Ingersoll-Rand HC-3 User manual

SERIES HC
Heat-of-Compression
Compressed Air Dryer
Models HC-3 – HC-239
IMPORTANT! BEFORE INSTALLING AND
OPERATING THE DRYER, IT IS
RECOMMENDED THAT THIS
MANUAL BE STUDIED AND
CLEARLY UNDERSTOOD.
THIS DRYER IS DESIGNED TO BE
USED ONLY WITH A NON-
LUBRICATED COMPRESSOR. USE
WITH A LUBRICATED
COMPRESSOR WILL VOID ALL
WARRANTIES AND MAY CAUSE
SEVERE DAMAGE.
Information
When making inquiries,
please provide the following
information:
1) Equipment Model Number
2) Equipment Serial Number
3) Equipment Operating
Pressure
4) Equipment Operating
Temperature
5) Approximate time in
service
6) Nature of Problem
For information, parts,
or service, contact your
local I In ng ge er rs so ol ll l- -R Ra an nd d
Service provider or
reach us at
www.air.irco.com

AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in
material and workmanship for a period of twelve months from the date of placing the Equipment in operation
or eighteen months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall be
obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period,
whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or,
furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and
operated such Equipment in accordance with good industry practices and has complied with specific
recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by
others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed
on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the
Equipment or any costs of labor performed by the Purchaser or others without Company‘s prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are
limited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performance
warranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the period
of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company
in writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.
Note that this is Ingersoll–Rand standard warranty. Any warranty in force at the time of purchase of the equipment or
negotiated as part of the purchase order may take precedence over this warranty.

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 2 September 2004
INDEX
PREFACE
SECTION 1: INTRODUCTION
1.1 General Information
1.2 Safety Instructions
1.2.1 Identification of signs and symbols in this manual
1.2.2 Safety tips for maintenance, inspection & assembly work
1.3 Personnel Qualification
1.4 Product Information
1.4.1 Theory of Operation
1.4.2 Pressure vessel regulations
1.4.3 Airtightness test
1.4.4 Overloading
1.4.5 Technical data sheet
1.4.6 Dryer Flow Capacities
1.4.7 Transport
1.4.8 Storage
1.4.9 Use of an afterfilter
SECTION 2: INSTALLATION
2.1 Set-up and installation
2.1.1 Mechanical installation
2.1.2 Filter installation
2.1.3 Electrical installation
SECTION 3: START UP AND OPERATION
3.1 Start-up / Shut down
3.1.1 Pressurizing dryer
3.1.2 Energizing dryer controls

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 3 September 2004
3.2 Operator interface
3.2.1 Main screen
3.2.2 Dryer status
3.2.3 Settings
3.2.4 Alarms
3.3 Program Steps
SECTION 4: MAINTENANCE
4.1 Suggested preventive maintenance schedule
4.2 Replacement / Disposal of the desiccant
4.3 Dewpoint meter maintenance (DPDS Option only)
4.4 Filters
4.4.1 General comments and use
4.4.2 Function
4.4.3 Assembly and installation
4.4.4 Maintenance
4.4.5 Changing of filter elements
4.4.6 Accessories
SECTION 5: SPARE PARTS LIST
5.1 Recommended spares for HC-3 TO HC-239
SECTION 6: TROUBLESHOOTING AND FAULTS
6.1 Introduction
6.2 High Dewpoint
6.3 Fail-to-shift
6.4 Primary Drain Failure
6.5 Secondary Drain Failure
6.6 Short-term shut-down
6.7 Shut-down in case of a fault or for maintenance

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 4 September 2004
SECTION 7: I-R ACTIVATED ALUMINA MSDS
7.1 Company Description
7.2 Material Description
7.3 Ingredients
7.4 Physical Data
7.5 Fire and Explosion Data
7.6 Reactivity Data
7.7 Health Hazard Information
7.8 Spill, Leak, and Disposal Procedures
7.9 Special Protection Information
7.10 Special Precautions and Comments
7.11 References
SECTION 8: AUXILIARY MANUALS & DRAWINGS

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 5 September 2004
PREFACE:
Thistechnical manual from I In ng ge er rs so ol ll l- -R Ra an nd d® ®isanaidingettingtoknowtheadsorption
dryer better and in utilizing its possibilities for application in accordance with its
intended use. Furthermore, this manual contains important information for safe,
proper and economic operation.
All instructions must be followed as written in order to avoid danger and damages
which could cause downtime and premature wear and tear on the adsorption dryer.
Inadditiontothetechnicalmanualandtheaccidentpreventionregulationswhichare
valid in the particular location where the dryer is being used, the recognized special
rules for safe and proper working procedures must also be followed.
Each person involved with the set-up, start-up, operation, maintenance and repairof
the adsorption dryer in the User Company must have first read and understood the
technical manual and especially the safety tips.

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 6 September 2004
SECTION 1:
1.1 GENERAL INFORMATION
The adsorption dryer of the HC-3 – HC-239 series is built according to the latest
technological developments and recognized safety rules. Its use, however, can
endanger life and limb of the user or of third parties and can lead to considerable
damage to the adsorption dryer and other material assets if:
• it is operated by personnel not trained or instructed in its use,
• it is improperly used,
• It is improperly maintained or serviced.
This can result in the loss of all damage claims.
This adsorption dryer is designed for neutral media (gas) free of aggressive water,
oil and solid elements. I In ng ge er rs so ol ll l- -R Ra an nd d® ®accepts no liability for corrosion damage and
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.
In the interest of further development, I In ng ge er rs so ol ll l- -R Ra an nd d® ®reserves the right to make
changes at any time, which, in keeping with the essential characteristics of the
adsorption dryer described here, may be necessary for increasing efficiency or for
reasons relating to safety or to normal business practice.
1.2 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 before installation and start-up, as well as by the specialist / operator in
charge, and it must always be within reach at the place where the adsorption dryer
is being used.

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 7 September 2004
SECTION 1: (Continued)
1.2.1 Identification of signs and symbols in this technical manual
Thesafety tips contained in this technical manual, whosedisregardcould endanger
people and machines, are indicated by a general danger sign and the additional
markings Danger! Or Attention!
Danger! / Attention!
Warning against electrical voltage!
Safety tips printed directly on the adsorption dryer must also be followed at all times
and must be kept completely legible.
Advice: This sign refers to a procedure or sequence of particular
interest or importance. All tips must be followed to ensure
proper use of this adsorption dryer.
• This dot refers to working or operational steps.Thesteps are to be carried out in
the order of their appearance from top to bottom.
- The sign of a hyphen marks enumerations.
1.2.2 Safety tips for maintenance, inspection and assembly work
The operator is to make sure that all maintenance, inspection and assembly work is
carried out by special personnel who are authorized and qualified, and who are
adequately informed through careful study of the technical manual. For this reason,
special attention should be paid to the following attention and danger sign:

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 8 September 2004
SECTION 1: (Continued)
1.2.2 Safety tips for maintenance, inspection and assembly work (Continued)
Attention!
− Never make structural changes to the adsorption
dryer that are not specifically authorized by
Ingersoll-Rand!
− Only use original spare and accessory parts!
− Carry out maintenance work only when the
adsorption dryer is switched off, depressurized,
and disconnected from the electric power supply!
Attention!
− Multiple power sources may exist in the electrical
panel. All possible power sources must be
disconnected before servicing dryer.
Advice: Refer to the desiccant material safety data sheet (MSDS) when
installing or disposing of desiccant, which can be found in
Section 7 of this User Manual.
Danger!
Wear protective goggles and mask when workingwith the desiccant!
Advice for protection:
− If desiccant comes into contact with the eyes, rinse eyes immediately with large
amounts of clear water.
− If the desiccant is spilled, clean up with effort to minimize the formation of dust.
− In case of fire, there is no restriction on the use of fire extinguishing material.
− A small dust mask must be worn.
1.3 PERSONNEL QUALIFICATION
The personnel involved in operation, maintenance, inspection, and assembly must
have the corresponding qualifications to do this work. Areas of responsibility and
supervision of the personnel must be precisely established by the operator. Should
thepersonnel not possess the necessary knowledge, then they must be trained and
instructed. If need be, this training may be carried out by the manufacturer/supplier
at the request of the operator of the adsorption dryer. Further, the operator is to
make sure that the personnel completely understand the contents of the technical
manual.

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 9 September 2004
SECTION 1: (Continued)
1.4 PRODUCT INFORMATION
The adsorption dryer is used for the purpose of drying compressed air and other
gases according toits respective design. Asa "standard model" the adsorptiondryer
is equipped with two desiccant vessels and, depending on certain conditions,
provides pure, dry and oil-free compressed air or gases.
1.4.1 Theory of Operation
The HC heat-of-compression dryer uses the hot air from the compressor to
regenerate the desiccant. Each tower is sized for a minimum of 4 hours online,
but may be extended by use of the optional DPDS which will allow the dryer to
switch towers based on water load rather than time.
The DPDS (Dewpoint Demand System) is optional equipment and may or may
not be present on your particular air dryer. If your dryer is equipped with the
DPDS, see the associated DPDS Installation and Operating Guide for more
operational details.
The regeneration cycle is split up into three functions.

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 10 September 2004
SECTION 1: (Continued)
A. Regeneration Cycles
1. Heating. Hot air directly from the compressor enters the inlet of the HC
and is directed by the inlet 2-way valves into the regenerating tower. This
hot, thirsty air regenerates the bulk of the water from the desiccant. The
air is then directed into the aftercooler where it is cooled, the coalescing
separator where liquid water is removed through the drain trap system,
then into the drying tower where the air is actually dried to its final low
dewpoint. The heating cycle lasts 90 minutes.

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 11 September 2004
SECTION 1: (Continued)
2. Stripping. At the end of heating, the inlet valves shift position, directing
the hot inlet air directly into the aftercooler, separator, and drying tower.
We now begin stripping. The stripping phase of regeneration lasts 90
minutes. At the beginning of stripping, the regenerating tower is
depressurized through a muffler. During stripping, a small adjustable flow
of dry air is used to remove the last little bit of moisture from the
regenerating tower.

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 12 September 2004
SECTION 1: (Continued)
3. Cooling. At the end of stripping, the regenerating tower is repressurized.
The cooling cycle valves open and cooling begins. The cooling cycle lasts
60 minutes. During cooling, a portion of the dry outlet air is directed into
the regenerating tower to reduce the temperature of the bed prior to
tower shift.

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 13 September 2004
SECTION 1: (Continued)
1.4.2 Pressure vessel regulations
The pressure vessels are designed according to the standard technical
requirements. They fulfill the test of the certifying procedure and carry the “U”,
“UM” ASME Symbol.
Range of Application:
Type HC-3 – HC-239
Operating overpressure Max. 150 PSIG
Operating Temperature Max.
Min. 500°F 20°F
Attention!
Never weld on or alter a pressure vessel in any
way!
1.4.3 Airtightness test
All adsorption dryers are subjected to an airtightness test prior to shipment using
compressed air.
1.4.4 Overloading
Attention!
Protect the adsorption dryer from overloads!
The adsorption dryer can become overloaded, if:
− The inlet flow is too high,
− The temperature of the air at the discharge of the
aftercooler is too high,
− The min. operating pressure is too low,
− The temperature of the air at the discharge of the
compressor is too low.

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 14 September 2004
SECTION 1: (Continued)
1.4.5 Technical data sheet
MODEL HC-3 HC-6 HC-7 HC-9
Flow (SCFM) @ 100 PSIG
100°F Drying Temperature 301 535 677 836
Vessel OD – Inches 12 16 18 20
Desiccant type IR Activated Alumina
Lbs. Desiccant / Vessel 223 397 502 620
Inlet connection 2 NPT 2 NPT 3 FLG 3 FLG
Outlet connection 2 NPT 2 NPT 3 FLG 3 FLG
FILTER
• Afterfilter AF-350 AF-550 AF-1000 AF-1000
Voltage 115/1/60 Standard -
Consult Factory for other voltages
Cooling Water GPM 9 16 20 25
Stripping Flow SCFM 6 11 14 17
Cycle time 8 Hour NEMA Cycle –
4 Hours drying/ 4 Hours Regeneration
Outlet Dewpoint Variable
DPDS Control Adjustable
High Humidity Alarm Adjustable
Pressure Switch Setpoints 10 PSI Fail to Shift 60 PSI Initiate Cooling
Cooler outlet high
temperature alarm 105°F
Low regeneration
temperature alarm Adjustable
Process flow Downward Regeneration / Upward Drying

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 15 September 2004
SECTION 1: (Continued)
1.4.5 Technical data sheet
MODEL HC-14 HC-21 HC-30 HC-41
Flow (SCFM) @ 100 PSIG
100°F Drying Temperature 1204 1880 2708 3686
Vessel OD – Inches 24 30 36 42
Desiccant type IR Activated Alumina
Lbs. Desiccant / Vessel 893 1395 2009 2735
Inlet connection 3 FLG 4 FLG 4 FLG 6 FLG
Outlet connection 3 FLG 4 FLG 4 FLG 6 FLG
FILTER
• Afterfilter AF-1400 AF-2400 AF-3600 AF-7200
Voltage 115/1/60 Standard -
Consult Factory for other voltages
Cooling Water GPM 36 56 80 110
Stripping Flow SCFM 24 38 54 74
Cycle time 8 Hour NEMA Cycle –
4 Hours drying/ 4 Hours Regeneration
Outlet Dewpoint Variable
DPDS Control Adjustable
High Humidity Alarm Adjustable
Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling
Cooler outlet high
temperature alarm 105°F
Low regeneration
temperature alarm Adjustable
Process flow Downward Regeneration / Upward Drying

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 16 September 2004
SECTION 1: (Continued)
1.4.5 Technical data sheet
MODEL HC-54 HC-69 HC-85 HC-103
Flow (SCFM) @ 100 PSIG
100°F Drying Temperature 4814 6093 7522 9101
Vessel OD – Inches 48 54 60 66
Desiccant type IR Activated Alumina
Lbs. Desiccant / Vessel 3572 4521 5581 6753
Inlet connection 6 FLG 6 FLG 8 FLG 8 FLG
Outlet connection 6 FLG 6 FLG 8 FLG 8 FLG
FILTER
• Afterfilter AF-7200 AF-7200 AF-7200 AF-10000
Voltage 115/1/60 Standard -
Consult Factory for other voltages
Cooling Water GPM 143 138 172 208
Stripping Flow SCFM 96 122 150 182
Cycle time 8 Hour NEMA Cycle –
4 Hours drying/ 4 Hours Regeneration
Outlet Dewpoint Variable
DPDS Control Adjustable
High Humidity Alarm Adjustable
Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling
Cooler outlet high
temperature alarm 105°F
Low regeneration
temperature alarm Adjustable
Process flow Downward Regeneration / Upward Drying

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 17 September 2004
SECTION 1: (Continued)
1.4.4 Technical data sheet
MODEL HC-122 HC-143 HC-166
Flow (SCFM) @ 100 PSIG
100°F Drying Temperature 10832 12712 14742
Vessel OD – Inches 72 78 84
Desiccant type IR Activated Alumina
Lbs. Desiccant / Vessel 8037 9432 10939
Inlet connection 8 FLG 8 FLG 10 FLG
Outlet connection 8 FLG 8 FLG 10 FLG
FILTER
• Afterfilter AF-16000 AF-16000 AF-16000
Voltage 115/1/60 Standard -
Consult Factory for other voltages
Cooling Water GPM 247 289 335
Stripping Flow SCFM 217 254 295
Cycle time 8 Hour NEMA Cycle –
4 Hours drying/ 4 Hours Regeneration
Outlet Dewpoint Variable
DPDS Control Adjustable
High Humidity Alarm Adjustable
Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling
Cooler outlet high
temperature alarm 105°F
Low regeneration
temperature alarm Adjustable
Process flow Downward Regeneration / Upward Drying

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 18 September 2004
SECTION 1: (Continued)
1.4.6 Dryer Flow Capacities
Model Selection Chart:
MODEL 85 PSI 90 PSI 95 PSI 100 PSI 105 PSI 110 PSI 115 PSI
HC-3 262 274 287 301 313 327 342
HC-6 465 486 509 535 557 581 608
HC-7 588 615 645 677 705 735 769
HC-9 726 760 796 836 870 908 950
HC-14 1046 1094 1146 1204 1253 1308 1368
HC-21 1634 1709 1790 1880 1957 2042 2136
HC-30 2353 2462 2578 2708 2819 2941 3076
HC-41 3203 3351 3509 3686 3837 4003 4187
HC- 54 4183 4376 4583 4814 5011 5228 5469
HC-69 5295 5539 5801 6093 6343 6617 6922
HC-85 6537 6837 7161 7522 7830 8169 8545
HC-103 7909 8273 8664 9101 9474 9884 10339
HC-122 9413 9846 10312 10832 11276 11764 12305
HC-143 11047 11555 12102 12712 13233 13805 14441
HC-166 12812 13401 14035 14743 15347 16011 16748
Note: Maximum operating pressure is 150 PSIG; higher pressures available as an option. Consult factory.
Minimum Inlet Pressure (PSIG) 85 90 95 100 105 110 115
Correction Factor 1.15 1.1 1.05 1 .96 .92 .88
CORRECTION FACTOR FOR COOLING WATER TEMPERATURE
TEMPERATURE ºF 75 80 85 90
Correction Factor .85 .9 1.0 1.2
To correct for a cooling water temperature other than 85°F, or an operating pressure
other than 100 psig, multiply dryer capacity by the correction factors listed above.
Example: To size for an inlet flow of 1300 SCFM @ 90 Psig, using 90 ° F cooling water:
Multiply 1300 * (1.1) * (1.2) = 1716 Use model HC-21

USER MANUAL
Series HC
Reference No. 145 Final Rev 5 Page 19 September 2004
SECTION 1: (Continued)
1.4.7 Transport
After the adsorption dryer has been delivered, it must be checked for damage that
may have occurred during transport. The Transport Company must be informed to
register any damage. Shipping damage is not covered by any warranty.
1.4.8 Storage
If the adsorption dryer is to be stored for a prolonged period of time, it should be
stored in a dry place, preferably indoors; protected from the elements including
freezing or extremely warm temperatures.
1.4.9 Use of a pre and afterfilter
Use of a prefilter is not necessary with a heat-of-compression dryer. An afterfilter
should be provided to prevent desiccant dust from migrating downstream.