Ingersoll-Rand HL Series User manual

Rev 3, November 2011

The following manual contains various guides for IR technical personnel troubleshooting the IR desiccant dryers models HL-EH-HB.
SAFETY AND OPERATION PRECAUTIONS
Because an air dryer is pressurized and contains rotating parts, the same precautions should be observed as with any piece of machinery
of this type where carelessness in operation or maintenance could be hazardous to personnel. In addition to obvious safety rules that
should be followed with this type of machinery, safety precautions as listed below must be observed:
1. Only qualified personnel shall be permitted to adjust, perform maintenance or repair this air dryer.
2. Read all instructions completely before operating unit.
3. Pull main electrical disconnect switch and disconnect any separate control lines, if used, before attempting to work or perform
maintenance on the unit.
4. Do not attempt to service any part while machine is in an operational mode.
5. Do not attempt to remove any parts without first relieving the entire air system of pressure.
6. Do not operate the dryer at pressures in excess of its rating.
7. Do not operate the dryer without guards, shields and screen in place.
8. Inspect unit daily to observe and correct any unsafe operating conditions.
The following warnings are located on the dryer to warn of various hazards.
OSHA
Heading Descriptions
WARNING
“Warning” is used to indicate a hazardous situation which has some probability of death or severe injury. Warning should not be
considered for property damage accidents unless personal injury risk is present.
“Caution” is used to indicate a hazardous situation which may result in minor or moderate injury.
“Notice” is used to indicate a statement of company policy as the message relates directly or indirectly to the safety of personnel or
protection of property. Notice should not be associated directly with a hazard or hazardous situation and must not be used in place of
“Danger,” “Warning,” or “Caution.”
NOTICE
The user of any air dryer manufactured by Ingersoll Rand, is hereby warned that failure to follow the above Safety and Operation
Precautions may result in personal injury or equipment damage. However, Ingersoll Rand does not state as fact, nor does it mean to
imply, that the preceding list of Safety and Operating Precautions is all inclusive, and further, that the observance of this list will prevent
all personal injury or equipment damage.

Desiccant DPC Controller
Checking Inputs/Outputs
The DPC controller used on the HL, EH and HB Desiccant dryers communicates with an Expansion
Adapter so the controller can have more inputs and outputs. If you experience problems with an output
that goes to a component on the dryer you can press and hold the i button on the controller for 5 seconds
and this will allow you to access the software data table in the controller. By using the following
instructions you can see which inputs or outputs are on or off. Example: the blower output is on in the
data table but the expansion module is output is off (blower not running but should be), this indicates that
either the cable or the expansion module is bad. The expansion adapter when operating normally should
show a green power led light and a green communication led. The expansion module will show a green
led light when operating normally, and any outputs will show red. The expansion module uses relays to
output a signal, if the red indicator light is on but no output to the terminal strip is ON then the module is
bad.
Press and hold i button for five seconds, then press Enter.
Display will show Inputs/Outputs. Press Enter
Display will show I (Inputs)
To toggle between Inputs and Outputs press Set button. When you have made your selection press Enter.
Display will show 000-007, this is the Input or Output addresses inside the controller software. To scroll
up or down press the arrow or set button, there are a total of 255 addresses. Below are the Input and
Output addresses being used in the Desiccant DPC controller that are the most used by service
technicians. When the Input/Output is ON it is indicated by a black block, OFF is indicated by a _.To exit
this mode press the i button until you return to the main menu. Note: Due to variations in software and
dryer configurations some of these addresses may vary
Controller Inputs
Software Address Physical Address on Controller
0LT Pressure Switch I0
1RT Pressure Switch I1
2Heater HI Temp Switch I2
Controller Outputs
Software Address Physical Address on Controller
0RT Inlet Valve O0
1LT Inlet Valve O1
2RT Purge Valve O2
3LT Purge Valve O3
4Heater Contactor O4
5Remote Alarm O5
Expansion Module Outputs
Software Address Physical Address on Expansion Module
32 Blower 0
33 RT Depress Valve 1
34 LT Depress Valve 2
35 Repress Valve 3
Controller Analog Inputs
Physical inputs (Depends on various options (see machine specific wiring schematic))
AI0 Heater Output Temperature
AI1 Purge Temperature (monitors the purge air out the exhaust to turn the heater off at 190 deg F on
dryers with EMS option).
AI2 Dew Point Transmitter
AI3 Compressor Interlock (used on HL dryers to cycle the dryer on and off with the air compressor)
or Hi Tout (High air Temp Out of dryer (Option))

Setting Date Time on DPC
To set the Date and Time on the DPC press and hold the i button for 5 seconds, then press the set button.
System will appear in the display, press enter. Date and time will appear in the display Press enter to show
the current military time, press enter to set time and enter the current time using the number keys on the
key pad, when through press enter. Press set next to set the date, then enter to change the date using the
keypad numbers, when through press enter to save you selection. To return to the main menu keep
pressing the i button.
How the Dew point sensor works with the DPC
The EMS system has a dew point sensor that is powered by the dual voltage DC power supply located in
the control panel. The sensor power supply voltage should be 24 VDC + or - .05 VDC for proper
operation of the sensor. The sensor “reads” the dew point and sends a 4-20 DC Ma signal to terminal
TB2-18; at this point it is converted to a 0-5 VDC voltage signal because of a 250 Ohm precision resistor
that is grounded through TB2-17 (Note: refer to the model specific wiring for exact terminal numbers).
Troubleshooting Dew Point Problems
The best way to troubleshoot a problem with the dew point sensor is to first remove the probe from the
sample port and observe the reading on the DPC controller. It should start to rise as it is exposed to moist
ambient air, If not check the wiring connections. Most of the time problems with the EMS is either a lose
connections or a bad probe. The best way to determine if the controller is working properly is to source a
0-5 VDC signal to the controller (AN2 + and 0 volt (always refer to machine specific wiring schematic
for correct terminal)) and watch the DPC readout change. If the display does not change then the problem
is in the controller, if it does then check the wiring; resistor or probe because this is where the problem is.
The dew point meter reading can be compared with a known good dew point meter and the reading should
be within 2 or 3 degrees of the reading you are getting on the suspect meter to determine if the probe is
bad. Also Note: The air flow across the dew point probe should be very low, almost to the point that you
can’t feel the air flow out of the sample port. This air flow should be adjusted at the outlet of the sample
port; the inlet valve (if equipped) should be fully open. The tubing going to the sample port should be
stainless steel although copper can be used, never use polymer tubing. See the dew point scaling chart in
this document for more information concerning the dew point probe input to the DPC.
Various Resistors used with the DPC
There are 3 types of resisters used on the DPC controllers and they are as follows.
R1= 10K Ohm resister ¼ watt 1%, This resistor is used as a "pull up" resistor for the thermistors, one for
each temp sensor, installed from signal to ground.
R2 = 200 Ohm ½ watt .5 %, This resistor is used to put a base load on the power supply to ensure that it is
stable and in the regulation range, installed 5v to ground. Power supply voltage should be 5 VDC + or -
.05 volts DC.
R3 = 250 Ohm ¼ watt .01%, This resistor is used to convert the 4-20 Ma signal from the dew point sensor
to a 0-5 VDC signal for the DPC.

The following chart will help convert voltage coming back to the controller from the dew point probe to the dew point that
is displayed on the DPC controller. The DPC will issue alarm (Dew point Sensor Failure) if the voltage is less than
approximately 1.003 since this is the program set point for the alarm (Scaling range for the probe is +68 F to -148 F) . The
controller expects to see a voltage signal from approximately 1.025 VDC to 5 VDC. You will normally see the dew point
sensors fail to the extremely low side -148 and lower so this is why the alarm is setup this way. When checking the DCV
signal from the dew point sensor with your meter, always place your negative lead back the power supply ground and not
the equipment ground.

DESICCANT CONTROLLER OPTIONS
1 On POWERUP shows program version (DD01v01) for 10 sec then shows PRESS ON .
2 Enter TECH MODE (TM) anytime. Press 2+3. To turn enabled optional features ON or OFF.
3 Enter FACTORY MODE (FM) only when OFF. Press 2 then 5 then 3. To enable option features . New controls (July, 2009 and newer) press 2&5 in order to enter FACTORY MODE.
4 Press OFF to execute 30 sec SHUTDOWN SEQUENCE, opens inlet valves, closes purge valves.
5 Press "i" 5 sec to set time, see inputs and outputs. Press "i" several times to exit.
6 Press SELECT DISPLAY to move to next screen.
7 Press ENT (if displayed) to move to alternate screen, such as ALARMS or % TIME.
8 Press BLANK KEY to go back one screen in Customer Mode.
9 Press BLANK KEY at BEGIN TECH MODE to go back to Customer Mode.
10 Press BLANK KEY at BEGIN FACTORY MODE to go back to Customer Mode.
11 Main Displays are RT DRY LT REGEN and STEP 4 TIME 10300 (sec)
12 ALARM LIST; ENT to see last 20 ALARMS, DATE (dd;mm) and TIMES (hh:mm)
13 OPERATING TIMES; ENT to see Operating Hours; No purge hours; Heater Hours
14 If OFF, hit OFF to get back to PRESS ON
Dryer Type DPC Display
FEATURE NAME HL EH HB CUSTOMER Tec Mode Factory Mode ADD HDWRE DESCRIPTION
1 PDP ADJUSTER : -40, -4, 40 std no yes no none Changes cycle length to
change dewpoint; 16 m for -4;
24 m for +40
2 Restart: ZERO or AT FAIL std std std no yes no none On power fail, restart at
beginning (zero) or where
failed.
3 PURGE ADJUST, % Purge Select std no Select % no none Match length of purge to
compressor output.
4 Fail To Shift (FTS) opt opt opt FTS Alarm no yes Pressure switches Alarm if incorrect pressures at
steps 1,4,15,18
5 Dewpoint Temp opt opt opt HH Alarm;
Dewpoint
On/Off; set Select DEW TRANS Dew trans: -100
only plus cell.
Display dewpoint and hi
humidity alarm
6 EMS opt opt opt NO PURGE On/Off; set BRD or DEW
TRANS
DEWTRANS HTLS - midpoint bed with
board; HTD - outlet with
DEWTRANS
7 Hi Humidity (HH) opt opt opt HH Alarm On/Off; set BRD or DEW
TRANS
DEWTRANS Measure outlet dewpoint;
alarm if high
8 COMPRESSOR INTERLOCK std NO PURGE On/Off Enable none Close purge valve when
compressor unloads and
current purge finishes
9 -100 opt opt opt no yes Enable Repress line;
25% Mol Sieve
4 minute NEMA Cycle
10 Primary Operating Mode: HTLS std no yes Select HTLS Heatless cycle
11 Primary Operating Mode: HTD std no yes Select HTD Heated Cycle
12 Primary Operating Mode: BLWR std no yes Select BLWR Blower Cycle
13 High Outlet Temp Alarm (HOT) opt opt On Alarm On/Off; set Enable Thermistor in outlet Display alalrm on high outlet
temp
14 Power Saver (PSV)
(EMS)
opt opt No Purge On/Off Enable; Set Purge out
connection,
thermistor
Terminate purge when heat
comes through bed
15 Cool Sweep opt no On/Off Enable Purge line Add 1 hour of dry purge to
cooldown
16 Dual Mode std std no Select mode Enable none Standard with HTD or BLWR
17 Extended Heating (EXT HTG) opt opt no On/Off Enable DP TRANS plus
PWR SAVER
Extends heating for new dryers
with MLC and PWR Saver
18 PID Heater Control std std HTR Temp HTR Temp
Setpoint
P=200; I = 50; D=
10; PWM = 120
none Smooth operating heater
control
Bergh Desiccant DPC
Cheatsheet_IR Data.xls
10/25/2007