Ingersoll-Rand HC-3 User manual

U
Us se er r M Ma an nu ua al l
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

USER MANUAL
Series HC
Reference IR - 222 Rev 3
Page 2 10/17/2013

USER MANUAL
Series HC
Reference IR - 222 Rev 3
Page 3 10/17/2013
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 a pre and afterfilter
SECTION 2: INSTALLATION
2.1 Set-up and installation
2.1.1 Mechanical installation
2.1.2 Preventative maintenance prior to start-up
2.1.3 Filter installation
2.1.4 Electrical installation

USER MANUAL
Series HC
Reference IR - 222 Rev 3
Page 4 10/17/2013
SECTION 3: START UP AND OPERATION
3.1 Start-up
3.1.1 Pressurizing dryer
3.2 Operator interface
SECTION 4: MAINTENANCE
4.1 Suggested preventive maintenance schedule
4.1.1 Introduction
4.1.2 Periodic maintenance schedule
4.2 Replacement / Disposal of the desiccant
4.2.1 For first time fill-up
4.2.2 To replace used desiccant
4.3 Dew point meter maintenance (DPDS Option only)
4.4 Afterfilter
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 afterfilter elements
4.5 Filter Accessories

USER MANUAL
Series HC
Reference IR - 222 Rev 3
Page 5 10/17/2013
SECTION 5: TROUBLESHOOTING AND FAULTS
5.1 Introduction
5.2 High Dew Point
5.2.1 Changed operating conditions
5.2.2 Old desiccant
5.2.3 Towers not reversing
5.2.4 Cooler discharge air temperature too high
5.2.5 Dew point indication in error
5.2.6 Two-way valve leakage
5.3 Fail-to-shift
5.3.1 Solenoid valve failed to operate
5.3.2 Pilot air tubing leakage
5.3.3 Two-way switching valve actuator leakage
5.4 Primary Drain Failure
5.4.1 Plugging or sticking due to foreign matter
5.5 Secondary Drain Failure
5.5.1 Solenoid valve failure
5.5.2 Liquid level probe failure
5.6 Short-term shut-down
5.7 Shut-down in case of a fault or for maintenance
SECTION 6: SPECIFICATIONS, PARTS LIST(S), & DATA REPORTS
SECTION 7: AUXILIARY MANUALS (IF APPLICABLE)
SECTION 8: CUT SHEETS
SECTION 9: DRAWINGS

USER MANUAL
Series HC
Reference IR - 222 Rev 3
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PREFACE:
Thistechnicalmanual from I In ng ge er rs so ol ll l- -R Ra an nd d® ®isanaidingettingtoknowthe adsorption
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.
Inadditiontothetechnicalmanualandthe accidentpreventionregulationswhich are
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,maintenanceandrepairof
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 IR - 222 Rev 3
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SECTION 1
INTRODUCTION
Prior to installation and start-up of this dryer,
please read and implement this section.

USER MANUAL
Series HC
Reference IR - 222 Rev 3
Page 8 10/17/2013
SECTION 1:
INTRODUCTION
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 IR - 222 Rev 3
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SECTION 1: (Continued)
1.2.1 Identification of signs and symbols in this technical manual
Thesafetytips contained in this technical manual, whose disregard could 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.

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Series HC
Reference IR - 222 Rev 3
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SECTION 1: (Continued)
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:
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 8 of this User Manual.
Danger!
Wear protective goggles and mask whenworkingwith 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.
Danger!
Do not attempt to service or maintain dryer while system is hot!