks or more, it may return to the (2). - Page 7 b. Press ‘ESC’ at any time to return to the Main Menu. CONTROL PANEL NOTE: On dryers with air-cooled condensers, regular condenser cleaning is recommended. Dirtiness of ambient air at installation site will determine frequency of service. Typically once a month is recommended.
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Page 8: Using The Rs-485 Port Connector (J8)
To reinstitute SCHEDULED MODE, push ‘Schedule On/Off TEMP SENSOR - Occurs if the temperature and Enter’ button. sensor circuit is open or shorted. If open, none of the LED’s in the temperature display will IMPORTANT: Dryer must be energized 24 hours before be illuminated. -
Page 9: Using The Usb Host Feature (J7)
2.4 Using the USB Host Feature (J7) USB Event History The EMM connect is equipped with a USB Host port located When a USB flash drive is installed in the controller it will at J7 on the control board which allows for the connection begin to automatically log all dryer events: power loss, of a USB flash drive. -
Page 10: Using The Ethernet Feature (J3)
Firmware updates for the EMM connect can be performed via the USB flash drive. In order to perform a firmware update; place the image.hex and lang.hex files provided by SPX in the root folder of a USB thumb drive. The energy savings page shows the estimated annual energy... - Page 11 Figure 3: Event History The dryer settings screen allows the customer to view/edit various dryer set points and setup E-mail alerts that will send an e-mail to up to 3 different e-mail addresses whenever an alarm or warning occurs on the dryer. Figure 5: Settings The dryer scheduler page allows the customer to view/edit the daily start/stop times that will be used when operating...
- Page 12 Modbus Registers Holding Register Reference Address Name Units Description 40001 0x0000 DRYER_STATUS Status ID Status ID for the dryer 40002 0x0001 ALARM_STATUS Flag Bits Alarm flag bits 40003 0x0002 WARNING_STATUS Flag Bits Warning flag bits 40004 0x0003 RESERVED Reserved 40005 0x0004 SERVICE_TIMER Hours...
- Page 13 Modbus Register Details Page 1 of 3 Dryer Status Register 40001 Decimal Description 0x0000 Standby 0x0001 Fixed 0x0002 0x0003 Reserved 0x0004 Reserved 0x0005 Reserved 0x0006 Reserved 0x0007 Reserved Dryer Alarm Flags Register 40002 Mask Description 0x0001 High Discharge Temperature 0x0002 High Refrigerant Pressure 0x0004 Low Refrigerant Pressure...
- Page 14 Modbus Register Details Page 2 of 3 Dryer Model Register 40017 Decimal Description 0x0000 Non-Cycling MRD 0x0001 Non-Cycling LRD 0x0002 ES-MRD 90 0x0003 ES-MRD 120 0x0004 ES-MRD 140 0x0005 ES-MRD 190 0x0006 ES-MRD 245 0x0007 ES-MRD 280 0x0008 ES-MRD 360 0x0009 ES-MRD 450 0x000A...
- Page 15 Modbus Register Details Page 3 of 3 UI Language Register(s) 40021 Decimal Mask Description 0x0000 English 0x0001 Spanish 0x0002 French 0x0003 German 0x0004 Portuguese 0x0005 Italian 0x0006 Polish 0x0007 Danish 0x0008 Dutch 0x0009 Norwegian 0x000A Finnish 0x000B Swedish 0x000C Czech 0x000D Reserved 0x000E...
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Page 16: Maintenance
3.0 MAINTENANCE 3.1 Daily Models 0.5 & 0.75 A. Check separator to make sure the automatic drain is discharging. 3.2 Weekly Head A. Blow down the separator weekly by pushing the test button on the control panel. Bowl O-Ring 3.3 Monthly A. -
Page 17: Troubleshooting Guide
4.0 TROUBLESHOOTING GUIDE: MODELS 0.5 & 0.75 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION A) Water downstream of dryer 1. Residual free moisture remaining in Blow out system with dry air downstream pipelines 2. Air bypass system is open Check valve positions 3. -
Page 18: Models 1.0 - 3.5
TROUBLESHOOTING GUIDE: MODELS 1.0 – 3.5 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION A) Water downstream of dryer 1. Residual free moisture remaining in 1. Blow out system with dry air downstream pipelines 2. Air bypass system is open 2. Check valve positions 3. -
Page 19: Reference Sizing
5.0 REFERENCE SIZING Determining dryer capacity at actual operating conditions To determine the maximum inlet flow capacity of a dryer at various operating conditions, multiply the rated capacity from Table 1 by the multipliers shown in Table 2. Example: How many scfm can an air-cooled model 1.5 handle when compressed air to be dried is at 200 psig and 100°F;... -
Page 20: Engineering Data
ENGINEERING DATA Models 0.75 Air System Data Maximum / Minimum Inlet Air Pressure (compressed air at inlet to dryer) 232 psig (16 barg) / 30 psig (2 barg) Maximum / Minimum Inlet Air Temperature (compressed air at inlet to dryer) 120°F (49°C) / 40°F (4.4°C) Maximum / Minimum Ambient Temperature 110°F (43°C) / 40°F (4.4°C) -
Page 21: Dryer Set Point Table
DRYER SET POINT TABLE DIP Switch Settings DIP Switch Description Evaporator Outlet Temperature Sensor Disabled Enabled Status Menu Scrolling Disabled Enabled Reserved Reserved Dryer Configuration Description Units Lower Upper Increment Default Service Interval Hours 9999 4000 Energy Cost Decimal 0.00 0.99 0.01 0.13... -
Page 22: Dryer Alarm Table
DRYER ALARM TABLE Alarm Conditions Alarm Text Alarm Trigger Delay Monitored Exit Condition Alarm Action HIGH PRESSURE High pressure switch open 1 Second Always Manually reset the Halt compressors high pressure switch. De-energize alarm Alarm reset button relay #1 pressed LOW PRESSURE Low pressure switch open 3 Minutes... -
Page 23: Controller Screen Shots Status Menu Screens
CONTROLLER SCREEN SHOTS DEMM32 - User Interface Diagram Status Menu Screens Status Menu VERSION 2.x Power-up Delay 02/24/2011 09:40 MANUAL MODE Up/Down HRS TO SERVICE 4970 Up/Down Total Hours Up/Down DISCHARGE xxx.x°C / xxx°F Up/Down EVAPORATOR IN xxx.x°C / xxx°F Up/Down Up/Down Hidden if evaporator... -
Page 24: Setup Menu Screens
CONTROLLER SCREEN SHOTS DEMM32 - User Interface Diagram Setup Menu Screens Setup Menu MAIN MENU LANGUAGE Enter LANGUAGE ENGLISH Down/Up MAIN MENU DATE & TIME Enter DATE & TIME 02/24/2011 09:40 Down/Up MAIN MENU SCHEDULE Enter SCHEDULE MON ON IGNORE Down/Up MAIN MENU 02/24/2011 09:55... -
Page 25: Network Menu Screens
CONTROLLER SCREEN SHOTS DEMM32 - User Interface Diagram Network Menu Screens Network Menu Network Menu NETWORK MENU IP ADDRESS TYPE Enter IP ADDRESS TYPE DYNAMIC Up/Down NETWORK MENU IP ADDRESS Enter IP ADDRESS 192.168.0.2 Up/Down Up/Down NETWORK MENU SUBNET MASK Enter SUBNET MASK 255.255.255.0... -
Page 26: Wiring Diagrams
6.0 WIRING DIAGRAM Model 0.5: 120/230 VAC... -
Page 27: Model 0.75: 120/230 Vac
WIRING DIAGRAM Model 0.75: 120/230 VAC... -
Page 28: Models 1.0 - 2.5: 460 Vac
WIRING DIAGRAM Models 1.0 – 2.5: 460 VAC Sheet 1 of 2... - Page 29 WIRING DIAGRAM Models 1.0 – 2.5: 460 VAC Sheet 2 of 2...
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Page 30: Model 3.5: 460 Vac
WIRING DIAGRAM Model 3.5: 460 VAC Sheet 1 of 2... - Page 31 WIRING DIAGRAM Model 3.5: 460 VAC Sheet 2 of 2...
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Page 32: Models 1.0 - 3.5: 575-460/3/60 Transformer Pack
WIRING DIAGRAM Models 1.0 – 3.5: 575-460/3/60 Transformer Pack... -
Page 33: Dimensions / Weights
7.0 DIMENSIONS / WEIGHTS Dimensions, inches (mm) Model 0.75 37.56 (954) 37.56 (954) 38.60 (980) 38.60 (980) 58.06 (1475) 58.06 (1475) 58.06 (1475) 25.62 (651) 25.62 (651) 32.15 (817) 32.15 (817) 32.15 (817) 32.15 (817) 32.15 (817) 1.63 (41) 1.63 (41) 1.88 (48) 1.88 (48) 2.77 (70) -
Page 34: Models 0.5 And 0.75
8.0 REPLACEMENT PARTS: Models 0.5 and 0.75 VIEW ORIENTATION REFERENCE RIGHT REAR, VIEW-A (covers and center support shelf removed for clarity) RIGHT FRONT, VIEW-B (covers and center support shelf removed for clarity) 13 14 LEFT REAR, VIEW-C (covers and center support shelf removed for clarity) - Page 35 Condensing Unit Assembly consists of: Compressor, Condenser, Fan Assembly, Hot Gas Bypass Valve, Filter/Dryer, Base Pan, Accumulator (in some cases) and interconnecting piping. Items 3, 4, and 20 are located in the electrical enclosure located behind the control panel. Refer to the appropriate Electrical Schematic to identify part. Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison...
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Page 36: Replacement Parts
REPLACEMENT PARTS: Models 1.0 through 3.5 (Air-Cooled Units) VIEW ORIENTATION REFERENCE RIGHT REAR, VIEW-A (covers and center support shelf removed for clarity) RIGHT FRONT, VIEW-B (covers and center support shelf removed for clarity) 11 12 LEFT REAR, VIEW-C (covers and center support shelf removed for clarity) -
Page 37: Models 1.0 Through 3.5 Air-Cooled Units
Items 13, 14, 15, 16, 17, 18, 19, 20, and 22 are located in the electrical enclosure located behind the control panel. Refer to the appropriate Electrical Schematic to identify part. NOTE: Consult factory with the dryer serial number when ordering Item 18, Digital PC Board. Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison... -
Page 38: Water-Cooled Units
REPLACEMENT PARTS: Models 1.0 through 3.5 (Water-Cooled Units) VIEW ORIENTATION REFERENCE RIGHT REAR, VIEW-A (covers and center support shelf removed for clarity) RIGHT FRONT, VIEW-B (covers and center support shelf removed for clarity) LEFT REAR, VIEW-C (covers and center support shelf removed for clarity) - Page 39 Items 8, 9, 10, 11, 12, 13, 14, 15, and 17 are located in the electrical enclosure located behind the control panel. Refer to the appropriate Electrical Schematic to identify part. NOTE: Consult factory with the dryer serial number when ordering Item 13, Digital PC Board. Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison...
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Page 40: Cabinet Panels (All Models)
5002111 5002111 5002111 Cabinet Panel - Left 5002084 5002084 5002108 5002108 5002108 Cabinet Panel - Right upper 5002085 5002085 5002109 5002109 5002109 Cabinet Panel - Right lower 5002086 5002086 5002110 5002110 5002110 Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison... - Page 41 NOTES...
- Page 42 NOTES...
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Page 43: Warranty
WARRANTY The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with procedures and recommendations outlined in manufacturer’s instruction manuals, to be free from defects in material or workmanship for a period as specified below, provided such defect is discovered and brought to the manufacturer’s attention within the aforesaid warranty period. - Page 44 4647 S.W. 40th Avenue Ocala, Florida 34474-5788 U.S.A. P: (724) 745-1555 F: (724) 745-6040 E: hankison.americas@spx.com www.spx.com/hankison Improvements and research are continuous at SPX. Specifications may change without notice. ISSUED 04/2015 Form No.: 5003343 Revision: E COPYRIGHT ©2015 SPX Corporation...
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