Ingersoll-Rand RD1600A Instruction manual

1
INSTALLATION, OPERATION & MAINTENANCE MANUAL
FOR
HEATLESS REGENERATIVE
COMPRESSED AIR DRYER
Model
RD1600A
Book: 22948434 (7-21-06) Rev A
This manual contains important safety information.
Do not destroy this manual. This manual must be available to the personnel who operate
and maintain this machine.
Revised (10-12)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.

2
Table of Contents
Warranty Statement Page 3
Section 1 Handling the Dryer Page 4
Section 2 Safety Instructions Page 5
Section 3 Dimensions and Specifications Page 6
Section 4 Installing The Dryer Page 8
Section 5 Start-Up Page 10
Section 6 Principle of Operation Page 11
Section 7 Operation Page 12
Section 8 Shutdown Procedure Page 13
Section 9 Maintenance & Troubleshooting Page 14
Section 10 Parts Ordering Page 16

3
INGERSOLL-RAND AIR DRYER WARRANTY
Ingersoll-Rand, through its distributors, warrants to the initial user that each AIR
DRYER manufactured by it, will be free of defects in material and workmanship
for a period of twelve (12) months from shipment to the initial user or eighteen
months from date of delivery from the factory to the distributor, whichever occurs
first.
Ingersoll-Rand will provide a new part or repaired part, at its election, in place of
any part, which is found upon its inspection to be defective in material and
workmanship during the period prescribed above. Such part will be repaired or
replaced without charge to the initial user during normal working hours at the
place of business of an Ingersoll-Rand distributor authorized to sell the type of
equipment involved or other establishment authorized by Ingersoll-Rand. User
must present proof of purchase at the time of exercising warranty.
The above warranty does not apply to failures occurring as a result of abuse;
misuse, negligent repairs, corrosion, erosion and normal wear and tear,
alterations or modifications made to the product without express written consent
of Ingersoll-Rand; or failure to follow the recommended operating practices and
maintenance procedures as provided in the product’s operating and maintenance
publications.
Accessories or equipment furnished by Ingersoll-Rand, but manufactured by
others, including, but not limited to, engines, shall carry whatever warranty the
manufacturers have conveyed to Ingersoll-Rand and which can be passed on to
the initial user.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR
IMPLIED, (EXCEPT THAT OF TITLE),AND THERE ARE NO WARRANTIES OF
MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.

4
DO N
O
T REM
O
V
E,REPAIR,OR REPLACE
A
NY ITEM ONTHIS DR
Y
ERWHILE IT IS PRESSURIZED.
HANDLING THE DRYER SECTION 1
1.1 HANDLINGINSTRUCTIONS
Lift the dryer by the skid (see fork lift access in SECTION 3) or the
lifting lugs on the dryer vessels.
If the unit is to be lifted by an overhead device, attach the lifting
chains or cables to the vessel lifting lugs. Make sure that the chains
or cables are clear of all piping and dryer components.
DO NOT LIFT THE DRYER BY PIPING OR CONTROL BOX.
THESE COMPONENTS ARE NOT DESIGNED TO HOLD
THE WEIGHT OF THE DRYER. PERSONAL INJURY
AND/OR EQUIPMENT DAMAGE MAY RESULT.
WARNING
1.2 STORAGEINSTRUCTIONS
The unit should be stored indoors and covered with a tarpaulin to
keep it clean. The location should be free from corrosive gasses
and extreme humidity, which will cause damage to the unit.
If outside storage is required, the unit MUST BE adequately
covered to prevent rain or snow from accumulating on the
dryer. The unit must be placed on a paved surface to keep it out
of standing water and mud.
1.3 EQUIPMENT CHECK
Inspect the dryer for any damage that may have occurred during
shipment. Inspect all fittings, piping connections, fasteners, etc. for
loose connections. Also check gauges and lights for cracks or
breakage.
IF DRYER HAS BEEN DAMAGED DURING SHIPMENT:
(1) NOTIFY CARRIER IMMEDIATELY AND FILE A CLAIM.
(2) CONSULT FACTORY BEFORE OPERATING THE
DRYER.

5
SAFETY INSTRUCTIONS SECTION 2
DECALS
Decals are located on the machine to point out potential safety hazards. Read and follow these
instructions. If you do not understand the instructions, inform your supervisor.
Note that there are different decal headings:
! DANGER (Red Background) Indicates the presence of a
hazard which WILL cause serious injury, death
or property damage, if ignored.
(Orange Background) Indicates the presence of
a hazard which CAN cause serious injury, death
or property damage, if ignored.
(Yellow Background) Indicates the presence of
a hazard which WILL cause serious injury or
property damage, if ignored.
(Blue Background) Indicates important set-up,
operating or maintenance information.
WARNING
CAUTION
NOTICE
!
!
FREE SAFETY DECALS
To promote communication of Safety Warnings on
products manufactured by the Portable Compressor
Division in Mocksville, N.C. safety decals are free of
charge. Safety decals are identified by the decal
heading: DANGER, WARNING or CAUTION. Decal part
numbers are on the bottom of each decal and are also
listed in the compressor’s parts manual.
Submit orders for safety decals to the Mocksville
Parts Service Department. The no charge order should
contain only safety decals. Help promote product
safety! Replace decals that are not readable.

6
2.1INSTALLATION
BEFORE STARTING INSTALLATION PROCEDURES, TURN OF
F
POWER. SERIOUSPERSONALINJURYMAYRESULTIF THIS SAFET
Y
RULE IS NOT FOLLOWED.
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON DRYER
WHILE IT IS PRESSURIZED.
THESE ASME CODE VESSELS MUST BE PROTECTED BY
PRESSURE RELIEF VALVES. Refer to OSHA 1910.169 Par. b, Sub.
Par (3) and ASME Boiler and Pressure Vessel Code, Section VIII,
Division 1, UG-125 through UG-136. Also comply with all
applicable state and local codes.
WHEN INSTALLING AND OPERATING THIS EQUIPMENT, COMPL
Y
WITH THE NATIONAL ELECTRICAL CODE AND ALL
A
PPLICABL
E
FEDERAL, STATE, AND LOCAL CODES.
WHEN INSTALLING THIS DRYER, MAKE SURE THAT THE NEM
A
RATING OF THE CONTROL BOX IS APPLICABLE TO TH
E
INSTALLATION.
MAKE SURE THAT ALL CUSTOMER SUPPLIED WIRING AN
D
ELECTRICAL DEVICES ARE PROPERLY SIZED TO HANDLE TH
E
ELECTRICAL REQUIREMENTS OF THE DRYER. USE THIS DRYER FOR COMPRESSED AIR ONLY. AIR
FROM THIS DRYER IS NOT SUITABLE FOR
BREATHABLE AIR SYSTEMS WITHOUT FURTHER
TREATMENT.
DO NOT OPERATE THIS DRYER IF EITHER VESSEL HAS BEEN
DAMAGED BY FIRE. TAKE OUT OF SERVICE IMMEDIATELY.
2.3MAINTENANCE
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THE
DRYER WHILE IT IS PRESSURIZED. TURN OFF MAIN POWER TO
THE DRYER AND DEPRESSURIZE THE DRYER COM- PLETELY
BEFORE STARTING MAINTENANCE PROCEDURES.
DO NOT WELD OR GRIND EITHER VESSEL. IT WILL NOT BE
SAFE TO OPERATE. (Note: Any uncertified alteration to the
vessels VOIDS the ASME Code Certification.)
INSPECT OUTSIDE AND INSIDE OF VESSELS REGULARLY FOR
CORROSION AND DAMAGE (I.E., DENTS, GOUGES OR
BULGES). ANY DAMAGE TO THE VESSELS CAN MAKE THEM
UNSAFE TO USE. IF DAMAGED, TAKE OUT OF SERVICE
IMMEDIATELY.
ENSURE THAT MAINTENANCE PERSONNEL ARE ADEQUATELY
TRAINED, COMPETENT AND HAVE READ THE MANUALS.
HIGH PRESSURE AIR CAN CAUSE SERIOUS INJURY OR DEATH.
RELIEVE PRESSURE BEFORE REMOVING FILLER PLUGS/CAPS,
FITTINGS OR COVERS.
ALL PRESSURE CONTAINING PARTS, ESPECIALLY FLEXIBLE
HOSES AND THEIR COUPLINGS, MUST BE REGULARLY
INSPECTED, BE FREE FROM DEFECTS AND BE REPLACED
ACCORDING TO THE MANUAL INSTRUCTIONS.
ALWAYS WEAR EYE PROTECTION, GLOVES AND A RESPIRATOR
Y
PROTECTIVE DEVICE WHEN HANDLING THE DESICCANT
.
DESICCANT DUST MAY CAUSE EYE AND SKIN IRRITATION.
A
VOI
D
BREATHING THE DUST AND PROLONGED CONTACT WITH TH
E
SKIN.
FIRST AID IN CASE OF EYE CONTACT WITH DESICCANT DUST
;
IMMEDIATELY FLUSH THE EYES WITH PLENTY OF WATER FOR
AT
LEAST 15 MINUTES. CONSULT A PHYSICIAN.
ALL AIR PRESSURE EQUIPMENT INSTALLED IN OR CONNECTE
D
TO THE MACHINE MUST HAVE SAFE WORKING PRESSUR
E
RATINGS OF AT LEAST THE MACHINE SAFETY VALVE SETTING.
DISCONNECTED AIR HOSES WHIP AND CAN CAUSE SERIOU
S
INJURY OR DEATH. ALWAYS ATTACH A SAFETY FLO
W
RESTRICTOR TO EACH HOSE AT THE SOURCE OF SUPPLY O
R
BRANCH LINE IN ACCORDANCE WITH OSHA REGULATION 29CF
R
SECTION 1926.302 (b).
WHEN LOADING OR TRANSPORTING MACHINES, ENSURE THA
T
THE SPECIFIED LIFTING AND TIE DOWN POINTS ARE USED.
2.2OPERATION
NEVER OPERATE UNIT WITHOUT FIRST OBSERVING AL
L
SAFETY WARNINGS AND CAREFULLY READING TH
E
OPERATION AND MAINTENANCE MANUAL SHIPPED FROM TH
E
FACTORY WITH THIS MACHINE.
ENSURE THAT THE OPERATOR READS AND UNDERSTAND
S
THE DECALS AND CONSULTS THE MANUALS BEFOR
E
MAINTENANCE OR OPERATION.
AIR DISCHARGED FROM THIS MACHINE MAY CONTAI
N
CARBON MONOXIDE OR OTHER CONTAMINANTS WHICH WIL
L
CAUSE SERIOUS INJURY OR DEATH. DO NOT BREATHE THI
S
AIR.
AIR PRESSURE CAN REMAIN TRAPPED IN AIR SUPPLY LIN
E
WHICH CAN RESULT IN SERIOUS INJURY OR DE
A
TH. ALWAY
S
CAREFULLY VENT AIR SUPPLY LINE AT TOOL OR VENT VALV
E
BEFORE PERFORMING ANY SERVICE.
WHEN USING COMPRESSED AIR, ALWAYS USE APPROPRIAT
E
PERSONAL PROTECTIVE EQUIPMENT.
AVOID BODILY CONTACT WITH COMPRESSED AIR. NEVE
R
ALLOW THE UNIT TO SIT STOPPED WITH PRESSURE IN TH
E
RECEIVER-SEPARATOR SYSTEM.
DO NOT OPERATE DRYER IF EITHER VESSEL IS LEAKING
.
IMMEDIATELY TAKE THE DRYER OUT OF SERVICE AND NOTIF
Y
YOUR CERTIFYING AUTHORITY. DO NOT OPERATE THIS DRYE
R
ABOVE THE MAXIMUM WORKING PRESSURE.
OPERATING CONDITIONS FOR PROPER PERFORMANCE OF THI
S
DRYER ARE DIFFERENT THAN MAXIMUM OPERATING CONDITION
S
FOR THE VESSELS. BE SURE TO CHECK THE DRYER OPERATIN
G
CONDITIONS.

7
DIMENSIONS AND SPECIFICATIONS SECTION 3
FLO
W
CAPACITIES (SCFM) at various pressures (100
0
F)
60 PSIG 80 PSIG 100 PSIG 110 PSIG 125 PSIG 140 PSIG 150 PSIG 175 PSIG
726 920 1114 1211 1357 1503 1600 1843

8
INSTALLING THE DRYER SECTION 4
4.1 LOCATION WARNING
DO NOT INSTALL THIS DRYER IN AN ENVIRONMENT OF
CORROSIVE CHEMICALS, EXPLOSIVE GASSES, POISONOUS
GASSES, OR SATURATED STEAM HEAT.
Locate dryer in a protected, well vented area where ambient
temperatures are between 40
o
F and 120
o
F. Allow sufficient clearance
over and around the dryer for access to desiccant fill and drain ports
and controls. Refer to SECTIONS 3.
This dryer was equipped with insulation and heat tracing installed on
the inlet piping, purge exhaust lines and the prefilter housing to
prevent freezing of the equipment when it is used in ambient
temperatures below 40°F. The control box is also equipped with a
box heater to protect the control circuit from freezing.
Position the dryer in the upright position on a solid, level, vibration free
surface capable of supporting the dryer’s weight.
The dryer should not be located in extremely dirty areas where airborne
contaminants can accumulate on the dryer. If this cannot be
prevented, the dryer should be cleaned periodically. An accumulation
of dirt on the dryer may cause the inlet transfer valve to fail.
4.2 PIPING AND ANCILLARY EQUIPMENT
CAUTION
Make sure that the inlet air piping to the dryer and the outlet piping
are connected as shown in Section 3.
Make sure that the inlet and outlet piping assemblies are properly
supported. Excessive stress may cause damage and/or dryer
malfunctions.
Remove protective caps or covers from all valves before installing this
dryer.
If this dryer is to be installed into an existing piping system, clean the
existing inlet piping to remove all accumulated dirt, pipe scale, etc.,
before connecting the dryer. Make sure that the inlet and outlet
shutoff valves are tightly closed before connecting to the existing
piping system.
If excessive vibrations are present in the piping, install a flexible hose
between the compressor and the dryer inlet.
When installing the piping and any additional components, make sure
that adequate pipe supports are used. Excessive stress on the dryer
and components may cause damage or premature failure. Use either
overhead or stiff-leg type supports.
Once the location has been determined, place the drye
r
into position pe
r
SECTION 1.1.
4.2-1 BYPASS PIPING (optional)
The installation of bypass piping is not required, but will allow the
dryer and filter(s) to be taken off stream without interrupting the air
system.
In Figure 4A, recommended bypass piping layout and components
are shown.
Basic bypass piping should include an inlet isolation valve, a bypass
valve, and an outlet isolation valve. The isolation and bypass valves
must be bubble-tight.
4.2-2 FILTERS
CAUTION
MAKE SURE THAT THE ELEMENTS ARE INSTALLED IN ALL
FILTER HOUSINGS PRIOR TO START-UP.
THE DRYER AND PREFILTER ARE NOT DESIGNED TO HANDLE
LIQUID WATER. IF LIQUID WATER IS PRESENT IN THE AIR
SYSTEM, A SEPARATOR WITH AN AUTOMATIC DRAIN MUST BE
INSTALLED UPSTREAM OF THE PREFILTER AND DRYER TO
PREVENT FLOODING.
A coalescing prefilter has been installed before the dryer to remove
lubricating oils, dust and pipe scale contamination. The filter is
equipped with a automatic float drain and a pressure differential
indicator to monitor the condition of the element.
A particulate afterfilter has been installed downstream of the dryer to
remove any desiccant dust. The filter is equipped with a manual
drain and a pressure differential indicator to monitor the condition of
the element.
4.3 PRESSURE RELIEF VALVES
FIGURE 4A RECOMMENDED BYPASS PIPING LAYOUT AND COMPONENTS
3
V
AL
V
E BYPASS
PRESSURE RELIEF VALVES. Refer to OSHA
1910.169 Par. b, Sub. Par (3) and ASME Boiler and
Pressure Vessel Code,
Section VIII, Division 1, UG-125 through UG-136.
Also comply with all applicable state and local
codes.
CAUTION
A
full flow pressure relief valve has been installed on each tower.

9
INSTALLING THE DRYER SECTION 4
4.4 REMOTE PURGE EXHAUST PIPING
To reduce noise during purging and tower depressurization, this dryer
was supplied with mufflers for installation on the purge exhaust valves. If
the noise or humidity discharged from the dryer is unacceptable at the
dryer location, the purge of this dryer can be piped to a remote
location.
4.6 ELECTRICAL CONNECTIONS
WARNING
SERIOUS PERSONAL INJURY AND DAMAGE TO THE DRYER
WILL OCCUR IF THE DRYER IS CONNECTED TO A POWER
SOURCE OTHER THAN THE VOLTAGE LISTED ON THE DATA
TAG.
IMPORTANT
Make sure that the piping is as short as possible and does not
create back pressure on the dryer. The purge line must be
vented to atmospheric pressure.
To prevent liquid accumulation in the piping and purge valves,
the piping must be at the same level or lower than the purge
valves.
The purge valves have threaded pipe connections. Reference Section
3 for location. Use adequate pipe supports to prevent stress on
valves.
The distance will determine the size of piping that is recommended.
For distances of 10 feet or less, use piping of the same size as the
purge valves. For distances up to 20 feet, use piping one size larger
than the purge valves.
WHEN INSTALLING THE ELECTRICAL CONNECTIONS FOR
THIS DRYER, COMPLY WITH NATIONAL ELECTRICAL CODE
AND ALL APPLICABLE FEDERAL, STATE AND LOCAL
CODES
Power must be connected to the dryer's control box.
Check the electrical rating of the dryer as listed on the dryer data tag.
Make sure that the power source is correct for the dryer rating.
Open the box cover to access the power and alarm terminals. Wire
the power supply as shown in Figure 4C. Comply with all codes
applicable for this installation.
FIGURE 4C ELECTRICAL CONNECTIONS
4.5 INSTALLING THE PURGE MUFFLERS
To reduce the sound level during purge and tower depressurization,
this dryer was supplied with mufflers for installation on the purge
exhaust valves.
Mufflers were shipped separately. They should NOT be installed until
the dryer has been operated for several hours. From desiccant
installation, some dust may be present in the desiccant towers.
Operating the dryer with the mufflers installed immediately after the
towers have been filled with the desiccant or during initial start up may
cause the mufflers to clog.
IMPORTANT
The dryer must be operated for several hours without the
mufflers after the towers have been filled with desiccant. This
will prevent the mufflers from becoming clogged.
FIGURE 4B PURGE MUFFLER INSTALLATION
Control Power: 115
V
/
1PH/60Hz
Max amp draw: 4.3 AMPS
General
A
larm Contacts: 115
V
-230V/1PH/60Hz, 0.25 am
p
s

10
START UP SECTION 5
5.1 START UP WARNING The required purge flowfor this dryer is 200 SCFM. This flow is required
to
p
ro
p
erl
y
re
g
enerate the desiccant beds.
BEFORE STARTING THIS DRYER, FOLLOW THE INSTALLATION
INSTRUCTIONS AND PROCEDURES COMPLETELY. SERIOUS
PERSONAL INJURY CAN RESULT IF INSTRUCTIONS ARE NOT
CAREFULLY AND COMPLETELY FOLLOWED.
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS
DRYER WHILE IT IS PRESSURIZED.
Make sure the Stop button is pressed.
If the dryer is being started up for the first time, or after the
desiccant has been changed, the purge mufflers must be removed.
The dryer should be operated until no desiccant dust is visible at
the purge valves. Then the mufflers can be reinstalled. See Section
2.1 for safety precautions concerning desiccant dust.
If the dryer is being operated at a pressure other than rated inlet
conditions, the purge metering valve must be adjusted to maintain 200
SCFM purge flow.
Determine the dryer minimum operating pressure. Using the chart
in Figure 5A, find the valve setting for that pressure. The valve
is equipped with a set screw which must be loosened before the
valve is adjusted. Adjust the needle valve to the desired setting.
Tighten the set screw to prevent tampering.
FIGURE 5
A
PURGE METERING
V
ALVE SETTINGS
WARNING
WHEN OPERATING THIS DRYER WITHOUT THE MUFFLERS
INSTALLED, USE HEARING PROTECTION.
If bypass piping was installed on this dryer as outlined in SECTION 4.2,
close the inlet and outlet isolation valves. O
p
en the b
yp
ass valve.
Pressurize the air system. Once the air system is pressurized, slowly
open the inlet isolation valve. DO NOT open the outlet isolation valve.
To start the dryer, press the Run button which will light the Run LED.
One tower will already be pressurized. The other tower will depres-
surize. The purge valve on the tower that is not pressurized will be
open, air should be exhausting from the muffler.
60 PSIG
3.2 turns 80 PSIG 2.95 turns 100 PSIG
2.80 turns 125 PSIG
2.65 turns
FACTOR
Y
SETTING
150 PSIG
2.60 turns 175 PSIG
2.50 turns
5.2 ADJUSTING THE PURGE FLO
W
IMPORTANT
NEVER OPERATE THE DRYER WITH THE PURGE METERING
VALVE CLOSED. IF THE VALVE IS CLOSED, THE TOWERS WILL
NOT REPRESSURIZE AND SWITCHING FAILURE WILL OCCUR.
DO NOT ADJUST THE PURGE METERING VALVE ABOVE OR
BELOW THE RECOMMENDED SETTING FOR THE OPERATING
CONDITIONS OF THIS INSTALLATION. IMPROPER SETTING MAY
CAUSE POOR DRYER PERFORMANCE AND/OR EXCESSIVE USE
OF PROCESS AIR.
The purge flow can be adjusted for the operating conditions. This
dryer is equipped with a micrometer type needle valve.
The valve can be adjusted to the desired setting.
This dryer was shipped with the purge flow set for the rated inlet flow
At 150 PSIG. Reference Section 3 for rated flow. This setting should
be correct for most installations. Before placing the dryer on stream,
check the purge metering valve setting.
5.3CONDITIONINGTHEDESICCANTBED
To condition the desiccant bed, the dryer is operated without any outlet flow,
while the towers regenerate with purge air.
To start the dryer, press the RUN button which will light the Run LED.
The dryer should be set on the 10 minute time cycle. Observe the dryer
for several cycles. Make sure that it is operating properly.
Atinitialstartuporafterextendedshutdowns(over onemonth),thedryer
may take 24 to 48 hours of continuous operation for the bed
to be conditioned. Moisturethathasaccumulated onthedesiccant bed
should be removed before the dryer is placed on stream.
Once the moisture indicator on the dryer turns blue, the desiccant
bed is ready. Place the dryer on stream by opening the outlet isolation
valve. Make sure that the by-pass valve is closed.
PRINCIPLE OF OPERATION SECTION 6
6.1PRINCIPLEOFOPERATION
The RD1600A Heatless Regenerative Air Dryer utilizes the
pressure swing principleofoperation. Thedesiccantbedinone
towerdriestheairstream while the desiccant bed in the
other tower is regenerated.
Apurgeofdryairisusedfortowerregeneration.Itistakenfromthe
outlet of the dryer.
The dryer is equipped with a purge metering valve to allow
the correct amount of dry air to flow into the regenerating tower.
The heat created during adsorption of moisture in the drying tower
is retained in the desiccantbedand increases themoisture
removalcapacityofthepurge air.
The timing cycle of the dryer is controlled by two 3-way pilot valves.
A
patented shuttle valve system is used to repressurize, changeover
,
and depressurize the towers. The inlet transfer valve is controlled by
the pilot valves. The movement of the shuttle in the inlet
transfer valve mechanically actuatesthe external pneumatic
limit switches, which open the purge valves and depressurize the tower
.
The shuttle cannot shift untilthetowerpressuresarenearlyequal.
Thedryercannotdepressurize until the shuttle has fully seated and
the one of the limit switches is engaged.
To achieve maximum performance from this dryer, it should be
operated continuously. Operating this dryer for single shift periods
may result in varied outlet dew point performance.
The dryer operation consists of four stages; REPRESSURIZATION,
CHANGEOVER/DEPRESSURIZATION, DRYING and
REGENERATION.