Ingersoll-Rand TZ730 User manual

Heaterless Desiccant Adsorbent Compressed Air Dryer
Models TZ730 to TZ1710
This dryer configuration includes equipment
options as selected (X) below:
EMS OPTION
LDP OPTION
3V OPTION
More Than Air. Answers.
Online answers: http://www.air.irco.com
Phone : [phone]
Form: APDD 789
CCN: 38019691
Z103155 Rev. 08

ii

USER MANUAL
MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
iii
FOREWORD
Reading this user manual will fully familiarize you with the I In ng ge er rs so ol ll l- -R Ra an nd d®®adsorption
dryer. You will be better able to run this equipment in accordance with its intended use.
This manual contains important information for safe, proper and economic dryer
installation, start-up, operation and maintenance. Always keep it within reach where the
adsorption dryer is being used.
It is necessary to follow all instructions as written. Careful reading will avert danger,
avoid unnecessary downtime and minimize work for yourself and wear on the
equipment.
In addition to carefully reading this technical manual in its entirety, you must understand
your National, State and local rules and regulations regarding safety in the workplace,
their necessary precautions and procedures.
Each person responsible for the set-up, start-up, operation, maintenance or repair of
this adsorption dryer must have first read and understood this user manual – including
all the safety tips.
NOTE: IInnggeerrssoollll--RRaanndd®®recommends that installation, start-up and maintenance be
carried out by its factory-trained technicians in a regularly scheduled,
site-dedicated program. This will ensure the safety of personnel, the
integrity of equipment and the surety of warranty coverage.

USER MANUAL
MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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USER MANUAL
MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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TABLE OF CONTENTS
1. INTRODUCTION...........................................................................................................................................1
1.1 GENERAL.....................................................................................................................................................1
1.2 PRODUCT INFORMATION ...............................................................................................................................1
1.2.1 Pressure Vessel Regulations ..................................................................................................................2
1.2.2 Airtightness Test....................................................................................................................................2
1.3 SAFETY INSTRUCTIONS.................................................................................................................................2
1.3.1 Identification of Signs and Symbols in this Manual.................................................................................2
1.3.2 General Safety Tips for Assembly, Inspection and Maintenance..............................................................3
1.4 TECHNICAL DATA SHEET..............................................................................................................................4
1.5 OVERLOADING ............................................................................................................................................. 5
1.6 TRANSPORT..................................................................................................................................................5
1.7 STORAGE .....................................................................................................................................................5
1.8 USE OF A PREFILTER AND AFTERFILTER ........................................................................................................5
2. INSTALLATION ............................................................................................................................................7
2.1 GENERAL.....................................................................................................................................................7
2.2 ELECTRICAL CONNECTION............................................................................................................................7
2.3 FILTERS........................................................................................................................................................ 7
2.4 PURGE EXHAUST.......................................................................................................................................... 8
3. EQUIPMENT OPERATION..........................................................................................................................9
3.1 GENERAL OPERATING PRINCIPLES ................................................................................................................9
3.2 OPERATORCONTROLS ................................................................................................................................10
3.3 INITIAL START-UP......................................................................................................................................10
3.4 SHORT-TERM SHUT-DOWN.........................................................................................................................11
3.5 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE ........................................................................... 11
3.6 RESTARTING ..............................................................................................................................................12
4. MAINTENANCE........................................................................................................................................... 13
4.1 CHECKLIST.................................................................................................................................................13
4.1.1 Daily Check ........................................................................................................................................ 13
4.1.2 Weekly Check......................................................................................................................................13
4.1.3 Whichever Is First: After 2,500 Operating Hours or Annually.............................................................14
4.2 CHANGING THE FILTER ELEMENT................................................................................................................14
4.3 REPLACEMENT OF THE DESICCANT..............................................................................................................14
4.4 CHANGING THE PURGE REGENERATION ORIFICE..........................................................................................15
5. SPARE PARTS LIST....................................................................................................................................17
5.1 SPARE PARTS LIST FOR DRYER SERIES TZ730 TO TZ1050........................................................................... 17
5.2 SPARE PARTS LIST FOR DRYER SERIES TZ1200 TOTZ1710 .........................................................................18
6. FAULTS AND TROUBLESHOOTING .......................................................................................................19
6.1 DEW POINT TOO HIGH ................................................................................................................................19
6.2 VESSELSDONOT SWITCH OVER.................................................................................................................19
7. DRAWINGS..................................................................................................................................................21
APPENDIX A– MSDS: ACTIVATED ALUMINA .......................................................................................A-1
APPENDIX B – DRYER OPERATING SEQUENCE.................................................................................... B-1
APPENDIX C– DRYER FLOW CAPACITY & PURGE ADJUSTMENT...................................................C-1

USER MANUAL
MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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USER MANUAL
MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
1
1. INTRODUCTION
1.1 GENERAL
This adsorption dryer includes the latest technology and safety features. Its use,
however, can endanger life and limb and can lead to considerable damage to the
equipment and other material assets if:
 it is operated by personnel not instructed in its use,
 it is improperly used,
 it is improperly maintained or serviced.
Furthermore, ignorance of its use and proper service can result in the loss of any claim
for damage.
This adsorption dryer is designed for neutral media (such as air or nitrogen) which is
free of aggressive water, oil and solid elements. IInnggeerrssoollll--RRaanndd®®accepts no liability for
corrosion damage or malfunctions caused by aggressive media.
Applications other than those mentioned in this manual must be agreed to by I In ng ge er rs so ol ll l- -
R
Ra an nd d®®and confirmed in writing.
I
In ng ge er rs so ol ll l- -R Ra an nd d®®reserves the right to make changes at any time as may be necessary for
increasing safety or efficiency, or In the interests of further development.
1.2 PRODUCT INFORMATION
The adsorption dryer is used for the purpose of drying compressed air and other gases
according to its contracted design. Depending on certain conditions at the inlet, it
provides pure, dry and oil-free compressed air or gases. The standard model of
adsorption dryer is equipped with two desiccant vessels and a prefilter and afterfilter.
This standard model of dryer does not include an Energy Management System (EMS)
to provide automatic monitoring and control of the work/regeneration cycle to optimize
equipment efficiency. It is optionally available for retrofit if required. This manual also
includes references to optionally available Low Dew Point (LDP) and 3V (bypass)
systems/assemblies which may or may not be provided. Selected options included with
this dryer are indicated on the cover page by an “X” mark in the box.

USER MANUAL
MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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1.2.1 PRESSURE VESSEL REGULATIONS
The pressure vessels are designed and built to meet the American Society of
Mechanical Engineers (ASME) standards. They fulfill the test of the certifying procedure
and carry the ASME symbols Uor UM.
RANGE OF APPLICATION
Design Pressure Max: 150 psig
Design Temperature Max: 500 °F (260 °C)
Min: -20 °F (-29 °C)
1.2.2 AIRTIGHTNESS TEST
Each IInnggeerrssoollll--RRaanndd®®adsorption dryer is subjected to, and must pass, an airtightness test
prior to shipment.
1.3 SAFETY INSTRUCTIONS
This technical manual contains basic tips which must be followed during set-up,
operation and servicing. It is of utmost importance that it be read by the assembly
technician beforeinstallation and start-up as well as by the specialist/operator in charge.
It must always be within reach at the place where the adsorption dryer is being used.
1.3.1 IDENTIFICATION OF SIGNS AND SYMBOLS IN THIS MANUAL
The safety tips contained in this manual, whose disregard could endanger people and
equipment, are indicated by a general danger sign and the additional markings Danger!
or Attention! or Warning!
Danger! / Attention!
Safety sign in accordance with DIN 4844 - W9
Warning – high voltage!
Safety sign in accordance with DIN 4844 - W8
Safety tips printed directly on the adsorption dryer must be heeded at all times and must
be kept completely legible.

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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1.3.2 GENERAL SAFETY TIPS FOR ASSEMBLY, INSPECTION AND MAINTENANCE
The purchaser is to ensure that all assembly, maintenance and inspection work is
carried out by personnel qualified to do it.
The personnel involved in assembly, operation, maintenance and inspection must have
the corresponding qualifications to do this work. Areas of responsibility and supervision
of the personnel must be clearly established by the purchaser. Should the personnel
not possess the necessary knowledge, then they must be instructed. If need be, this
training may be carried out by the manufacturer/supplier at the request of the purchaser.
Further, the purchaser is to ensure that all personnel completely understand the
contents of this manual.
Attention!
Never make structural changes to the adsorption dryer
Only use recommended spare parts as listed in section 5
Never weld on a pressure vessel or change it in any way
Carry out maintenance only when the adsorption dryer is OFF,
depressurized and disconnected from the electric power supply.
Danger!
Refer to the desiccant Material Safety Data Sheet (MSDS) when
installing or disposing of desiccant (see Appendix A)
Wear protective goggles when working with the desiccant
If desiccant comes into contact with the eyes, rinse eyes
immediately with a lot of clear water
If the desiccant is spilled, clean up without causing swirls of dust
In case of fire, there is no restriction on the use of fire extinguishing
material; the reaction with water and foam is defined as strong
A mask must be worn whenever handling desiccant.

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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1.4 TECHNICAL DATA SHEET
Model TZ730 TZ820 TZ1050 TZ1200 TZ1450 TZ1710
Medium Air free of aggressive elements
Flange (150#)
Connection 3 inches 3 inches 3 inches 3 inches 3 inches 4 inches
STD flow capacity
(1) SCFM 730 820 1050 1200 1450 1710
LDP flow capacity
(1) SCFM 511 574 735 840 1015 1197
Desiccant
Standard Input temp from 100°F and dew point (2)-40°F
Filled with activated alumina
LDP Dryers Input temp from 100°F and dew point (2) -100°F
Filled with activated alumina
Desiccant Quantity
Per Chamber
(pounds) 405 460 600 700 800 952
Filter Size 1100 1100 1100 1380 1380 2100
Control Printed Circuit Board
Operating Electrical Power
Standard 120 Vac / 60 Hz
Special Voltage Consult factory Drying Time
Standard 5 min
LDP Dryers 2 min
(1) Flow capacity in scfm at 100 psig according to DIN ISO 7183
(2) Pressure dew point
NOTE: Settings for EMS:
 Standard dryers: EMS Control -40°F (-40°C) / High humidity -35°F (-35°C)
 LDP Dryers: EMS Control -100°F (-74°C) / High humidity -95°F (-69°C)

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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1.5 OVERLOADING
Attention!
Protect the adsorption dryer from overloads!
The adsorption dryer can become overloaded if:
The flow capacity of the medium to be dried increases
The temperature of the air at entry and, correspondingly, its
humidity increases
The minimum operating pressure is undercut
The prefiltration and separation of impurities are not sufficient
Introduction of oil into the air stream.
1.6 TRANSPORT
Immediately upon delivery of the adsorption dryer, it must be checked for any damage
that may have occurred during transport. If necessary, the damage must be recorded
on the shipping waybill/receipt. Liability for such damage usually rests with the shipper.
Contact I In ng ge er rs so ol ll l- -R Ra an nd d®
®to arrange for any required service or replacement parts.
Attention!
For transport within the company, only the skids of the adsorption dryers
may be used for lifting. Lifting at any other points on the equipment will
void the warranty and damage the equipment.
1.7 STORAGE
If the adsorption dryer is to be stored for a long period of time, its place of storage must
be dry and free of dust. The ambient temperature cannot go below 33°F (+1°C).
1.8 USE OF A PREFILTER AND AFTERFILTER
In order to prevent droplets of condensate, oil and dirt from getting into the desiccant, a
prefilter is installed in front of the adsorption dryer. An oil film on the desiccant reduces
the drying capacity and the dewpoint. In order to prevent breakdown in downstream
consumers caused by material that has been abraded from the desiccant bed, an
afterfilter is mounted behind the adsorption dryer. Since no condensate accumulates in
the afterfilter, this filter is always equipped with a manual vent valve.
Both filters are equipped with a differential pressure indicator as this ensures a direct
display of the degree of contamination of the filter elements.

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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USER MANUAL
MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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2. INSTALLATION
2.1 GENERAL
Ensure that the installation site is free of dust, dirt and litter. The site floor must be level
and strong enough to support the equipment. The site itself must ensure that the
equipment will not, under any circumstances, freeze.
Ensure that the IInnggeerrssoollll--RRaanndd®®adsorption dryer is carried only by its skid base frame.
The adsorption dryers must be positioned so that the side from which it is to be
operated is easily accessible. The upstream piping is to be connected at a slightly
downward slope towared the prefilter. Install shut-off valves on the inlet to the prefilter
and outlet of the afterfilter. Also, a bypass pipe with an additional shut-off valve should
be mounted onto the adsorption dryer to allow for an uninterrupted supply of
compressed air when the adsorption dryer requires maintenance or repair. The bypass
assembly is not provided: it is optionally available or can be customer furnished. If
vibrations occur at the installation site, the adsorption dryer skid frame must be placed
onto vibration dampers to avoid wearing down the desiccant by friction.
2.2 ELECTRICAL CONNECTION
Since the adsorption dryer has already been completely internally wired at the factory,
the customer only has to connect the power supply cable to the terminal strip according
to the supplied wiring diagrams (see section 7).
Warning – high voltage!
Be sure that power is removed from the line feed before making
connection between the site drop and the equipment.
This I In ng ge er rs so ol ll l- -R Ra an nd d®®adsorption dryer is normally controlled with a printed circuit board.
The set times are adjusted at the factory during the test run. Do not change these
adjustments!
NOTE: Contact IInnggeerrssoollll--RRaanndd®
®at 1 800 526-3615 if you have any questions.
2.3 FILTERS
If not already factory installed, you must install the prefiliter and afterfilter assemblies
where the air or gas temperature is lowest:
 The piping system must be cleaned.
 The filters must be installed vertically.
 An arrow on the upper part of the housing marks the direction of flow.

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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 Sufficient free space must be left below the filter housing to allow removal of the
filter bowl when changing filter elements.
2.4 PURGE EXHAUST
The purge exhaust may be piped to an open vent. Noise levels at the dryer may be
reduced by extending the purge exhaust piping to a remote location. Refer to the purge
piping selection chart below to prevent backpressure build-up.
EXTENDED LENGTHPIPE SIZE REQUIRED
TO 10 FEET SAME SIZE AS DRYER EXHAUST
TO 25 FEET 1 SIZE LARGER THAN DRYER EXHAUST
TO 50 FEET 2 SIZES LARGER THAN DRYER EXHAUST
TO 100 FEET 3 SIZES LARGER THAN DRYER EXHAUST
Extending purge exhaust piping must not affect the back pressure of a chamber being
regenerated. A pressure reading of 3-psig is considered too high for the dryer to
regenerate efficiently.

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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3. EQUIPMENT OPERATION
3.1 GENERAL OPERATING PRINCIPLES
This I In ng ge er rs so ol ll l- -R Ra an nd d®®dryer has two parallel adsorption chambers filled with desiccant.
While the medium is being dried flowing bottom-up in one chamber, regeneration of the
desiccant takes place from the top down in the other chamber. The changeover from
one chamber to the other is controlled by an Energy Management System (EMS) that
monitors desiccant performance by measuring the outlet air dew point. It can operate
continuously and is fully automatic.
The standard (STD) dryer has a cycle time of 10 minutes. Dryers with the Low Dew
Point (LDP) option have a 4-minute cycle time. In each case, half the cycle time is
dedicated to air drying work and the other half to desiccant regeneration, with one
chamber working to dry the air while the other regenerates. The cycle time affects air
flow and air quality. The longer cycle time allows greater saturation of the desiccant,
thereby decreasing its drying capacity over the period of the cycle. The faster cycling
provided with the LDP option ensures that the desiccant is regenerated more frequently,
thereby enhancing its drying performance. The dryer is configured at the factory. The
principles of operation are the same for both the STD and the LDP dryer.
Wet air enters the working desiccant chamber (it can be either the left or right) at the
inlet switching valve (bottom) and is dried as it flows upward through the desiccant bed.
Dry air exits the dryer through the outlet check valve.
At the outlet of the working chamber, a portion of the dry air (i.e., purge air) is diverted
to the regenerating chamber. That purge air, at near atmospheric pressure, will remove
previously adsorbed moisture as it flows downward through the desiccant bed and exits
through the purge exhaust muffler.
The purge air is controlled by a purge adjusting valve and purge orifices located in the
purge line. Purge pressure is indicated on the purge pressure gauge. Refer to
Appendix C for instructions on adjusting the purge rate.
Near the end of each half cycle, the chamber being regenerated will be repressurized.
For this to occur, the exhaust valve of the chamber being regenerated closes while
purge air continues to flow. Repressurizing the regenerated chamber to operating
pressure before placing it into service minimizes fluidization of the desiccant and helps
prevent desiccant abrasion which causes desiccant dust to prematurely block filter
elements.
Chamber switchover takes place when both towers are fully pressurized. This
minimizes desiccant movement which, in turn, minimizes creation of dust.
When switchover is complete, the regenerated tower will be placed into service and the
exhausted tower will begin a depressurization/regeneration cycle.

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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This dryer is designed to provide a specific pressure dewpoint performance (generally
-40°F (-40°C)) at worst-case operating conditions (maximum flow at lowest pressure
and highest inlet temperature). The regeneration purge flow rate required for the dryer
is adjusted to achieve that dewpoint based on those conditions.
For example, for dryers operating at 100 psig (690 kPa) and 100°F (38°C), the purge
flow rate is approximately 15% of the specified maximum inlet flow. Dryers operating
under less severe inlet conditions will introduce a reduced humidity load. The EMS
controls have been factory programmed to monitor the dryer outlet dewpoint so that
regeneration will only begin when low desiccant performance registers.
3.2 OPERATOR CONTROLS
The operator electrical control panel features the following indicators/controls:
 Dryer nameplate
 Three-way selector switch:
oDRYER OFF
oDRYER ON
oEMS ON (not functional on standard, non-EMS-equipped dryers)
There are shutoff valves on the prefilter, dryer chambers and afterfilter. They are
operated manually. There is another shutoff valve on dryers with the 3V option (i.e.,
bypass assembly – see paragraph 1.2).
There are two filters. The lower filter (i.e., prefilter) housing has a differential pressure
indicator (DPI) and an automatic drain. The upper filter (i.e., afterfilter) housing has a
DPI and vent valve.
Each chamber has a chamber relief valve at the top, a pressure gauge and desiccant
fill/drain (top/bottom) ports.
3.3 INITIAL START-UP
Attention!
All pipes and wire connections must be tightened!
Furthermore, before start-up:
 The pipes must be checked for the presence of scale,abraded
material from the threading, or other similar impurities.
 All shut-off valves on the prefilter, adsorption dryer, afterfilter and on
the bypass line (if installed) should be closed.
 The ambient temperature must not be less than 33°F.

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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NOTE: Breakdown resulting from faulty installation does not fall under the
I
In ng ge er rs so ol ll l- -R Ra an nd d®
®warranty obligation.
Perform the following tasks in sequence for the initial start-up:
 Remove purge exhaust mufflers for the initial 1 to 2 hours of operation
 Slowly open the inlet valve and observe the pressure build-up on the chamber
pressure gauge of the adsorption dryer. An abrupt pressure build-up is to be
avoided
 Turn the switch to the DRYER ON position.
 The adsorption dryer must be powered approximately 3 to 4 hours with the shut-
off valve behind the afterfilter closed. This regenerates the desiccant.
 After the regeneration phase, open the shut-off valve behind the afterfilter slowly
while observing the chamber pressure gauge. If the shut-off valve is opened
abruptly, it could put a stress on the system.
The adsorption dryer is now ready for operation and functions continuously and
fully automatically.
3.4 SHORT-TERM SHUT-DOWN
Follow this sequence when switching off theadsorption dryer:
 First close all the shutoff valves up- and downstream of dryer
 Then immediately switch DRYER OFF.
Danger!
Dryer will remain pressurized.
3.5 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE
Follow this sequence when switching off theadsorption dryer:
 First close all the shutoff valves up- and downstream of the adsorption dryer,
 Depressurize the dryer by using the hand valve mounted at the bottom of the
afterfilter,
 Then immediately switch DRYER OFF.

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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Danger!
Before any kind of maintenance or repair work is done, the dryer must
be depressurized and disconnected from the power source.
3.6 RESTARTING
 Close the hand valve mounted at the bottom of the afterfilter
 Slowly open the inlet isolation valve and pressurize the adsorption dryer up to the
regular operating pressure by keeping closed the shutoff valve mounted behind
the afterfilter
 Switch DRYER ON.
NOTE: If the dryer is restarted after a long standstill, proceed as for an initial
start-up (see paragraph 3.3).

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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4. MAINTENANCE
4.1 CHECKLIST
These checks are to be carried out by the operator during the routine operations cycle.
4.1.1 DAILY CHECK
 Carry out a general visual check of fittings, listen for a whistle which may identify
an air leak, and watch out for changes in indicated values during operation
 Check the silica gel outlet moisture indicator:
oBlue indicates an approximate dew point of -13°F
oPink indicates an approximate dew point of 32°F
oTransparent indicates an approximate dew point of 59°F.
 Check function by manually operating the automatic condensate drain on the
prefilter.
NOTE: Should the need for spare parts or service arise during work on the
adsorption dryer, then the dryer type and its construction must be
conveyed to I In ng ge er rs so ol ll l- -R Ra an nd d®®.This information is given on the nameplate
mounted on the electric cabinet. Telephone [phone] to arrange for
maintenance support.
4.1.2 WEEKLY CHECK
 Check the differential pressure on the prefilter, which should not exceed 5 psi(d).
Values greater than this indicate that the filter must be changed (see paragraph
4.2).
 Check the differential pressure on the afterfilter, which should not exceed 5
psi(d). Values greater than this indicate that the filter must be changed.
 Check the pressure of the regenerating vessel during regeneration after
depressurization. Any back pressure caused by blocked exhaust mufflers will
show there. Back pressure on the regenerating tower should not exceed 3 psig.
 Drain pilot filter/moisture indicator housing of any condensate.

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MODEL NO.: TZ730–1710
Rev. 08 – 14 September 2005
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4.1.3 WHICHEVER ISFIRST: AFTER 2,500 OPERATING HOURS OR ANNUALLY
 Check the desiccant for impurities and change it if necessary (see paragraph
4.3). A brownish/yellowish tone indicates that it has been soiled with oil. The
desiccant has a normal lifetime of about 10,000 operating hours.
 Check the outlet desiccant screens installed in the unit and, if necessary, clean
them.
 Check the function of the inlet valve assembly by sending electrical control
signals.
 Check the seat gaskets on the outlet check valves.
 Replace the dewpoint sensor humidity probe (return the original for calibration).
NOTE: In order to ensure continuous and trouble-free operation, a maintenance
contract with IInnggeerrssoollll--RRaanndd®
®is recommended.
4.2 CHANGING THE FILTER ELEMENT
 The filter element within the filter housing must be replaced when a differential
pressure of greater than 5 psi(d) has been reached or after one year of operation
 Depressurize the dryer and switch DRYER OFF
Danger!
Change filter elements only when the housing is fully
depressurized
 Separate the lower part of the housing from the upper part
 Loosen and remove the element by hand
 Install the new filter and the O-ring gasket, making sure that the filter seats
perfectly
 Refit the filter housing.
NOTE: Filter elements cannot be cleaned or reused.
4.3 REPLACEMENT OF THE DESICCANT
Dessicant life is determined by the quality of inlet air. Proper filtering of inlet air will
extend the life of the dessicant. In order to ensure trouble-free operation, we
recommend replacing the desiccant every 10,000 operating hours, or at least every 3
years.