PHE Manual

Heat Reactivated Regenerative Air Dryer PHE/PHI Owners Manual Contents CONTENTS ................................................................................................................................................................ 1 LIST OF FIGURES ....................................................................................................................................................... 1 A. INTRODUCTION................................................................................................................................................ 1 B. RECEIVING AND INSPECTION ........................................................................................................................... 2 C. STANDARD FEATURES..................................................................................................................................... 2 D. LOCATION RECOMMENDATIONS...................................................................................................................... 2 E. INSTALLATION RECOMMENDATIONS ............................................................................................................... 3 F. PRE-FILTRATION AND AFTER-FILTRATION REQUIREMENTS ............................................................................. 3 G. BACK PRESSURE REGULATOR RECOMMENDATIONS ....................................................................................... 3 H. PURGE EXHAUST PIPING.................................................................................................................................. 3 I. OPERATION ..................................................................................................................................................... 4 Standard Operation Sequence............................................................................................................................. 4 Initiation of Control Power ................................................................................................................................. 4 Demand Cycle Operational Sequence (Optional) ............................................................................................... 4 J. START UP ........................................................................................................................................................ 5 Deadheading the Dryer ....................................................................................................................................... 5 K. GENERAL MAINTENANCE................................................................................................................................ 6 L. TROUBLESHOOTING......................................................................................................................................... 6 Alarm Conditions: ............................................................................................................................................... 6 M. WARRANTY..................................................................................................................................................... 8 N. CAUTION ......................................................................................................................................................... 9 List of Figures 1. PHE25 THROUGH PHE1400 INLET VALVE 2. PHE CONTROL BOARD 3. PHE ELECTRICAL WIRING SCHEMATIC 4. PHE TIMING SEQUENCE DIAGRAM 5. PHE25 THROUGH PHE1400 FLOW SCHEMATIC (UP DRAFT DRYING, DOWN DRAFT REGENERATING) 6. PHE1000 - MECHANICAL DRAWING, DR # 65275M1 REV - 7. PHE1000 - ELECTRICAL DRAWING, DR # 65275E1 REV - Additional Information and Enclosures 1. RECOMMENDED SPARE PART LIST 2. U-1 FORMS 3. MATERIAL SAFETY DATA SHEET A. Introduction Air Systems Inc. 210, Flatfork Road, Wartburg, TN – 37887 (800) 264-1AIR Page 1 Many years of trouble free service can be expected from your Pioneer Heat Regenerative Desiccant Dryer. Superior Dew point depression will be obtained and operating problems will be avoided by careful installation and proper preventive maintenance procedures. B. Receiving and Inspection • Remove crate and packing. • Examine the unit for external and internal shipping damage. Report any damages to the transportation agency at once. This is the responsibility of the customer. • Check the nameplate to be sure the power supply is correct. • Inspect all piping and tubing. Vibration during shipment may have loosened the connections. • Standard PIONEER compressed air dryers are tested and operated before leaving the factory. They are ready to run after connecting the proper services. Note: To avoid erosion or powdering of desiccant in shipment, models PHE175 and larger are shipped without desiccant in vessels. The desiccant is shipped separately. Please fill the vessels with the desiccant before using the dryer. For desired performance use PIONEER Activated Alumina Plus – 100F only. C. Standard Features • NEMA 4 Electrical • Computer Controlled Diagnostic Panel • Sequence Lights 1. Left tower drying 2. Right tower drying 3. Left tower purging 4. Right tower purging 5. Left tower heating 6. Right tower heating 7. Failure to shift alarm 8. High temperature alarm and heater shutdown 9. Controller failure • Tower Safety Relief Valves • ASME Pressure Vessels ( PHE75 and larger) • Tower Pressure Gauges • Purge Pressure Gauge • Tower Exhaust Mufflers • Non-Lube Valves • Stainless Steel Inlet/Outlet Diffusers D. Location Recommendations The PIONEER Dryer should be located on a level floor free from vibrations and in clean surroundings. Although the dryer is a free standing package it may be secured by bolting the dryer to the floor. Allow approximately three (3) feet on all sided of the dryer to make connections and for ease of maintenance. The ambient temperature of the dryer should be in the range of plus 350F to plus 1200F. The dryer will function in warmer surroundings, however, the degree of dew point depression obtained will decrease. Air Systems Inc. 210, Flatfork Road, Wartburg, TN – 37887 (800) 264-1AIR Page 2 Operation of the dryer in ambient approaching freezing could freeze the separated liquids in the pre-filter sump or in the dryer itself. For dryer operation at temperatures below freezing, PIONEER recommends heat tracing the pre-filter sump and drain trap as well as the inlet manifold. Protective barriers are recommended for the prevention of accidental damage, that may occur to vehicular or personnel traffic. It is also recommended for dryer to be located in open areas. E. Installation Recommendations Install the following: • Inlet piping (including a shut-off valve). • Outlet piping (including a shut-off valve). • Pre-filters and after-filter if not purchased with dryer package. • Bypass piping if desired (We recommend the use of bubble tight valves). • A qualified electrician should check nameplate voltage and amperage. Install the correct power to the equipment. Power shall be supplied through a fused disconnect which is to be provided by the customer. • Access ports should be installed upstream and downstream of the dryer for dewpoint and temperature measurements. F. Pre-filtration and After-filtration requirements All regenerative desiccant dryers are designed to remove water in the vapor phase. The possibility of liquid carry over to the desiccant dryer must be avoided. Coalescing pre-filtration will eliminate the carry over of droplets and aerosol-sized mists of both liquid water and compressor lubricant. The use of a PIONEER Coalescer Filter will enhance the dewpoint depression capability of the dryer. Although the pre-filter sump can be manually drained of separated liquids, it is highly recommended that a suitable automatic drain trap be installed to eliminate any possibility of failure to drain the pre-filter. In installation with excessive oil carry-over, use a particulate filter before the coalescer for better performance and longer coalescer life. After filtration is also a very important process. All regenerative desiccant dryers gradually produce hard and abrasive desiccant fines. These contaminants should be removed with a PIONEER Particulate Filter. The elimination of the desiccant fine carryover will protect your plant systems and reduce future system malfunctions. G. Back Pressure Regulator Recommendations In dryer applications where sudden down stream demand for dry air frequently occurs a rapid pressure loss in the compressed air system is possible. It is recommended that a back pressure regulator be installed down stream from the dryer. The back pressure regulator will maintain a constant pressure within the dryer. This will eliminate any chance of fluidizing the desiccant bed by sudden flow surges that accompany rapid pressure loss. By eliminating fluidization and desiccant bed “bumping” the life of the desiccant charge will increase. Thus, the after-filter elements will not become prematurely clogged with desiccant fines. H. Purge Exhaust Piping Air Systems Inc. 210, Flatfork Road, Wartburg, TN – 37887 (800) 264-1AIR Page 3 To eliminate noise created by frequent de-pressurization of purge exhaust, the dryer’s exhaust may be piped to an outside or a more remote location. This will also eliminate any possible problem caused by indoor accumulation of condensed moisture from the purge exhaust. If the purge exhaust is extended to more than fifteen (15) feet, contact the factory for recommendations. The exhaust pipe shall be horizontal or flow downward to avoid accumulation of condensate at low points. If the purge exhaust is required it is recommended that an automatic drain to be placed at the low point. I. Operation The PIONEER dryer is specifically designed to remove moisture in the vapor phase. The dryers Computer Controlled Diagnostic Panel is completely automatic. It alternately cycles air flow through the units twin desiccant towers. Cycling between the twin towers accomplishes the adsorption and regeneration process and provides continuous flow of air. The compressed air laden with moisture vapor enters a tower and flows upward (or downward – depending on the configuration) through the desiccant bed. The desiccant has great affinity for the moisture and traps the moisture in its tiny pores. A small portion of the dry air is expanded to near atmospheric pressure by passing through an orifice specifically designed for the regeneration (purge) stream and flows downward, (or upward- depending on the configuration) counter current to drying flow, to strip the previously adsorbed moisture vapor. In addition a booster heater is used to enhance the adsorption capacity of the regeneration stream. Standard Operation Sequence A PHE Dryer is equipped with an external heater. The operation of the dryer can be readily traced by referring to the Flow Diagram, Wiring Schematic and Timing Sequence. The sequence is fully automatic and is controlled by the Computer Controlled Diagnostic Panel. Initiation of Control Power The inlet air is diverted to the left tower. At this time the heater will energize for pre-heat. Approximately five (5) seconds later the right tower purge (regeneration) exhaust valve will open. The heater will cycle off and on based on the air temperature leaving the heater. After three (3) hours the heater will shut down and the fifty-five (55) minute cool-down cycle begins. At the end of the cool-down cycle, the right exhaust valve will close and the dryer will slowly repressurize. At the end of the repressurization cycle (5 minutes) the inlet selector valve will switch inlet valves and the inlet stream will divert from the left tower to the right tower. The heater will reenergize for pre-heat. Five (5) seconds after switch over, the left tower exhaust valve will open and de-pressurize the tower. The heater will cycle on and off based on the air temperature leaving the heater. After three (3) hours, the heater will shut down and the purge air will continue to flow and cool the bed for fifty-five (55) minutes. At the end of the cool down cycle, the left exhaust valve closes and the tower will slowly re-pressurize. At the end of repressurization cycle (5 minutes), the towers will switch roles and the process will continue. Demand Cycle Operational Sequence (Optional) The operational sequence of this system is similar to that of the standard system described in Section 2. The Demand Cycle Control reduces the frequency of the tower switching, thus the purge air loss and heater power consumption is proportional to the dryers moisture loading. The purge (regeneration) Time is three (3) hours heating and fifty-five (55) minutes cooling. At the end of the regeneration time, the regenerated tower will re-pressurize and remain in the stand-by state. Switch over will not occur until the Air Systems Inc. 210, Flatfork Road, Wartburg, TN – 37887 (800) 264-1AIR Page 4 drying tower reaches a preset moisture capacity. When the drying tower reaches the preset moisture capacity, the switch over will occur and the tower will be regenerated. Located on the electrical enclosure door is a Demand Cycle ON/OFF Switch. The switch allows the operator to select between the fixed operating cycle or the moisture load Demand Cycle Control. When the switch is in the OFF position, the dryer will operate on a fixed standard cycle. When the switch is in the ON position, the dryer will operate in the demand cycle control mode. J. Start Up WARNING Never operate the dryer without air flow or purge flow. It may damage the heater and void warranty. Prior to start-up, make certain the switch settings on 4 position slide switch located in the lower left hand corner of the computer controlled diagnostic panel are set as follows (refer to figure) Switch # 1: OFF Switch # 2: ON for 60 Hz ; OFF for 50 Hz Switch # 3: ON for 50 Hz ; OFF for 60 Hz Switch # 4: ON The block valves upstream and down stream of the dryer should be closed and the by-pass should be open. Before turning the dryer control switch ON, S-L-O-W-L-Y pressurize the dryer by gradually opening the block valve upstream of the dryer. When both tower pressure gauges indicate line pressure, the dehydration outlet block valve can be opened and the dehydration system by-pass valve closed. Compressed air now flows through the pre-filter, the Dryer, and the after-filter. The dryer operation should never be initiated by SUDDENLY pressurizing the dryer towers from the dryer inlet. The sudden inrush of high velocity air into the desiccant bed would cause desiccant-fines and hasten the need for after-filter element replacement and desiccant bed replacement. The dryer control power switch now be turned on Immediately, or at most, one minute after activating the dryer control circuit, one tower will depressurize to atmospheric pressure through the purge exhaust valve. Regenerating purge air will then flow to the regenerating tower. Adjust the manual purge flow control valve so that the purge pressure gauge indicates (45 psig pressure) the proper pressure for actual dryer operating conditions. The purge orifice pressure can only be properly set when the purge exhaust valve is open and the pressure in the regenerating tower is zero (0) pressure. Other purge pressures may be required for different units; if so, the different pressures other than 45 psig will be noted. Deadheading the Dryer After start up has been completed and the dryer has been checked for proper operation, “deadheading” the dryer is recommended. To “deadhead” the dryer is to operate it without a load to remove any moisture adsorbed by the desiccant prior to installation. The air flow through the dryer is used for regeneration only. This is accomplished by closing the outlet block valve and operating the unit for a minimum of three to five days prior to placing the dryer on-line. Air Systems Inc. 210, Flatfork Road, Wartburg, TN – 37887 (800) 264-1AIR Page 5 NOTES : 1. Purge exhaust mufflers: Clean periodically; replace if necessary. The desiccant dust migration during shipment may cause frequent muffler clogging during the first week of operation. It may require clean up several times. K. General Maintenance Warning : Before servicing any component make certain the component is depressurized. 1. Pre-filtration : Change filter elements periodically, once every three (3) or six (6) months. Also, look for excessive pressure drop. Inspect automatic drain and clean if necessary. 2. After Filtration : Change filters elements periodically, once every three (3) or six (6) months. Also look for excessive pressure drop. 3. Control Air Filter (25 scfm and larger dryers) : Change filter elements periodically, once every three (3) or six (6) months. Also, look for excessive pressure drop. 4. Purge flow rate adjustment : The purge flow rate should be checked periodically for proper adjustment. The purge pressure for full load operation should be set at 45 psig. 5. Solenoid Valves : The solenoid valves should be inspected periodically for proper operation. The inspection should include monitoring the tower pressure gauge on each tower during the regeneration cycle. The back pressure on the regenerating tower should be approx. 0-5 psig. The higher back pressure indicates valve malfunctioning and/or clogging of the muffler. Failure of a solenoid to function may be caused by : • Faulty control circuit. Check the electrical system to verify the solenoid coil is receiving electrical input. • A burnt out coil. Replace the coil. • Clogged solenoid valve, disassemble and clean. • Damaged valve seat, replace valve. 6. Desiccant Replacement : Contaminated desiccant should be drained through the drain port. Fresh desiccant should be charged through the desiccant fill port. Always leave adequate plenum above the desiccant bed to permit bed motion and expansion during the dryer operation. For warranty reasons and superior performance use Pioneer Activated Alumina Plus –100F. Change the desiccant periodically for optimum performance. NOTE : The useful life of desiccant depends upon the quality of air. To ensure proper performance use time schedule maintenance, e.g. once a year. 7. Inlet Valve Maintenance (Models PHE25 through PHE1400) : Pioneer uses easy to service non-lube valves as standard. Inspection and maintenance may be done without removing the valve from the line of the dryer. Larger models use wafer type air actuated butterfly valves. For more information, please consult factory. L. Troubleshooting Alarm Conditions: Failure to shift: Alarm light blinks @ once every second. Heater over temperature: Alarm light is ON constantly. Controller malfunction: Alarm light blinks four (4) times per second. High Dewpoint: Constantly ON, The high dewpoint alarm light is a separate light from the main alarm indicator. Air Systems Inc. 210, Flatfork Road, Wartburg, TN – 37887 (800) 264-1AIR Page 6 Problem Problem cause Solution Poor Dewpoint 1. Excessive inlet flow. 2. Excessive inlet temperature. 3. Excessive water. 4. Desiccant contamination. 5. Pre-filter drain failure. 6. Low purge flow. 7. Low inlet pressure. 8. Liquids entering dryer outlet. 9. Heater failure 1. Reduce flow to rated capacity. 2. Inspect, repair or replace upstream cooler. 3. Check upstream separator, pre-filter and their drain traps. Clean, repair or replace. 4. Replace desiccant and pre-filter element. 5. Check if clogged. Clean, repair or replace. 6. Adjust purge pressure to 45 psig or other specified pressure. 7. Check for pressure loss over pre-filter. 8. Inspect pre-filtration system and drains. 9. Refer to heater failure Excessive Pressure Drop 1. Excessive Inlet flow. 2. Low Inlet pressure. 3. Excessive pressure drop over pre-filter and/or after filter. 1. Reduce flow to rated capacity. 2. Check for pressure loss over pre-filter. 3. Change elements. Purge Failure 1. Purge flow control valve or orifice clogged. 2. Purge exhaust valve fails to close. 3. Purge muffler clogged. 1. Remove and clean. 2. Check solenoid actuator, purge exhaust valve and diagnostic control board. 3. Check muffler; replace if necessary. Pressurizati-on Failure 1. Repressurization Failure. 2. Purge exhaust valve fails to close. 1. Check regulator, orifice and check valve. 2. Check solenoid actuator, purge exhaust valve, and diagnostic control board. Switch over Failure 1. No control Air. 2. Electric power loss. 3. Switching valve fails. 1. Check control air filter and control air lines. 2. Check power supply and diagnostic control board. 3. Check inlet valve, actuator, and solenoid. High Back Pressure in Off Stream Tower 1. Purge muffler clogged. 2. Restrictive purge exhaust piping. 3. Check valve leakage. 1. Clean or replace. 2. Replace with large size pipe. 3. Repair or replace. Tower Failure (Failure to Shift) 1. Purge exhaust fails to close. 2. Purge exhaust valve fails to open. 3. Inlet valve fails to open. 4. Inlet valve fails to close. 1. Check solenoid actuator, purge exhaust valve and diagnostic control board. 2. Check solenoid actuator, purge exhaust valve, and diagnostic board. 3. Check inlet valve, tower selector valve solenoid, and diagnostic control board. 4. Check inlet valve, tower selector valve solenoid, and diagnostic control board. Heater Failure 1. Tower Failure. 2. Heater Over temperature. 3. Bad control thermocouple control. 1. Reset tower failure alarm. Refer to tower failure. 2. Refer to purge failure. Pressurization failure, high limit set too low. Control set too high. Tower failure. 3. Replace thermocouple. Heater Light ON but not heating 1. Contactor Failure. 2. Heater Burnt out. 1. Repair or replace Contactor. 2. Replace heater. Air Systems Inc. 210, Flatfork Road, Wartburg, TN – 37887 (800) 264-1AIR Page 7 M. Warranty Pioneer products are warranted to be free from defects in material and workmanship for a period of one year (15 months for distributors stock items) from the date of shipment, provided the equipment is used according to PIONEER’S recommended usage. PIONEER’S liability is limited to repair of, refund of, purchase price paid for, or replacement in kind is PIONEER’S sole option. In no event shall PIONEER be liable or responsible for incidental or consequential damages, even if the possibility of such incidental or consequential damages has been made known to PIONEER Air Systems Inc.. The usual maintenance and replacement type products are not covered by this warranty. One (1) year parts only (no labor) warranty applies to equipment sold outside the mainland U.S.A. The following procedure supplements the above stated warranty – 1. Models may be replaced in factory with rebuilt units of similar age or new units (subject to availability). Replacement units will be invoiced at standard prices. Upon return of the defective unit, full credit will be issued provided the unit shows no sign of mistreatment or misuse. PIONEER will not be responsible for removal, reinstallation, shipping, handling, downtime costs or consequential damages. 2. Return Merchandise Authorization Authorization of material or equipment return must be obtained prior to the return of, repair of, or issuance of credit for any materials. Please follow the procedures listed below • Contact the Pioneer customer service department by phone (423) 346-6693. Authorization for valid returns will be issued a RMA# (Return Material Authorization Number). Company name and description of the problem will be logged and noted under this RMA#. Future correspondence must reference the RMA#. • Each shipping container returned MUST be clearly marked on the outside with the proper RMA#. If the container and shipping papers are not clearly marked, the shipment may be refused. Pioneer is not responsible for merchandize returned with no RMA Numbers. Marking containers will help to speed the service process. • After the receipt of the materials or equipment in question, a Pioneer representative will inspect the returned materials. NOTE: A RMA# does not guarantee a full credit for the returned goods. The final decision of credit allowances rests with Pioneer after receiving the materials or equipment in question. Unauthorized service claims will be disallowed. When larger models require warranty service, contact factory describing the malfunction. The factory will then provide their services of a service technician or authorize the procurement of a competent local service. Unauthorized service claims will be disallowed. 3. Customer responsibility includes the following routine preventive maintenance : • Keeping exhaust muffler clean. • Desiccant replacement. • Provide proper ventilation in the area. • Maintaining proper volume, pressure and temperature. • Maintaining proper electrical requirement. • Removal of corrosive elements from the compressed air and atmosphere. • Keeping automatic drains clean (Best-Aire options). Air Systems Inc. 210, Flatfork Road, Wartburg, TN – 37887 (800) 264-1AIR Page 8 Notes: When a factory technician is requested for service, due to one or more of the above reasons, customer will be invoiced on non-warranty service call basis. Changes by customer to the equipment will void all warranty. N. Caution • Because of higher pressure and electrical voltage, only qualified personnel should work on equipment. • Remove air pressure from a device under pressure before working on it. • PIONEER Air Systems, Inc. does not test its products for breathing air or applications requiring FDA approval. The user is advised to do its own testing. Notes: Pioneer Air Systems Inc. 210, Flatfork Road, Wartburg, TN - 37887 Tel : (800) 264-1AIR, (423) 346-6693 Fax : (423) 346-3865, (423) 346-7522 Email : sales@pioneerair.com WWW Address : http://www.pioneerair.com Copyright © 1998 - Pioneer Air Systems, Pioneer Engineering. All rights reserved. Information in this document is subject to change without notice. Air Systems Inc. 210, Flatfork Road, Wartburg, TN – 37887 (800) 264-1AIR Page 9