SPX RDH-HP Series Bedienungsanleitung
RDH-HP Series
Pressure-Swing Desiccant Type Compressed Air Dryers
Models: RDH-HP-715G, RDH-HP-1550G, RDH-HP-5200G
FORM NO.: 3245430 REVISION: 04/2014 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
INSTRUCTION MANUAL
MODELS RATED
FLOW
REFER
AS
MODELS
RDH-HP-715G 715 SCFM 715
RDH-HP-1550G 1550 SCFM 1550
RDH-HP-5200G 5200 SCFM 5200
2
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
of one (1) year from the date of shipment to the buyer by the manufacturer or manufacturer’s authorized distributor, or eighteen months from the
date of shipment from the factory, whichever occurs first, provided such defect is discovered and brought to the manufacturer’s attention within
the aforesaid warranty period. The manufacturer will repair or replace any product or part determined to be defective by the manufacturer within
the warranty period, provided such defect occurred in normal service and not as a result of misuse, abuse, neglect or accident.
The warranty covers parts and labor for the warranty period. Repair or replacement shall be made at the factory or the installation site, at
the sole option of the manufacturer. Any service performed on the product by anyone other than the manufacturer must first be authorized by
the manufacturer. Normal maintenance items requiring routine replacement are not warranted. Unauthorized service voids the warranty and
any resulting charge or subsequent claim will not be paid. Products repaired or replaced under warranty shall be warranted for the unexpired
portion of the warranty applying to the original product. The foregoing is the exclusive remedy of any buyer of the manufacturer’s product. The
maximum damages liability of the manufacturer is the original purchase price of the product or part.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, OR STATU-
TO RY, AND IS EXPRESSED IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE. THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR DAMAGE BY REASON OF STRICT LI-
ABILITY IN TORT OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN, MANUFACTURE OR INSPECTION OF THE EQUIP-
MENT OR ITS FAILURE TO DISCOVER, REPORT, REPAIR, OR MODIFY LATENT DEFECTS INHERENT THEREIN. THE MANUFACTURER,
HIS REPRESENTATIVE OR DISTRIBUTOR SHALL NOT BE LIABLE FOR LOSS OF USE OF THE PRODUCT OR OTHER INCIDENTAL OR
CONSEQUENTIAL COSTS, EXPENSES, OR DAMAGES INCURRED BY THE BUYER, WHETHER ARISING FROM BREACH OF WARRANTY,
NEGLIGENCE OR STRICT LIABILITY IN TORT.
The manufacturer does not warrant any product, part, material, component, or accessory manufactured by others and sold
or supplied in connection with the sale of manufacturer’s products.
AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY
BEFORE MATERIAL IS RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.
CONTENTS
1.0 DESCRIPTION................................................................ 4
2.0 INSTALLATION................................................................ 6
3.0 OPERATION ................................................................. 12
4.0 MAINTENANCE ............................................................ 16
5.0 TROUBLESHOOTING .................................................. 18
6.0 REPLACEMENT PARTS ............................................... 19
3
IMPORTANT:
READ PRIOR TO STARTING THIS EQUIPMENT
A. UNPACKING
This shipment has been thoroughly checked, packed and inspected
before leaving our plant. It was received in good condition by the car-
rier and was so acknowledged.
1. Check for Visible Loss or Damage. If this shipment shows evidence of
loss or damage at time of delivery to you, insist that a notation of this
loss or damage be made on the delivery receipt by the carrier’s agent.
2. Check for Concealed Loss or Damage. When a shipment has been
delivered to you in apparent good order, but concealed damage is
found upon unpacking, notify the carrier immediately and insist on his
agent inspecting the shipment. Fifteen days from receipt of shipment
is the maximum time limit for requesting such inspection. Concealed
damage claims are not our responsibility as our terms are F.O.B. point
of shipment.
B. MOVING CAUTION:
Do not lift by piping. Use lifting lugs or fork lift.
GENERAL SAFETY
INFORMATION
1. Pressurized devices: This equipment is a pressure
containing device. Do not exceed maximum operating
pressure as shown on equipment serial number tag.
Make sure equipment is depressurized before working
on or disassembling it for service.
2. Electrical: This equipment requires electricity to operate.
Install equipment in compliance with national and local
electrical codes. Standard equipment is supplied with
NEMA 4, 4x electrical enclosures and is not intended for
installation in hazardous environments.
Disconnect power supply to equipment when performing
any electrical service work.
3. Breathing Air: Air treated by this equipment may not be
suitable for breathing without further purification. Refer
to OSHA standard 1910.134 for the requirements for
breathing quality air.
4. Noise: Do not operate dryer without mufflers installed.
5. High Velocity Air: Do not stand near mufflers during
tower depressurization.
I. INSTALLATION
1. Install on level surface.
2. Ambient temperature range: 35 to 120°F (1.7 to 49°C)
[ if low ambient package supplied: -10 to 120°F (-23 to 49°C) ]
3. Install purge mufflers if shipped separately.
4. Connect air from compressor to inlet.
• Maximum compressed air temperature: 120°F (49°C)
• Maximum compressed air pressure: Refer to serial number
tag.
• Minimum compressed air pressure: 100 psig (6.9 barg)
5. Connect outlet to air system.
6. Refer to serial number tag for correct voltage. Make electrical
connection to terminal strip in control panel. Connect line to
position 5, neutral to position 6 and ground to position 7.
7. Verify voltage selector switch (115V or 230V). Position should
match voltage on Serial Number Tag.
II. START UP
1. Set or verify controller settings. See section 3.1.1.
2. SLOWLY pressurize unit.
3. Energize dryer by turning on/off switch on. (“I” is on; “O” is off)
4. Adjust purge air flow rate. Turn purge rate valve until Purge
Pressure Gauge reads as shown in the following table.
NOTE: One tower must be purging when setting purge pressure.
MINI INSTRUCTIONS
For complete instructions on installation, operation and maintenance, consult manual.
III. OPERATIONAL CHECKPOINTS
1. Check that dryer is energized (indicating lights are illumi-
nated)
2. MOISTURE INDICATOR - Indicator should be green (Allow
4 hours after start up for indicator to turn green).
3. TOWER PRESSURE GAUGES -
• Tower on line should read line pressure
• Tower off line should read 2 psig (0.14 barg)or less while
purging. If pressure exceeds 2 psig (0.14 barg) replace
purge muffler elements.
NOTE: An extra set of elements is shipped with dryer.
4. PURGE PRESSURE GAUGE - Verify proper setting.
5. CHECK FOR ALARM CONDITION.
IV. DEPRESSURIZATION
Isolate dryer. Run timer until both tower pressure gauges read
0 psig (0 kgf/cm
2
)(test mode may be used to speed up cycle).
4
1.0 DESCRIPTION
Desiccant is regenerated by driving off (desorbing) the water collected
on its surface. Pressure-swing (also called heatless or heaterless
because no outside heat is added) dryers regenerate by expanding a
portion (approximately 14 - 15% at 100 psig, 7 barg) of the dried air to
atmospheric pressure. This “swing in pressure” causes the expanded air
to become very dry (have a very low vapor pressure). This very dry air
(called purge air) plus the stored heat of adsorption allows the moisture
to desorb from the desiccant. The purge air then carries the desorbed
water out of the dryer.
1.1 Function
1.1.1 Dryer
Dual tower regenerative desiccant dryers are an economical and reliable
way to dry compressed air to dew points below the freezing point of wa-
ter (dew points as low as -150°F (101°C) [1 ppb @ 100 psig, 7.0 barg]
are possible) or reduce the moisture content of compressed air when
used in critical process applications.
These dryers continuously dry compressed air by using two identical
towers, each containing a desiccant bed. While one tower is on-stream
drying the compressed air, the other tower is off-stream being regener-
ated (reactivated, i.e., dried out). The towers are alternated on- and
off-stream so that dry desiccant is always in contact with the wet
compressed air. In this way a continuous supply of dry air downstream
is possible.
Desiccant dryers lower the dew point of compressed air by adsorbing the
water vapor present in the compressed air onto the surface of the desic-
cant. Desiccant is a highly porous solid containing extensive surface
area.
Adsorption occurs until the partial pressure of the water vapor in the
air and that on the surface of the desiccant come into equilibrium. As
adsorption occurs, heat is released (referred to as the heat of adsorption)
and is stored in the bed for use during regeneration.
5
8
1
5C 5D 8
7 ) (
2
61
5A
10A 9A 3A 3B 9B 10B
5B
11
INLET
TOWER
4B
TOWER
4A
OUTLET
FIGURE 1A
TOWER 4A DRYING: TOWER 4B REGENERATING
Purge Stream
Process Stream
FIGURE 1B
TOWER 4B DRYING: TOWER 4A REGENERATING
1.2 Description of Operation
1.2.1 Dryer (Refer to Figure 1A.)
Compressed air flows through inlet switching valve (3A) (normally open)
to tower (4A) where the air is dried. After the air is dried it flows through
check valve (5A) and then to the dryer outlet.
A portion of the dry air, the purge stream, branches off from the main air
stream prior to the outlet. The purge stream flow rate is controlled by the
adjustable purge rate valve (6) and the purge orifice (7).
The purge flow, which has been throttled to near atmospheric pressure,
is directed through check valve (5D) to tower (4B). As the purge flow
passes over the desiccant in tower (4B), it removes the water vapor
which was deposited there while the tower was on-line drying. The purge
air then passes through purge and repressurization valve (9B) (normally
closed) and purge muffler (10B) to the atmosphere.
After regeneration, purge and repressurization valve (9B) (normally
open) closes allowing tower (4B) to repressurize slowly. Adequate
repressurization time is allowed so that tower 4B is fully repressurized
before switchover. After a controlled time period, air inlet switching valve
(3B) (normally open) opens and inlet switching valve (3A) (normally
open) closes, purge and repressurization valve (9A) (normally closed)
then opens.
(Refer to Figure 1B.) Tower (4B) is now drying the main air stream while
tower (4A) is being regenerated by the purge air stream. The operation
of the inlet switching (normally open) and purge and repressurization
valves (normally closed) is sequenced by the control system located in
the electrical box.
8
1
5C 5D 8
7 ) (
2
61
5A
10B
9B
3B
3A
9A
10A
5B
11
INLET
TOWER
4B
TOWER
4A
OUTLET
1. Pressure Gauges
2. Purge Pressure Gauge
3. Inlet Switching Valves
4. Desiccant Drying Towers
5. Check Valves
6. Adjustable Purge Rate Valve
7. Purge Orifice
8. Pressure Relief Valves
9. Purge / Repressurization Valves
10. Purge Mufflers
11. Moisture Indicator
6
BC E
D
Desiccant
Dryer
Compressor
Aftercooler
Separator
A
Prefilter(s) Afterfilter
A
Receiver Receiver
(B & C) PREFILTERS - Adequate filtration is required upstream of the
dryer in order to protect the desiccant bed from contamination. The fol-
lowing filtration is recommended:
B - Particulate/Gross Liquid Removal - On heavily contaminated sys-
tems use a gross contaminant filter to remove solids and high inlet liquid
concentrations.
C - Oil Aerosol Removal -On systems with lubricated compressors,
use an oil removal filter to remove oil aerosols and protect desiccant bed
from oil contamination.
(D) DESICCANT DRYER
(E) AFTERFILTER - To ensure downstream air purity (prevent desiccant
dust from traveling downstream) adequate filtration downstream of the
dryer is required. Typically 1 micron filtration is specified although finer
filtration is available.
OR
Oil Vapor Adsorber - Use as an afterfilter to remove oil vapor and its
subsequent taste and odor and to protect down-stream components
from solid particles 0.01 micron and larger.
NOTE: By-pass lines and isolation valves are recommended so that
maintenance work can be performed without shutting off the air supply.
2.2 Physical Location
Dryer must be installed with suitable overhead protection.
2.1 Location in the compressed air system.
NOTE: Air Compressor should be adequately sized to handle air system
demands as well as purge loss. Failure to take this into account could
result in overloading air compressors and/or insufficient air supply
downstream.
NOTE: It is desirable to install dryer where compressed air is at the
lowest possible temperature (downstream of aftercoolers) and the high-
est possible pressure (upstream of pressure reducing valves) without
exceeding the maximum working pressure. (Refer to Figure 2A)
(A) AFTERCOOLER/SEPARATOR - Compressed air entering dryer must
be cooled to at least 120°F (49°C). Use aftercooler and separator if
higher temperatures are present.
NOTE: Installation of a refrigerated dryer ahead of a pressure-swing
desiccant dryer does not increase desiccant dryer capacity or reduce
purge flow requirements. However a cooling unit installed ahead of the
desiccant dryer reduces the inlet air temperature and outlet air dew point.
2.0 INSTALLATION
2.3 Minimum & Maximum Operating Conditions
The compressed air supply inlet should be checked periodically to ensure
that equipment design specifications are not exceeded. Normally the
compressor installation includes intercoolers, aftercoolers, separators,
receivers, or similar equipment which adequately pretreat the com-
pressed air supply in order to avoid excessively high air temperatures
and liquid slugging of downstream equipment.
2.3.1 Compressed air conditions
2.3.1.1 Maximum working pressure: Refer to Serial Number Tag.
WARNING
Do not operate the dryer at pressures above the maximum pressure
shown on the tag.
2.3.1.2 Minimum working pressures: 100 psig (7 barg)
2.3.1.3 Maximum inlet compressed air temperature:
120°F (49°C)
NOTE: If inlet air is higher than 120°F (49°C) the air must be pre-
cooled with an aftercooler.
2.3.2 Ambient temperatures:
Minimum:
Standard units: 35°F (1.7°C)
Units with optional low ambient package: - 10°F (-23°C)
Maximum: 120°F (49°C)
NOTE: If dryer is installed in ambients below 35°F (1.7°C) heat tracing
of the prefilters and inlet piping and valves is necessary to prevent con-
densate from freezing. If installing heat tracing, observe electrical class
code requirements for type of duty specified.
2.4 Mounting
Install dryer on a level pad on floor. Holes are provided in
the floor stand base angles for floor anchors if desired.
NOTE: Floor anchors must be used if area is subject to vibrations.
2.5 Piping
2.5.1 Inlet and Outlet connections
Observe location of inlet and outlet connections as indicated in Figure
2C or 2D and connect inlet and outlet piping.
NOTE: All piping must be supported so as not to bear on the dryers or
filters.
2.5.2 Isolation valves
If isolation valves are installed, it is recommended that gate valves be
used to ensure that dryer is pressurized slowly. This is particularly true
if isolation valves are placed before and after pre- and afterfilters where
rapid pressurization could cause excessive pressure drop across filter
elements.
FIGURE 2A
7
Icon idenification
Air Inlet
Air Outlet
Left Tower Pressure Gauge
Right Tower Pressure Gauge
Purge Pressure Gauge
Electrical Entry
Inlet Pressure Gauge
Outlet Pressure Gauge
Automatic Condensate Drain
Purge Muffler
FIGURE 2B
8
FIGURE 2C Model 715G
3.1/4" X 9.1/4" FORKLIFT TUBE
OPENINGS (83mm X 235mm)
3 PLACES
DESICCANT DRAIN
PORT
MOUNTING HOLES
7/8" DIA.
HIGH EFFICIENCY OIL
REMOVAL PREFILTER
AIRLINE AFTERFILTER
AIRLINE PREFILTER
PROCESS AIR OUTLET
NPS 3 BOSS FITTING
TOP VIEW
ELECTRICAL ENCLOSURE
SEE DETAIL
SIDE VIEW
(SEE AC SIDE DETAIL)
RIGHT TOWER
PRESSURE GAGE
PURGE PRESSURE GAGE
PURGE PRESSURE
ADJUSTMENT VALVE
DESICCANT FILL PORT
FRONT VIEW
LEFT TOWER
PRESSURE GAGE
MOISTURE INDICATOR
TOWER PRESSURE
RELIEF VALVE
PROCESS AIR INLET
NPS 3 BOSS FITTING
PURGE MUFFLER
ENCLOSURE DETAIL
(ENLARGED)
3 PRONG MALE
ELECTRICAL PLUG
POWER SWITCH
ELECTRICAL ENCLOSURE
NEMA CLASS 4/4X
9
FIGURE 2D Model 1550G
ELECTRICAL ENCLOSURE
SEE DETAIL A
AIRLINE AFTERFILTER HIGH EFFICIENCY OIL
REMOVAL PREFILTER
SEPARATOR PREFILT ER
TOP VIEW
MOUNTING HOLES
7/8" DIA.
DESICCANT FILL PORT
DESICCANT DRAIN
PORTS
LEFT TOWER
PRESSURE GAUGE
PURGE PRESSURE GAUGE
RIGHT TOWER
PRESSURE GAUGE
ELECTRICAL ENCLOSURE
NEMA CLASS 4/4X
POWER SWITCH
3 PRONG MALE
ELECTRICAL PLUG
DETAIL A
TOWER PRESSURE
RELIEF VALVE
PURGE MUFFLER
PROCESS AIR INLET
NPS 3 BOSS FITTING
CONDENSATE DRAIN
3/4 NAT. HOSE
MALE THREAD
3.1/4" x 9.1/4" FORKLIFT TUBE
OPENINGS (83mm X 235mm)
SIDE VIEW
REAR VIEW OF DRYER
PROCESS AIR OUTLET
NPS 3 BOSS FITTING
MOISTURE INDICATOR
LIFTING LUGS
10
FIGURE 2E Model 5200G
SIDE VIEW
MOISTURE INDICATOR
SECTION B
(ENLARGED)
PILOT AIR REGULATOR
DETAIL A
3 PRONG MALE
ELECTRICAL PLUG
POWER SWITCH
ELECTRICAL ENCLOSURE
NEMA CLASS 4/4X
PURGE PRESSURE GAGE
RIGHT TOWER
PRESSURE GAGE
LEFT TOWER
PRESSURE GAGE
PROCESS AIR OUTLET
NPS 3 BOSS FITTING
4 PLACES
OUTLET SHUT OFF
VALVE NPS 3
4 PLACES
SEE SECTION B
DESICCANT FILL PORT
AIRLINE AFTERFILTER
HF7-76-6F-S
MOUNTING HOLES
1 INCH DIA.
6 PLACES
PURGE MUFFLER
3.1/2" X 9.1/2" FORKLIFT
OPENINGS (90mm X 241mm)
2 PLACES
CONDENSATE DRAIN
3/4 NPS MALE
PIPE THREAD
REAR VIEW
TRIP-L-TRAP
TOWER PRESSURE
RELIEF VALVE
TOP VIEW
B
HIGH EFFICIENCY OIL
REMOVAL PREFILTER
SEPARATOR PREFILTER
PROCESS AIR INLET
NPS 3 BOSS FITTING
4 PLACES
INLET SHUT OFF
VALVE NPS 3
4 PLACES
DESICCANT DRAIN
PORT ELECTRICAL
ENCLOSURE
SEE DETAIL A
Dieses Handbuch passt für folgende Modelle
3
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