Pressure-Swing Desiccant Type Compressed Air Dryers: Instruction Manual

Bulletin M733E
A, (03/09)
Revision
Copyrightⓒ2008 SPX Corporation. All rights reserved.
INSTRUCTION MANUAL
HHE, HHL and HHS SERIES

with AccuShift™ Switching Valves
MODELS
REFER
HHE HHL HHS RATED
AS
SERIES SERIES SERIES FLOW
MODELS
w/ Timer w/ Level 1 w/ Level 2
Controller Controller Controller
HHE-1.1 HHL-1.1 HHS-1.1 40 SCFM 1.1

HHE-1.6 HHL-1.6 HHS-1.6 60 SCFM 1.6
HHE-2.5 HHL-2.5 HHS-2.5 90 SCFM 2.5
HHE-3.2 HHL-3.2 HHS-3.2 115 SCFM 3.2
HHE-4.6 HHL-4.6 HHS-4.6 165 SCFM 4.6
HHE-7.3 HHL-7.3 HHS-7.3 260 SCFM 7.3
HHE-10.4 HHL-10.4 HHS-10.4 370 SCFM 10.4
HHE-12.7 HHL-12.7 HHS-12.7 450 SCFM 12.7
HHE-16.7 HHL-16.7 HHS-16.7 590 SCFM 16.7
HHE-21.2 HHL-21.2 HHS-21.2 750 SCFM 21.2
HHE-26.3 HHL-26.3 HHS-26.3 930 SCFM 26.3
HHE-31.9 HHL-31.9 HHS-31.9 1130 SCFM 31.9
HHE-38.2 HHL-38.2 HHS-38.2 1350 SCFM 38.2
HHE-43.8 HHL-43.8 HHS-43.8 1550 SCFM 43.8
HHE-59.4 HHL-59.4 HHS-59.4 2100 SCFM 59.4
HHE-84.9 HHL-84.9 HHS-84.9 3000 SCFM 84.9
PRESSURE-SWING
HHE-116.0 HHL-116.0 HHS-116.0 4100 SCFM 116.0
HHE-152.9 HHL-152.9 HHS-152.9 5400 SCFM 152.9
Contents
DESICCANT TYPE
1. General Safety Information................................. 2
2. Receiving, Moving, Unpacking............................... 2
3. Description.................................................................. 3
4. Installation.................................................................. 8
5. Controllers – General........................................... 16
COMPRESSED
6. Controller – Timer Based...................................... 18
7. Controller – Level 1................................................ 21
8. Controller – Level 2................................................ 32
9. Operation...................................................................... 49
AIR DRYERS
10. Maintenance................................................................ 55
11. Troubleshooting...................................................... 56
12. Notes.............................................................................. 57
WARRANTY...................................................................... 60
SERVICE DEPARTMENT : +82-51-728-5360

1. General Safety Information 2. Receiving, Moving, Unpacking
1.1 Pressurized Devices 2.1 Receiving:

• This equipment is a pressure-containing device. • This shipment has been thoroughly checked, packed and
• Do not exceed maximum operating pressure as shown on the inspected before leaving our plant.
equipment serial number tag. • It was received in good condition by the carrier and was so
• Verify that equipment is fully de-pressurized before performing acknowledged.
service or maintenance functions. • Check for visible loss or damage. If this shipment shows evidence
of loss or damage at time of delivery to you, insist that the carrier’s
1.2 Electrical: agent make a notation of this loss or damage on the delivery
• This equipment requires electricity to operate. receipt.
• Install equipment in compliance with national and local electrical
codes. 2.2 Moving:
• Standard equipment is supplied with NEMA 4,4X electrical CAUTION: Use lifting lugs or forklift. Do not lift equipment
enclosures and is not intended for installation in hazardous by piping.
environments.
• Disconnect power supply to equipment when performing any 2.3 Unpacking:
electrical service work. • Check for concealed loss or damage. When a shipment has been
delivered to you in apparent good order, but concealed damage
1.3 Breathing Air: is found upon unpacking, notify the carrier immediately and insist
• Air treated by this equipment may not be suitable for breathing that his agent inspects the shipment.
without further purification. • Fifteen days from receipt of shipment is the maximum time limit
• Refer to OSHA standard 1910.134 for the requirements for for requesting such inspection.
breathing quality air. • Concealed damage claims are not our responsibility as our terms
are F.O.B. point of shipment.
1.4 Noise:
CAUTION: Do not operate dryer without mufflers
installed.
1.5 High Velocity Air:

CAUTION: Do not stand near mufflers during tower
depressurization.
— 2—
3. Description
3.1 Dryer Function 3.2 Automatic Purge Saving System

• Dual tower regenerative desiccant dryers are an economical Featured with the Level 2 Controller, the Automatic Purge Saving
and reliable way to dry compressed air to dew points below the System is designed to save energy (purge air) when pressure-swing
freezing point of water (dew points as low as -100°F (-73.3°C) dryers are operated at reduced loads.
[0.2 ppmV @ 100 psig, 6.9 barg] are possible) or reduce the The patented Purge Saving System operates by monitoring the
moisture content of compressed air when used in critical process changes in temperature within the desiccant beds. These changes
applications. in temperature are the result of heat (thermal energy) that is
• These dryers continuously dry compressed air by using two released when a bed is on-line drying (heat of adsorption), and the
identical towers, each containing a desiccant bed. While one heat that is used when a bed is off-line being regenerated (heat of
tower is on-stream drying, the other tower is off-stream being desorption). The magnitude of these changes in temperature is an
regenerated (reactivated, i.e., dried out). The towers are indirect measure of the water vapor content in the air being dried.
alternated on- and off-stream so that dry desiccant is always in This information is used to determine the time a tower stays on line
contact with the wet compressed air. In this way a continuous during the drying cycle.
supply of dry air downstream of the dryer is possible.
• Desiccant dryers lower the dew point of compressed air by
adsorbing the water vapor present in the compressed air onto
the surface of the desiccant. Desiccant is a highly porous solid
containing extensive surface area.
• Adsorption occurs until the partial pressure of the water vapor
in the air and that on the surface of the desiccant come into
equilibrium. As adsorption occurs, heat is released (referred to
as the heat of adsorption) and is stored in the bed for use during
regeneration.
• Desiccant is regenerated by driving off (desorbing) the water
collected on its surface. Pressure-swing (also called heatless or
heater-less because no outside heat is added) dryers regenerate
by expanding a portion (approximately 14 -15% at 100 psig,
6.9 barg) of the dried air to atmospheric pressure. This “swing in
pressure” causes the expanded air to become very dry (have a
very low vapor pressure). This very dry air (called purge air) plus
the stored heat of adsorption allows the moisture to desorb from
the desiccant. The purge air then carries the desorbed water out
of the dryer.
— 3—
3.3 Description of Operation – Dryer
3.3.1 Models 1.1 to 84.9 w/ Shuttle Valve
(Refer to Fig. 3-1a.) Compressed air flows through inlet shuttle valve (3) OUTLET
to tower (4A) where the air is dried. After the air is dried it flows through 11
5
outlet shuttle valve (5) and then to the dryer outlet. A portion of the dry
air, the purge stream, branches off from the main air stream prior to 1 8 1
the outlet. The purge stream flow rate is controlled by the adjustable
purge rate valve (6) and the two purge orifices (7). 7 7
6 2
The purge flow, which has been throttled to near atmospheric pressure, TOWER TOWER
is directed to tower (4B). As the purge flow passes over the desiccant 4A 4B
in tower (4B), it removes the water vapor, which was deposited there
while the tower was on-line drying. The purge air then passes through 3
purge and repressurization valve (9B) (normally closed) and purge
muffler (10B) to the atmosphere. 9A 9B
INLET
After regeneration, purge and repressurization valve (9B) (normally
10A 10B
closed) closes allowing tower (4B) to repressurize slowly. Adequate
repressurization time is allowed so that tower (4B) is fully repressurized FIGURE 3-1a
before tower switchover. After a controlled time period, purge and TOWER 4A DRYING
TOWER 4B REGENERATING
repressurization valve (9A) (normally closed) then opens. This causes
the inlet and outlet shuttle valves to shift, directing the air flow through
tower (4B).
(Refer to Fig. 3-1b.) Tower (4B) is now drying the main air stream OUTLET
while tower (4A) is being regenerated by the purge air stream. The 11
5
operation of the purge and repressurization (normally closed) valves is
sequenced by the control system located in the electrical enclosure. 1 8 1
7 7
6 2
TOWER TOWER
4A 4B
9A 9B
INLET
10A 10B
FIGURE 3-1b
TOWER 4A REGENERATING
TOWER 4B DRYING
1. Tower Pressure Gauges 8. Safety Valve

2. Purge Pressure Gauge 9. Purge and Repres-
3. Inlet Shuttle Valve surization Valves
4. Desiccant Drying Towers 10. Purge Mufflers
5. Outlet Shuttle Valve 11. Moisture Indicator
6. Adjustable Purge Rate Valve A Left Tower Suffix
7. Purge Orifices B Right Tower Suffix
Process Stream
Purge Stream
— 4—
3.3.2 Models 116.0 to 152.9 w/ check Valves
(Refer to Fig. 3-2a.) Compressed air flows through inlet switching OUTLET
valve (3A) (normally open) to tower (4A) where the air is dried. After 8 5A 11 5B 8
the air is dried it flows through outlet check valve (5A) and then to 6
the dryer outlet. A portion of the dry air, the purge stream, branches 1 5C 2 5D 1
7
off from the main air stream prior to the outlet. The purge stream flow
rate is controlled by the adjustable purge rate valve (6) and the single
purge orifice (7).
The purge flow, which has been throttled to near atmospheric pressure, TOWER TOWER
is directed through purge check valve (5D) to tower (4B). As the purge 4A 4B
flow passes over the desiccant in tower (4B), it removes the water
vapor which was deposited while the tower was on-line drying. The
purge air then passes through purge and repressurization valve (9B)
(normally closed) and purge muffler (10B) to the atmosphere.
9A 3A 3B 9B
After regeneration, purge and repressurization valve (9B) (normally 10A 10B
closed) closes allowing tower (4B) to re-pressurize slowly. Adequate INLET
repressurization time is allowed so that tower (4B) is fully re- FIGURE 3-2a
TOWER 4A DRYING
pressurized before switchover. After a controlled time period, air TOWER 4B REGENERATING
inlet switching valve (3B) (normally open) opens and inlet-switching
valve (3A) (normally open) closes, purge and repressurization
valve (9A) (normally closed) then opens. OUTLET
8 5A 11 5B 8
(Refer to Fig. 3-2b.) Tower (4B) is now drying the main air stream while
tower (4A) is being regenerated by the purge air stream. The operation 6
1 5C 2 5D 1
of the inlet switching (normally open) and purge and repressurization 7
(normally closed) valves is sequenced by the control system located

in the electrical enclosure.
TOWER TOWER
4A 4B
9A 3A 3B 9B
10A 10B
INLET
FIGURE 3-2b
TOWER 4B DRYING
1. Tower Pressure Gauges 8. Safety Valves

3. Inlet Switching Valves surization Valves
5. Check Valves 11. Moisture Indicator
6. Adjustable Purge Rate Valve A & C Left Tower Suffixes
7. Purge Orifice B & D Right Tower Suffixes
Process Stream
Purge Stream
— 5—
3.3.3 Models 1.1 to 12.7 (High Pressure O
(Refer to Fig. 3-3a.) Compressed air flows through inlet switching OUTLET
valve (3A) (normally open) to tower (4A) where the air is dried. After 11
the air is dried it flows through shuttle valve (5) and then to the dryer 5
outlet. A portion of the dry air, the purge stream, branches off from 1 1
8
the main air stream prior to the outlet. The purge stream flow rate is
controlled by the adjustable purge rate valve (6) and the two purge 7
6 2
7
orifices (7).
TOWER TOWER
The purge flow, which has been throttled to near atmospheric pressure, 4A 4B
is directed to tower (4B). As the purge flow passes over the desiccant
in tower (4B), it removes the water vapor which was deposited while
the tower was on-line drying. The purge air then passes through
3A 3B
purge and repressurization valve (9B) (normally closed) and purge 9A 9B
muffler (10B) to the atmosphere. INLET
After regeneration, purge and repressurization valve (9B) (normally 10A 10B
closed) closes allowing tower (4B) to re-pressurize slowly. Adequate FIGURE 3-3a
repressurization time is allowed so that tower (4B) is fully re- TOWER 4A DRYING
pressurized before switchover. After a controlled time period, air TOWER 4B REGENERATING
inlet switching valve (3B) (normally open) opens and inlet-switching
valve (3A) (normally open) closes, purge and repressurization
valve (9A) (normally closed) then opens. OUTLET
(Refer to Fig. 3-3b.) Tower (4B) is now drying the main air stream while 11
tower (4A) is being regenerated by the purge air stream. The operation 5
of the inlet switching (normally open) and purge and repressurization 1 8 1
(normally closed) valves is sequenced by the control system located
in the electrical enclosure. 7
6 2
7
TOWER TOWER
4A 4B
3A 3B
9A 9B
INLET
10A 10B
FIGURE 3-3b
TOWER 4B DRYING
1. Tower Pressure Gauges 8. Safety Valve

3. Inlet Switching Valves surization Valves
5. Shuttle Valve 11. Moisture Indicator
6. Adjustable Purge Rate Valve A Left Tower Suffix
7. Purge Orifices B Right Tower Suffix
Process Stream
Purge Stream
— 6—
3.4 Automatic Purge Saving System
(Refer to Figure 3-4a for Models 1.1 through 84.9 and Figure 3-4b for
Models 116.0 through 152.9)
Assume tower A is on-line drying while tower B has just gone off-line OUTLET
to be regenerated. At the beginning of tower B’s regeneration cycle a 11
5
thermistor temperature measurement is made at position B1. After the
tower has been regenerated, another measurement is made at B1. The 1 8 1
drop in temperature sensed during regeneration is an indirect measure
of the water vapor content of the inlet air. The Automatic Purge Saving 7 7
6 2
System’s microprocessor then uses this information to calculate an A2 B2
allowable temperature rise in the bed during the drying cycle. TOWER TOWER
4A 4B
When tower B goes back on-line, a temperature probe at position B2
measures the initial bed temperature at this point and then monitors A1 3 B1
the bed until the calculated temperature rise occurs. The temperature
rise occurs as heat of adsorption is released during the drying process. 9A 9B
The time for the temperature rise to occur depends on flow rate. At INLET
100% flow the temperature rise takes 5 minutes, at 50% flow it takes 10A
FIGURE 3-4a
10B
10 minutes. Models 1.1 through 84.9
TOWER 4A DRYING
NOTE: If after 30 minutes, the bed temperature has not risen to the TOWER 4B REGENERATING
calculated value, the dryer will automatically switch towers.
When the calculated temperature rise is reached, the towers switch
OUTLET
with tower A now drying and tower B being regenerated. Tower B
8 5A 5B 8
regenerates for 3.9 minutes, re-pressurizes, and remains idle until it 11
is called upon for the next drying cycle. 6
1 5C 2 5D 1
7
A2 B2
TOWER TOWER
4A 4B
A1 B1
9A 3A 3B 9B
10A 10B
INLET
FIGURE 3-4b
Models 116.0 through 152.9
TOWER 4A DRYING
TOWER 4B REGENERATING
1. Tower Pressure Gauges 8. Safety Valve(s)

3. Inlet Shuttle or Switching surization Valves
Valves 10. Purge Mufflers
4. Desiccant Drying Towers 11. Moisture Indicator
5. Shuttle or Check Valve(s) A & C Left Tower Suffix(es)
6. Adjustable Purge Rate Valve B & D Right Tower Suffix(es)
7. Purge Orifice(s)
Process Stream
Purge Stream
— 7—
4. Installation 4.1.4 Heatless Pressure-Swing Desiccant Air Dryer
4.1.5 Afterfilter(s) –
4.1 Location in the compressed air system To ensure downstream air purity (prevent desiccant dust from
traveling downstream) adequate filtration downstream of the dryer
NOTE: The air compressor should be adequately sized to handle
is required.
air system demands as well as purge loss. Failure to take this into
• First Afterfilter - Particulate Removal -Typically 1-micron filtration
account could result in overloading air compressors and/or insufficient
is specified although finer filtration is available.
air supply downstream. It is desirable to install the dryer where the
• Second Afterfilter - Oil Vapor Adsorption -This filter is used to
compressed air is at the lowest possible temperature (downstream of
remove oil vapor and its subsequent taste and odor and to protect
aftercoolers) and the highest possible pressure (upstream of pressure
down-stream components from solid particles 0.01 micron and
reducing valves) without exceeding the maximum operating pressure
larger.
of the equipment. (Refer to Figure 4-1)
NOTE: By-pass lines and isolation valves are recommended so
that maintenance work can be performed without shutting off the air
supply.
Compressor Aftercooler Separator Receiver Prefilters Desiccant Dryer Afterfilters Receiver
FigureFigure
4-1 4-1
4.1.1 Aftercooler/Separator – 4.2 Physical Location

Compressed air entering dryer must be cooled to a temperature of The dryer must be installed with suitable overhead protection
140°F (60°C) or lower. Use of an aftercooler and condensate separator as well as clearance to change desiccant. Sufficient clearance
may be necessary to reduce inlet air temperature to an acceptable around the periphery of the dryer should be provided to allow
level. maintenance personnel access to all areas for routine inspections
NOTE: Installation of a refrigerated dryer ahead of a pressure-swing and adjustments.
desiccant dryer does not increase desiccant dryer capacity or reduce
purge flow requirements. 4.3 Minimum & Maximum Operating Conditions
4.1.2 Receiver(s) – The compressed air supply to the dryer inlet should be checked
Air receivers dampen pulsations from the compressor discharge line periodically to ensure that dryer design specifications are not
and can eliminate some of the condensed moisture that is carried over exceeded. Normally the compressor installation includes intercoolers,
from the aftercooler and separator. They also provide a reservoir of aftercoolers, separators, receivers, or similar equipment, which
stored air for response to system demands in excess of compressor adequately pretreat the compressed air supply in order to avoid
capacity. Size and location of receivers in the compressed air system excessively high air temperatures and liquid slugging of downstream
need to be considered carefully. Flows must not exceed the adjusted equipment.
maximum inlet capacity of the desiccant air dryer.
4.4 Maximum Operating Pressure (MOP):
4.1.3 Prefilter(s) –
Adequate filtration is required upstream of the dryer in order to • 150 psig (10.3 barg) is standard.
protect the desiccant bed from contamination. The following filtration, • 250 psig (17.2 barg) is optional.
equipped with automatic condensate drains, is recommended: Refer to Dryer Serial Number Tag.
• First Prefilter - Particulate/Gross Liquid Removal - On heavily WARNING - Do not operate the dryer at pressures above the
contaminated systems, a gross contaminant filter to remove solids maximum operating pressure shown on the serial number tag.
and high inlet liquid concentrations should be used.
NOTE: Consult factory for applications requiring higher maximum
• Second Prefilter - Oil Aerosol Removal - On systems with
operating pressures.
lubricated compressors, an oil removal filter to remove oil
aerosols and protect the desiccant beds from oil contamination
is required.
— 8—
4.5 Minimum Operating Pressures: NOTE: When quarter-turn valves (e.g. ball or butterfly valves) are
used for isolation of pressure components, care should be taken to
4.5.1 For 150 psig (10.3 barg) MOP models - open or close valves slowly.
• 60 psig (4.1 barg) is the minimum operating pressure for dryers
operated on ISO classes 1, 2, 3, and 4. 4.11 Electrical Connections
4.5.2 For 250 psig (17.2 barg) MOP models - Refer to the appropriate controller sections for detailed information
• 120 psig (8.3 barg) is the minimum operating pressure for dryers on connections, ratings, and operation of the Level 1 or Level 2
operated on ISO classes 1, 2, 3, and 4. Controller.
Refer to Dryer Serial Number Tag. NOTE: Refer to the dryer serial number tag for allowable voltages,
WARNING - Do not operate the dryer at pressures below the frequency and power rating.
minimum operating pressure shown on the serial number tag.
NOTE: Consult factory for applications requiring lower minimum 4.12 Provisions for Purge Exhaust
operating pressures. • Purge exhaust must be routed through the factory supplied
mufflers or piped to a remote location.
4.6 Maximum Compressed Air Temperature at Dryer • Purge mufflers - If shipped separately, install purge exhaust
Inlet: mufflers in the locations shown in Figures 4-2, 4-3 or 4-4.
• If purge exhaust is piped to a muffler located in a remote location,
• 140°F (60°C) for all models.
choose a combination of diameters, lengths, and turns that limits
the additional pressure drop to 1 psid or less.
4.7 Ambient Temperatures:
WARNING - Do not operate dryer without installed mufflers.
4.7.1 Minimum Ambient Temperature Exhausting compressed air directly to atmosphere will result in
• Standard units: 35°F (2°C) noise levels above OSHA permissible levels and rapidly expanding
• Units with optional low ambient package: -20°F ( -29°C) gas could potentially cause harm to persons or property.
4.7.2 Maximum Ambient Temperature
• 120°F (49°C) 4.13 Initial Desiccant Charge
The dryer is shipped complete with desiccant and is ready to operate
NOTE: If dryer is installed in ambients below 35°F (2°C), low ambient after piping and electrical connections are made and controller settings
protection requiring heat tracing and insulation of the prefilter bowls, are established.
auto drains and/or sumps, and lower piping with inlet switching and
purge/repressurization valves is necessary to prevent condensate
4.14 Icon Identification
from freezing. If installing heat tracing, observe electrical class code
requirements for type of duty specified. Purge mufflers and their relief P
mechanisms must be kept clear from snow and ice buildup that could Left Tower
Pressure Gauge
prevent proper discharge of compressed air.
4.8 Mounting P
Right Tower
Install dryer on a level pad. Holes are provided in the dryer base
Pressure Gauge
members for floor anchors.
NOTE: Floor anchors must be used if area is subject to vibration.
4.9 Piping Air Outlet

Inlet and Outlet connections
Observe locations of inlet and outlet connections as shown in Figures
4-2, 4-3 or 4-4 and connect inlet and outlet piping as indicated.
Air Inlet
NOTE: All piping must be supported so as not to bear on the dryers
or filters.
4.10 Isolation Valves Purge

If isolation or bypass valves are installed, care must be used to P Pressure Gauge
ensure that equipment is pressurized slowly. This is particularly true if
isolation valves are placed before and after pre and afterfilters where
rapid pressurization could cause excessive pressure drop across Electrical
filter elements. Inlet

— 9—
L
(MAX)
A
J B
CENTERLINE OF CUSTOMER
INLET/OUTLET CONNECTIONS
M D
(MAX)
E
7/8” X 1 1/4” SLOT (TYP 4 PLCS)
[22mm] [32mm]
C
TOP VIEW
F
LIFTING LUG OUTLET SHUTTLE
P VALVE ASSY
AIR OUTLET
PILOT AIR FILTER
DESICCANT FILL PORT
PURGE PRESSURE GAUGE

LEFT CHAMBER & REGULATOR
PRESSURE GAUGE
WARNING: Disconnect the main power
supply before removing this cover.
PURGE ADJUSTING VALVE
MOISTURE INDICATOR
RIGHT CHAMBER
PRESSURE GAUGE N H
(MAX)
ASME CODE TAG
CONTROL ENCLOSURE
ASME PRESSURE
P
RELIEF VALVE
AIR INLET
INLET SHUTTLE
VALVE ASSY
PURGE EXHAUST
VALVE
G PURGE EXHAUST
MUFFLER
DESICCANT DRAIN PORT
FRONT VIEW RIGHT SIDE VIEW REAR VIEW

RIGHT CHAMBER REMOVED FOR CLARITY
Figure 4-2
1.1-12.7 Model General Arrangement
(continued on next page)
— 10 —
DIMENSIONS IN INCHES
MODEL 1.1 1.6 2.5 3.2 4.6 7.3 10.4 12.7
A 27.5/8 27.5/8 27.5/8 38.3/8 38.3/8 41.3/8 49.3/8 49.3/8
B 13.13/16 13.13/16 13.13/16 19.13/16 19.13/16 20.11/16 24.11/16 24.11/16
C 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4
D 29.1/2 29.1/2 29.1/2 35.1/2 35.1/2 35.1/2 35.1/2 35.1/2
E 14.3/4 14.3/4 14.3/4 17.3/4 17.3/4 17.3/4 17.3/4 17.3/4
F 2.13/16 2.13/16 2.13/16 2.13/16 2.13/16 3.1/4 3.1/4 3.1/4
G 14 14 14 15 15 15 16 16
H 39 54 71 45 45 63 53 61
J 1.3/4 1.3/4 1.3/4 1.3/4 1.3/4 2.3/4 2.3/4 2.3/4
L 35 35 37 50 50 51 58 58
M 35 35 35 41 41 41 42 42
N 49 64 81 57 57 75 65 73
P 1 NPT 1 NPT 1 NPT 1 NPT 1 NPT 2 NPT 2 NPT 2 NPT
WT/LBS 365 445 575 685 685 1010 1215 1350
DIMENSIONS IN MILLIMETERS
MODEL 1.1 1.6 2.5 3.2 4.6 7.3 10.4 12.7
A 702 702 702 975 975 1051 1254 1254
B 351 351 351 487 487 525 627 627
C 32 32 32 32 32 32 32 32
D 749 749 749 902 902 902 902 902
E 375 375 375 451 451 451 451 451
F 71 71 71 71 71 83 83 83
G 356 356 356 381 381 381 406 406
H 991 1372 1803 1143 1143 1600 1346 1549
J 44 44 44 44 44 70 70 70
L 889 889 948 1264 1264 1305 1470 1470
M 889 889 889 1041 1041 1041 1062 1062
N 1235 1616 2047 1437 1437 1894 1658 1861
P 1 NPT 1 NPT 1 NPT 1 NPT 1 NPT 2 NPT 2 NPT 2 NPT
WT/KGS 166 202 261 311 311 458 551 612
Figure 4-2
(continued from previous page)
— 11 —
M
(MAX) H
D
E
G
B
7/8” X 1-1/4” SLOT (TYP 4 PLACES)
F P
C A [22mm] [32mm] AIR INLET
L BOTTOM RIGHT SIDE VIEW

(Models 43.8, 59.4 and 84.9)
(MAX)
TOP VIEW
P
F AIR OUTLET
PURGE PRESSURE DESICCANT FILL PORT

ADJUSTMENT VALVE
MOISTURE INDICATOR
LIFTING LUG
LEFT CHAMBER RIGHT CHAMBER

PRESSURE GAUGE PRESSURE GAUGE
CONTROL
ENCLOSURE
N H
(MAX) PURGE
EXHAUST
MUFFLER
ASME CODE TAG
P
AIR INLET
PILOT AIR
FILTER
DESICCANT DRAIN PORT
ASME PRESSURE
G RELIEF VALVE
FRONT VIEW RIGHT SIDE VIEW REAR VIEW

(Models 16.7 through 38.2)
Figure 4-3
— 12 —
MODEL 16.7 21.2 26.3 31.9 38.2 43.8 59.4 84.9
A 46.3/4 47.9/16 52.11/16 56.7/16 57.5/16 63.1/8 69.13/16 73.3/8
B 23.3/8 23.13/16 26.5/16 28.1/4 28.11/16 31.9/16 34.7/8 36.11/16
C 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4
D 45.1/2 45.1/2 53.1/2 53.1/2 53.1/2 53.1/2 53.1/2 59.1/2
E 22.3/4 22.3/4 26.3/4 26.3/4 26.3/4 26.3/4 26.3/4 29.3/4
F 3.1/4 3.1/4 3.1/4 5.1/8 5.1/8 5.9/16 5.9/16 5.9/16
G 9.3/16 9.11/16 11.7/16 11 11 5.1/4 6.3/16 8.1/2
H 97.5/16 100.13/16 105.9/16 107.1/8 112.1/8 109.1/2 111.5/16 117.3/8
L 55 57 63 66 68 74 82 86
M 51 51 59 59 59 59 59 67
N 104 107 112 115 120 117 119 125
P 2 NPT 2 NPT 2 NPT 3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE
WT/LBS 1473 2134 2414 2875 3722 4167 4417 9010
MODEL 16.7 21.2 26.3 31.9 38.2 43.8 59.4 84.9
A 1187 1208 1338 1434 1456 1604 1773 1864
B 594 604 669 717 728 802 886 932
C 32 32 32 32 32 32 32 32
D 1156 1156 1359 1359 1359 1359 1359 1511
E 578 578 679 679 679 679 679 756
F 83 83 83 130 130 141 141 141
G 234 247 291 279 279 133 157 216
H 2472 2561 2681 2721 2848 2781 2827 2981
L 1387 1438 1603 1673 1724 1876 2080 2172
M 1295 1295 1499 1499 1499 1499 1499 1693
N 2631 2720 2841 2924 3051 2980 3026 3180
P 2 NPT 2 NPT 2 NPT 3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE
WT/KGS 668 968 1095 1304 1688 1890 2004 4087
Figure 4-3
— 13 —
ASME PRESSURE
FLOW FLOW
RELIEF VALVE
M
(MAX)
D
E
FLOW FLOW
7/8” X 1-1/4” SLOT (TYP 4 PLACES)

[22mm] [32mm]
C B
A
L
(MAX)
TOP VIEW
P
F AIR OUTLET
FLOW FLOW FLOW
LIFTING LUG DESICCANT FILL PORT
PURGE PRESSURE MOISTURE INDICATOR

ADJUSTMENT VALVE
LEFT CHAMBER RIGHT CHAMBER PILOT AIR FILTER

PRESSURE GAUGE PRESSURE GAUGE
CONTROL N
ENCLOSURE OVERALL
LENGTH
H
PURGE EXHAUST MUFFLER

P
DESICCANT DRAIN PORT AIR INLET
FRONT VIEW RIGHT SIDE VIEW REAR

Figure 4-4
116.0-152.9 model General Arrangement
— 14 —
MODEL 116.0 152.9
A 82.7/8 93.3/8
B 41.7/16 46.11/16
C 1.1/4 1.1/4
D 59.1/2 63.1/2
E 29.3/4 31.3/4
F 33.3/16 35.7/8
G 13.13/16 19.7/16
H 115.13/16 116.3/16
J 36.3/16 38.7/8
L 100 105
M 88 89
N 124 124
P 6 FLANGE 6 FLANGE
WT/LBS 9900 12000
MODEL 116.0 152.9
A 2106 2372
B 1053 1186
C 32 32
D 1511 1613
E 756 806
F 843 911
G 351 494
H 2942 2951
J 919 988
L 2537 2667
M 2227 2253
N 3158 3158
P 6 FLANGE 6 FLANGE
WT/KGS 4500 5445
Figure 4-4
116.0-152.9 model General Arrangement
— 15 —
5. Controllers – General purge air requirements are reduced. This reduction can translate to
energy savings at the air compressor.
5.1 Overview The Level 1 Controller offers 8 selectable fixed-cycle Energy (purge)
Saver modes (0% to 70% in 10 % increments) to reduce purge time
The solid-state dryer controller is located in a polycarbonate, NEMA to match the load on the dryer.
Class 4/4X, IP66 rated electrical enclosure mounted to a center panel
located between the two desiccant towers. Controls are available in Level 2 Controllers feature the Automatic Purge Saving System
three functional levels. The Timer Controller offers a fixed-time cycle (APSS) as described in Sections 3.2 and 3.4. When Level 2 Controllers
that provides a dew point corresponding to ISO compressed air quality are operated in demand rather than fixed cycle modes, the APSS
class 2. Both the Level 1 and Level 2 controls offer four fixed-time automatically adjusts to dryer loading and extends drying time when
cycles that provide dew points corresponding to ISO compressed air possible. Average purge use is thus automatically reduced.
quality classes 1 through 4. A key difference between the Level 1 and A feature-by-feature comparison of each controller can be found in
Level 2 controls is the way in which they address energy savings. When Table 5-1.
inlet flow is less than the adjusted rated capacity of the dryer, average
Desiccant Dryer Controllers Timer Level 1 Level 2

Fixed Cycle
Category Feature Controller Fixed Cycle Only
and APSS
AC Input Voltage: 100-240 VAC, 50-60 Hz (See Note 1) •

AC Input Voltage: 85-264 VAC, 47-63 Hz (See Note 1) • •
DC Input Voltage: 11.5-28 VDC (See Note 1) • •
Auxiliary power terminals (See Note 2) • •
Solenoid valve coil voltage 12 VDC 12 VDC 12 VDC
NEMA 4/4X, IP 66 electrical enclosure rating • • •
Soft on/off switch with two power recovery modes (See Note 3) • •
Tower status LEDs (amber=drying) •
General
Tower status LEDs (green=drying, amber=regenerating) • •
Process valve status LEDs (on=valve open, off=valve closed) • •
Operating mode LEDs (see next category for number of modes) •
Alarm LED (red) • •
Voltage-free alarm contacts, 5A rating • •
Alarm reset switch (mounted on front panel) • •
Service reminder LEDs (See Note 4) • •
Vacuum fluorescent text display •
60-150 or 120-250 psig MOP (selectable via jumper on circuit board) • •
ISO Class 1 (-100°F/-73°C PDP) - fixed cycle (4 minute) • •
ISO Class 2 (-40°F/-40°C PDP) - fixed cycle (10 minute) • • •
ISO Class 3 (-4°F/-20°C PDP) - fixed cycle (16 minute) • •
Operating Modes ISO Class 4 (+38°F/+3°C PDP) - fixed cycle (24 minute) • •
(See Note 5 and
Fixed Cycle Energy (purge) Saver (See Note 6) •
Note 7)
Manual Cycle (test mode) • •
ISO Class 2 (-40°F/-40°C PDP) - demand cycle •
ISO Class 3 (-4°F/-20°C PDP) - demand cycle •
ISO Class 4 (+38°F/+3°C PDP) - demand cycle •
Controlled shutdown and restart (upon user supplied contact closure) • •
Tower pressure switches (2) • •
High Humidity Alarm Optional
Digital I/O
Filter monitor alarm (1 or 2 filters) Optional
Electric drain alarm (1 or 2 filters) Optional
Electric drain test (1 or 2 filters) Optional
Analog I/O
Thermistors (4) •
(12 bit accuracy)
Communication RS232 communication port • •
Table 5-1
Feature Comparison
— 16 —
Table 5-1 (continued from previous page)
Notes:
1. The Timer Controller will accept AC (Alternating Current) input power. The Level 1 and Level 2 Controllers will accept either AC
(Alternating Current) or DC (Direct Current) input power.
2. (Level 1 & Level 2 Controllers) The auxiliary power terminals are in parallel with the input power terminals (i.e., there are two common
terminals for each input power connection point, L, N, and PE. The auxiliary power terminals provide a connection point for another device
that operates on the same voltage as the Desiccant Dryer Controller.
3. (Level 1 & Level 2 Controllers) The controller has two power recovery modes. For Level 1 the selection is made using a jumper on the
circuit board. For Level 2 the selection is made using the switches on the front panel. In one mode, the controller remembers its state (on
or off) prior to a power interruption and returns to that state when power is restored. In the other mode, the controller always returns to the
off state when power is restored after an interruption.
4. (Level 1 & Level 2 Controllers) The service reminder LEDs indicate that it is time to perform preventive maintenance on the (a) filters
and drains, (b) valves, or (c) desiccant. The user selects between Normal and Severe service intervals. For Level 1 the selection is made
using a jumper on the circuit board. For Level 2 the selection is made using the switches on the front panel.
5. (Level 1 & Level 2 Controllers) For Level 1 and Level 2, the operating mode (with exception of the MOP) is selected via switches on the
front panel.
6. (Level 1 Controllers) The Level 1 Energy (purge) Saver feature has eight settings, 0% to 70% in 10% increments. Energy Saver setting
= 100% – (percentage of adjusted allowable inlet flow). (e.g. if the maximum adjusted allowable inlet flow to a dryer was 1000 SCFM, but
the actual flow to the inlet was only 300 SCFM, then the Energy Saving setting would be 100%-((300/1000)*100%)=70%. At 300 SCFM,
only 30% of the dryer capacity is being utilized. Average purge requirements and the related energy needed to compress that purge air can
be reduced by 70%.) The selection is made using a switch on the front panel.
7. PDP - Pressure Dew Point
MOP - Maximum Operating Pressure
— 17 —
6. Controller – Timer Based 6.2 Connections – Timer Based Controller
See Figure 6-2, Point-to-Point Diagram for the location and function of
This section provides connection, adjustment and operational the various cable and cord connectors that are provided on the bottom
information for the Timer Based – Fixed Cycle Controller. Similar of the Timer Based enclosure.
information for the Level 1 – Fixed Cycle Controller and Level 2 6.2.1 Connections - Input Power
Controller featuring the APSS, Automatic Purge Saving System, can
be found in Sections 7 and 8 respectively. 6.2.1.1 VAC Input Power Connections
Single-phase, alternating current (AC) input power connection of 100-
6.1 Reference Figures – Timer Based Controller 240 VAC / 1 ph / 50-60 Hz. can be made at terminals mounted within
the control enclosure. See reference figures for proper polarity.
• Figure 6-1, Front Panel Overlay – Timer Controller
• Figure 6-2, Point-to-Point Diagram – Timer Controller
Program Step 1 2 3 4 5 6 7 8
Left tower status drying drying drying drying regen regen regen regen
Right tower status regen regen regen regen drying drying drying drying
Left purge solenoid off off off off off off on off
Right purge solenoid off off on off off off off off
Left purge valve closed closed closed closed closed closed open closed
Right purge valve closed closed open closed closed closed closed closed
Table 6-1
Cycle Sequence Steps –Timer Based Controller
Dryer MOP 60 - 150 psig (4.1 - 10.3 barg) 120 - 250 psig (8.3 - 17.2 barg)
ISO Class 2 2
-40°C -40°C
Dew Point
-40°F -40°F
Cycle Time (minutes) 10 10
Time from start of cycle Time from start of cycle
Time
(minutes:seconds) (minutes:seconds)
t0 00:00 00:00
t1 00:02 00:02
t2 00:06 00:06
t3 04:12 04:12
t4 05:00 05:00
t5 05:02 05:02
t6 05:06 05:06
t7 09:12 09:12
t8 10:00 10:00
Reference Data
Purge time (min:sec) 04:12 04:12
Repress. time (min:sec) 00:48 00:48
Table 6-2
Fixed Cycle Timing –Timer Based Controller
— 18 —
Power ON Light
Left Tower Right Tower

DRYING Light DRYING Light

Figure 6-1
Front Panel Overlay –Timer Based Controller
(Note: Figure is representative of Models 1.1 through 84.9)
— 19 —
BASE
BLACK/GREY +VE
BLACK
VOLTAGE FUSE 5 x 20mm

LABEL 1 Amp Slow Blow
Live
Neutral Black
Sleeve
Earth
White Sleeve
100 - 240v 50/60 Hz
SUPPLY
INPUT GREEN/YELLOW
TERMINALS
100 - 240V
50/60 Hz
GRN/YEL
GRN/YEL
BROWN
BROWN
BLUE
BLUE
NEGATIVE FROM POWER SUPPLY

NEGATIVE TO RIGHT PURGE
NEGATIVE TO LEFT PURGE
EARTH POSITIVE NEGATIVE TOP

(CONTROL TIMER BOARD)
FUSE 5 x 20mm
1 Amp Slow Blow
LEFT TOWER RIGHT TOWER

PURGE VALVE PURGE VALVE
SOLENOID COIL SOLENOID COIL
Figure 6-2
Point-to-Point Connection Diagram –Timer Based Controller
— 20 —
7. Controller – Level 1 Alarm Alarm
Power Controller Alarm or Alarm
N.O. N.C.
To On or Service Relay
Contact Contact
This section provides connection, adjustment and operational Controller Off? Reminder Coil
(TB2-7) (TB2-8)
information for the Level 1 – Fixed Cycle Controller. Similar information No N/A N/A De-Energized Open Closed
for the Level 2 Controller featuring the APSS, Automatic Purge Saving
Yes Off N/A Energized Closed Open
System, can be found in Section 8.
Yes On No Energized Closed Open
7.1 Reference Figures – Level 1 Controller Yes On Yes De-Energized Open Closed
• Figure 7-1, Front Panel Overlay – Level 1 Controller Table 7-1

• Figure 7-2, Electrical Schematic – Level 1 Controller Common Alarm Relay Logic –Level 1 Controller
• Figure 7-3, Point-to-Point Diagram – Level 1 Controller
• Figure 7-4, Panel Layouts – Level 1 Controller
• Figure 7-5, Enclosure Penetrations – Level 1 Controller 7.2.3 Connections – Remote Start / Stop
Terminals TB1-1 and -2 are used to provide a 5 VDC output to a remote
7.2 Connections – Level 1 Controller switch or volt free contacts that when closed will stop the dryer at the
end of the current half cycle. The dryer will resume running at the
See Figure 7-5, Enclosure Penetrations for the location, size and
beginning of the new half cycle when the remote switch or contacts
function of the various cable and cord connectors that are provided
are reopened. When dryer operation is in the remote stop state,
on the bottom of the Level 1 enclosure.
all four tower drying (green) and regenerating (amber) LEDs flash
7.2.1 Connections - Input Power simultaneously.
7.2.1.1 VAC Input Power Connections Note: Remote start / stop is disabled when the dryer is in the Manual
Single-phase, alternating current (AC) input power connections ranging cycle operation mode. When the dryer is in the remote stop state, the
from 85-264 VAC and 47 to 63 Hz. can be made at terminals TB5-20, only front panel and remote selector switches (see Section 7.2.4) that
-22, and -24. See reference figures for proper polarity. These terminals remain enabled are the power on/off switches.
are connected to accessory output terminals TB5-21, -23, and -25 7.2.4 Connections – Remote Switches
respectively. Accessory output terminals can be used to direct power The controller door is equipped with four momentary-contact, push
at the same voltage and frequency to external devices. button switches. Pressing the appropriate icon printed on the display
CAUTION: Accessory output terminals are NOT controlled by overlay actuates these switches. The display board containing the
the power on/off switch and are always energized when power switches, display LEDs and the J2 terminal strip is mounted on the
is provided to terminals TB -20, -22, and -24. inside of the enclosure door. The terminal strip provides connection
points for remotely mounted, NO (normally open), momentary-contact
7.2.1.2 VDC Power Connections push buttons that provide the same function as the board mounted
• The control and display boards operate on low-voltage direct switches. The terminal – switch combinations are:
current. The controller is provided pre-wired with an AC to 12 VDC • Terminals J2-1 and -2 (remote switch to select ISO dew point
power supply board. For users with AC power as described in class or manual cycle / test mode)
Section 7.2.1.1, their AC input is directed to the power supply • Terminals J2-3 and -4 (remote switch to select % energy savings
board where it is conditioned and returned to the control board mode)
as 12 VDC at terminals TB4-18 and -19. • Terminals J2-5 and -6 (remote power on / off switch)
• For users with direct current (DC) input power ranging from 11.5 NOTE: Care must be exercised in using this remote switch to
to 28 VDC, use of the AC to DC power supply board is not needed stop a dryer. Closing this switch will affect the same response
and their connections can be made at terminals TB4-18 and -19 as a loss of power. Both purge-repressurization valves will close.
by first removing the black and red leads coming from the power On standard pressure models 116.0&152.9 and high pressure
supply board. See reference figures for proper polarity. models 1.1 through 12.7, both inlet-switching valves will open. A
7.2.2 Connections – Common Alarm Contacts tower that is actively purging when the power on/off button is
Connections to voltage-free common alarm contacts with a maximum actuated will be subjected to a rapid repressurization that can
5-amp rating can be made at terminals TB2-7 through -9. lead to fluidization and subsequent abrasion of the desiccant bed.
• Terminal TB2-9 is the common contact connection. Ideally, dryers should only be powered off during those portions of
• Terminal TB2-7 is the N.O. (normally open) contact connection. the drying cycle when both desiccant towers are at full operating
• Terminal TB2-8 is the N.C. (normally closed) contact pressure. Use of the remote start/stop connections as described
connection. in Section 7.2.3 would be preferable in most cases.
• The alarm relay coil is energized when power is supplied to the • Terminals J2-7 and -8 (remote alarm reset and manual cycle
controller input terminals and there are no alarms. increment switch)
• The coil is de-energized when power is removed or when an
alarm condition exists.
• Additional information on the common alarm relay logic appears
in Table 7-1.
— 21 —
7.2.5 Connections – RS232 Use the following sequence to manually reset the accumulated service
Refer to Figure 7-4, Panel Layouts – Level 1 Controller. RS232 interval time for all timers.
connections can be made at the 3-pin connector labeled J5 and • Pause for about 1 second at each instruction. If the sequence is
located at the upper left-hand corner of the control board. A cable for executed too quickly it will not work.
this connection can be purchased through your distributor. • With the controller already on, press and hold the alarm reset
button.
7.3 Control Board Jumpers – Level 1 • Press and hold the on/off button.
Refer to Figure 7-3, Point to Point Connection Diagram – Level 1 • Release the on/off button.
Controller. In the upper left hand corner of the control board there • Release the alarm reset button. The service interval time is now
are four two-pin jumpers labeled J1 through J4. Only three of the reset; the maintenance LED flashes three times to acknowledge
four jumper pairs are utilized. Pair J2 is not used. The jumper is a the action.
removable bridge that is used to make or break continuity between
Normal Severe
the two pins that form a pair. When installed in the ON position, the Service Item
Service Service
jumper is placed on both pins of the pair and continuity between the (Customer check points
Interval Interval
pins is established. When installed in the OFF position, the jumper is are listed for each item)
(J3 OFF) (J3 ON)
removed or stored on a single pin and continuity is broken. Jumper Filters
functions are as follows: 1. Check prefilter Delta-P 4,000 2,000
7.3.1 Jumper J1 – Maximum Operating Pressure 2. Ensure prefilter drain is discharging Hours Hours
3. Check afterfilter Delta-P
Jumper J1 is used to select the maximum operating pressure. Installed
in the OFF position when operating at inlet pressures of 60 to 150 psig Desiccant
(4.1 to 10.3 barg). Installed in the ON position when operating at 1. Check moisture indicator 8,000 4,000
2. Check dryer outlet dew point Hours Hours
inlet pressures of 120 to 250 psig (8.3 to 17.2 barg). This setting
3. Inspect mufflers for excessive dusting
will affect tower purge and repressurization times. (Refer to serial
number tag.) Valves
1. Ensure valves are cycling properly
4,000 2,000
7.3.2 Jumper J2 – Unused. 2. Check for switching failure alarms
Hours Hours
3. Inspect valves for leaks - adjust purge
7.3.3 Jumper J3 – Service Reminder Interval valve as needed
Jumper J3 is used to select the service reminder interval. Installed in
the OFF position when the Normal service reminder interval is desired. Table 7-2
Installed in the ON position when the Severe service reminder interval Jumper J3 – Service Reminder Intervals
is desired. Service items, check points and time intervals appear in 7.3.4 Jumper J4 – Power Recovery Mode
Table 7-2. Jumper J4 is used to select the power recovery mode. When power
7.3.3.1 Filter Service to the controller is interrupted, the position of this jumper controls the
When the service interval for filters has expired the following LEDs recovery mode of the dryer when power is restored. Installed in the
will blink: OFF position when automatic power recovery is not desired. Installed
• Service LED (amber) in the ON position when automatic power recovery is desired.
• Three filter LEDs (amber) • Jumper J4 installed in the OFF position – Automatic power
recovery is turned off. The controller returns to the off state when
7.3.3.2 Desiccant Service interrupted power to the controller is restored.
When the service interval for desiccant has expired, the following • Jumper J4 installed in the ON position – Automatic power recovery
LEDs will blink: is turned on. The controller remembers its state (on or off) prior to
• Service LED (amber) a power interruption and returns to that state (at the beginning of
• Both tower regenerating LEDs (amber). The service function the prior ISO operating cycle) when power is restored. If power
overrides the normal display of the tower regenerating LEDs. is interrupted while the controller is in the Manual cycle mode,
7.3.3.3 Valve Service the controller will return to the prior ISO operating cycle and not
When the service interval for valves has expired, the following LEDs the Manual cycle when power is restored.
will blink:
• Service LED (amber)
• Valve LEDs (green) The service function overrides the normal
display of the valve LEDs.
To extinguish the blinking LEDs and restart the timer for a new service
interval, press the alarm reset button.
NOTE: Time continues to accumulate as long as power is supplied to
the controller, whether the controller is switched on or off.
— 22 —
7.4 Front Panel Overlay – Level 1 Controller
Filter service /
maintenance LED
Left tower pressure

switch LED: Filter service /
On=switch closed maintenance LED
Off=switch open
Right tower pressure

Left tower drying LED switch LED:
On=switch closed
Off=switch open
Left purge valve LED
On=valve open
Off=valve closed Right tower drying LED
Right purge valve LED

On=valve open
Off=valve closed
Left tower regenerating

LED Right tower
regenerating LED
Filter service /
maintenance LED
Operating mode LEDs

ISO Class 1 – 4
Energy (purge) savings
LEDs
Operating mode
selector switch
Energy savings icon
Operating mode LED

Manual (test) mode Energy/purge savings
-100°F/-73°C selector switch
-40°F/-40°C
Communications icon -4°F/-20°C
Maintenance / service
+38°F/+3°C
reminder LED
Power On LED
Alarm LED
Power On / Off Switch
Reset switch for alarm

and maintenance
reminder – Advance
switch for manual cycle
Figure 7-1
Front Panel Overlay – Level 1 Controller
(Note: Figure is representative of Standard Pressure Models 1.1 through 84.9)
(Note: Overlay for Standard Pressure Models 116.0 & 152.9 depicts a different
inlet valve and outlet/purge circuit. Overlay for High Pressure Models 1.1
through 12.7 depicts a different inlet valve circuit.)
— 23 —
7.4.1 Front Panel LEDs 7.4.2.3 Percent Energy / Purge Savings Selector Switch
• Power on - green • If dryer is operated at less than maximum flow capacity a
• Alarm – red reduction in purge air usage may be possible. Eight settings (0%
• Service / maintenance reminder – amber to 70% in 10% increments) reduce the purge time to match the
• Filters (pre, after, and pilot) service / maintenance reminders load on the dryer. Refer to the Operation Section to determine
- amber maximum inlet flow capacity at operating pressure. The Energy
• Operating mode (ISO class / manual (test) mode) – green savings selection can be changed at any time. Press the switch
• Energy (purge) savings % – green repeatedly until the desired selection’s LED is blinking. The LED
• Purge / repressurization valve status (On = valve open; Off = valve for the current selection remains illuminated until the end of the
closed) – green current half-cycle, at which time the new selection becomes
• Left and right tower status (regenerating) - amber active. At this time, the LED for the new selection switches from
• Left and right tower status (drying) - green blinking to illuminated, and the LED for the previous selection is
• Left and right tower pressure switch status (On = switch closed; extinguished.
Off = switch open) - green • Example: If the maximum adjusted allowable inlet flow to a
dryer was 1000 SCFM, but the actual flow to the inlet was only
7.4.2 Front Panel Switches
300 SCFM, then the Energy Saving setting would be 100%-
The front panel contains four momentary-contact push button switches.
((300/1000)*100%)=70%. At 300 SCFM, only 30% of the dryer
Refer to Figure 7-1, Front panel Overlay – Level 1 Controller for the
capacity is being utilized. Average purge requirements and the
appropriate icon associated with each switch. Pushing on the overlay
related energy needed to compress that purge air can be reduced
icon actuates the switch. Switching can be affected remotely by wiring
by 70%.
external push-buttons to the J2 terminals located on the rear of the
• Note: Button function is disabled when the remote start / stop
display board. Refer to Section 7.2.4.
feature has placed the dryer in the cycle interrupted (stop) mode.
7.4.2.1 Dryer On / Off Switch Refer to section 7.2.3.
This switch is used to turn the dryer on (run) or off (stop).
7.4.2.4 Reset / Manual Advance Switch
Caution: In the event of a loss of power, either intentional or • This switch is normally used to reset an alarm or service reminder.
unintentional, both purge-repressurization valves will close. On When the Manual cycle (test) mode is selected, this switch is used
standard pressure models 116.0 &152.9 and high pressure models to advance through the operating cycle one step at a time.
1.1 through 12.7, both inlet-switching valves will open. A tower that Note: Allow towers to fully repressurize before advancing to
is actively purging when the power off button is actuated will be tower switchover.
subjected to a rapid repressurization that can lead to fluidization
and subsequent abrasion of the desiccant bed. Ideally, dryers 7.4.3 Switching Failure Alarms
should be powered off at the end of any half cycle when both • When a tower does not de-pressurize, the Alarm LED, Pressure
desiccant towers are at full operating pressure. Switch LED, and Tower Regenerating LED will blink.
• When a tower does not re-pressurize, the Alarm LED, Pressure
Power recovery after an external loss of power is affected by the Switch LED, and Tower Drying LED will blink.
position of control board jumper J4 (power recovery mode). Refer to • To extinguish the blinking LEDs, correct the fault condition and
Section 7.3.4 for additional information. press the alarm-reset button.
7.4.2.2 Operating Mode Selector Switch • Refer to Table 7-4.
• Four fixed-time cycles provide varying degrees of dryness
corresponding to ISO Classes 1, 2, 3, and 4. 7.5 Fixed Cycle Timing
• Manual cycle (test mode) is used for troubleshooting and Refer to Table 7-3 for the fixed cycle timing for the Level 1
startup. Controller.
• The operating mode can be changed at any time. Press the
switch repeatedly until the desired mode’s LED is blinking. The 7.6 Event Sequence and Component Status
LED for the current mode remains illuminated until the end of
Refer to Table 7-4 for the event sequence and component status for
the current half-cycle, at which time the new selection becomes
the Level 1 Controller.
active. At this time, the LED for the new selection switches from
blinking to illuminated, and the LED for the previous selection is
extinguished.
• To select Manual (test) cycle, press and hold the switch for
approximately 2 seconds. The current ISO Class LED will remain
illuminated and the Manual cycle mode LED will illuminate. When
in the Manual cycle mode, the dyer can be advanced one step at
a time using the reset/manual advance switch. Refer to section
7.4.2.4.
• Note: Button function is disabled when the remote start / stop
feature has placed the dryer in the cycle interrupted (stop) mode.
Refer to section 7.2.3.
— 24 —
ISO Class 1 2 3 4 1 2 3 4
-73°C -40°C -20°C +3°C -73°C -40°C -20°C +3°C
Dew Point
-100°F -40°F -4°F +38°F -100°F -40°F -4°F +38°F
Cycle Time (minutes) 4 10 16 24 4 10 16 24
Energy (Purge) Time from start of cycle Time from start of cycle
Time
Savings Settings (minutes : seconds) (minutes : seconds)
t0 all 00:00 00:00 00:00 00:00 00:00 00:00 00:00 00:00
t1 all 00:02 00:02 00:02 00:02 00:02 00:02 00:02 00:02
t2 all 00:06 00:06 00:06 00:06 00:06 00:06 00:06 00:06
70% 00:26 01:16 02:09 03:19 00:19 00:58 01:46 02:52
60% 00:32 01:40 02:50 04:24 00:23 01:16 02:20 03:48
50% 00:39 02:03 03:31 05:28 00:27 01:33 02:53 04:43
40% 00:46 02:26 04:11 06:32 00:31 01:50 03:26 05:38
t3
30% 00:52 02:50 04:52 07:37 00:35 02:08 04:00 06:34
20% 00:59 03:13 05:33 08:41 00:40 02:25 04:33 07:29
10% 01:05 03:37 06:14 09:46 00:44 02:43 05:07 08:25
0% 01:12 04:00 06:55 10:50 00:48 03:00 05:40 09:20
t4 all 02:00 05:00 08:00 12:00 02:00 05:00 08:00 12:00
t5 all 02:02 05:02 08:02 12:02 02:02 05:02 08:02 12:02
t6 all 02:06 05:06 08:06 12:06 02:06 05:06 08:06 12:06
70% 02:26 06:16 10:09 15:19 02:19 05:58 09:46 14:52
60% 02:32 06:40 10:50 16:24 02:23 06:16 10:20 15:48
50% 02:39 07:03 11:31 17:28 02:27 06:33 10:53 16:43
40% 02:46 07:26 12:11 18:32 02:31 06:50 11:26 17:38
t7
30% 02:52 07:50 12:52 19:37 02:35 07:08 12:00 18:34
20% 02:59 08:13 13:33 20:41 02:40 07:25 12:33 19:29
10% 03:05 08:37 14:14 21:46 02:44 07:43 13:07 20:25
0% 03:12 09:00 14:55 22:50 02:48 08:00 13:40 21:20
t8 all 04:00 10:00 16:00 24:00 04:00 10:00 16:00 24:00
Reference Data
Purge time (min:sec)
at 0% Energy Savings 01:06 03:54 06:49 10:44 00:42 02:54 05:34 09:14
settings [(t3-t2) or (t7-t6)]
at 0% Energy Savings 00:48 01:00 01:05 01:10 01:12 02:00 02:20 02:40
settings [(t4-t3) or (t8-t7)]
Table 7-3
Fixed Cycle Timing – Level 1 Controller
— 25 —
Time (refer to Table 7-3)
Process valve name
t0 t1 t2 t3 t4 t5 t6 t7 t8
(Process valve state
w/ de-energized Left Tower Drying Right Tower Drying
pilot solenoid valve) Right Tower Regenerating Left Tower Regenerating
Half Cycle Half Cycle
Pilot Energized
Left purge valve (normally closed)
(open)
Left inlet valve (normally open)
Pilot Energized (closed)
(See NOTE 1)
Right inlet valve (normally open)
(See NOTE 1)
Pilot Energized
Right purge valve (normally closed)
(open)
Normal status of pressure switches
Left tower closed for < 5 open at t7,
closed closed closed closed closed closed
pressure switch sec. then open closed before t8
Right tower closed for < 5 open at t3,
Pressure switch status that causes an alarm
Left tower drying
open1 open1
Low tower pressurea
closed1
Fail to de-pressurizeb
open2
Fail to re-pressurizec
Right tower drying
open1 open1
Low tower pressured
Right tower regenerating
closed1
Fail to de-pressurizee
open2
Fail to re-pressurizef
Stop cycle on
Note Comments
fault
If the fault condition is clear for 2 cycles: the alarm LED stays on (without blinking); the tower and pressure switch LEDs stop
1: Check for fault condition at 15, 25,
no blinking (return to normal operation). Once the fault condition is clear, pressing the reset button will clear the alarm LED (and the
35,... seconds into half-cycle
tower and pressure switch LEDs if they are still blinking).
2: Check for fault condition just If the fault condition clears: resume cycling; the alarm LED stays on (without blinking); the pressure switch LED stops blinking
yes
before the end of the half-cycle (returns to normal operation). Once the fault condition is clear, pressing the reset button will clear the alarm LED.
a: Blink the following LEDs: Alarm + P1 + Left tower drying
b: Blink the following LEDs: Alarm + P1 + Left tower regenerating
c: Blink the following LEDs: Alarm + P1
d: Blink the following LEDs: Alarm + P2 + Right tower drying
e: Blink the following LEDs: Alarm + P2 + Right tower regenerating
f: Blink the following LEDs: Alarm + P2
NOTE 1:Standard Pressure Models 116.0 & 152.9 ONLY. High Pressure Models 1.1 Through 12.7 ONLY.
Table 7-4
Event Sequence and Component Status – Level 1 Controller
— 26 —
CUSTOMER AC TO DC
AC POWER PE POWER SUPPLY Y
01 TB5-20 41 SERVICE REMINDER 3 (PRE FILTERS)
CONNECTIONS GRN/YEL
G
02 85-264 VAC TB5-21 42 LEFT INLET VALVE OPEN (SEE NOTE 6)
47-63 HZ NEUTRAL Y
03 SEE NOTE 1 TB5-22 43 LEFT TOWER REGENERATING
WHT
G
04 TB5-23 44 LEFT PURGE VALVE OPEN
HOT G
05 TB5-24 45 LEFT TOWER DRYING
BLK
Y
06 TB5-25 46 PRESSURE SW. 1 (LEFT TOWER) CLOSED
NEG. Y
07 CUSTOMER 47 SERVICE REMINDER 1 (PILOT AIR FILTER)
BLACK
DC POWER HOT Y
08 48 SERVICE REMINDER 2 (AFTER FILTERS)
CONNECTIONS RED
POS. + G
09 11.5-28 VDC TB4-18 49 RIGHT INLET VALVE OPEN (SEE NOTE 6)
SEE NOTE 2 NEG. - DC INPUT Y
10 TB4-19 50 RIGHT TOWER REGENERATING
+ TB3-10 G
11 +12 51 RIGHT PURGE VALVE OPEN
TB3-11 G
12 52 RIGHT TOWER DRYING
RIGHT INLET VALVE G
13 (SEE NOTE 6) 53 POWER ON
+ TB3-12 Y
14 +12 54 MAIN SERVICE REMINDER
TB3-13 Y
15 55 COMMON ALARM
RIGHT PURGE VALVE Y
16 56 PRESSURE SW. 2 (RIGHT TOWER) CLOSED
+ TB3-14 G
17 +12 57 ENERGY SAVINGS 70%
TB3-15 G
18 58 ENERGY SAVINGS 60%
LEFT INLET VALVE G
19 (SEE NOTE 6) 59 ENERGY SAVINGS 50%
+ TB3-16 G
TB3-17 G
LEFT PURGE VALVE G
G
TB1-1 G
24 EXT. CONTACT 64 ENERGY SAVINGS 0%
TB1-2 G
25 +5 65 ISO CLASS 1 (-100°F/-70°C DEW POINT) CYCLE
G
26 66 ISO CLASS 2 (-40°F/-40°C DEW POINT) CYCLE
TB1-3 G
27 PRESSURE SW. 1 67 ISO CLASS 3 (-4°F/-20°C DEW POINT) CYCLE
TB1-4 LEFT TOWER G
28 68 ISO CLASS 4 (+37°F/+3°C DEW POINT) CYCLE
+5
G
29 69 MANUAL CYCLE (TEST MODE)
TB1-5 MULTIPLEXED LED BUS
30 PRESSURE SW. 2 70
TB1-6 RIGHT TOWER +5
31 71
TB2-7
32 COMMOM 72 ISO CLASS/MANUAL CYCLE
ALARM TB2-9 +5
33 73 J2-1 J2-2
CONNECTIONS
34 TB2-8
SEE NOTE 5 74 ENERGY SAVINGS %
35 75 +5
J2-3 J2-4
36 76 POWER ON/OFF
37 77 +5
J2-5 J2-6
38 78 ALARM RESET/MANUAL INCREMENT
39 79 J2-7 J2-8
CONTROL BOARD
40 80
REMOTE SW. CONNECTIONS = J2
DISPLAY BOARD
NOTES:
1. CUSTOMER POWER CONNECTIONS WHEN SUPPLY VOLTAGE IS AC (ALTERNATING CURRENT). TERMINALS TB5-21, TB5-23 AND TB5-25 CAN BE USED TO PROVIDE ACCESSORY POWER AT THE SAME VOLTAGE AND
FREQUENCY. AC POWER IS DIRECTED TO POWER SUPPLY BOARD WHERE IT IS CONVERTED TO 12 VDC AND RETURNED TO THE CONTROL BOARD.
2. CUSTOMER POWER CONNECTIONS WHEN SUPPLY VOLTAGE IS DC (DIRECT CURRENT). RED AND BLACK WIRES FROM THE POWER SUPPLY BOARD SHOULD BE REMOVED AND THE CUSTOMER SHOULD
MAKE THEIR POWER CONNECTIONS AT TERMINALS TB4-18 AND TB4-19.
3. VOLTAGE RATING OF VALVES IS 12 VDC.
4. VOLTAGE RATING OF SWITCHES IS 5 VDC.
5. WITH UNIT ON AND NO ALARMS, THERE SHOULD BE CONTINUITY BETWEEN TERMINALS TB2-7 AND TB2-9.
6. STANDARD PRESSURE MODELS 116.0 & 152.9 ONLY. HIGH PRESSURE MODELS 1.1 THROUGH 12.7 ONLY.
Figure 7-2
Electrical Schematic – Level 1 Controller
— 27 —
JUMPERS
JUMPER
(SEE NOTE 3)
JUMPER NO. & JUMPER JUMPER

FUNCTION OFF ON
J1 - MAXIMUM OPERATING PRESSURE 150 PSIG 250 PSIG

- - JUMPER PINS
J2 - UNUSED
J3 - SERVICE INTERVAL NORMAL SEVERE
J4 - POWER RECOVERY MODE OFF AUTO
JUMPER JUMPER
OFF ON
JUMPER BASE
ENCLOSURE
DOOR
INTERIOR ENCLOSURE
J2
1 2 3 4 5 6 7 8 INTERIOR
AC TO DC
POWER SUPPLY
RED WIRE
TO TB4-18
J1
J2
J3
J4
BLK WIRE
TO TB4-19
CONTROL BOARD
TB5
TB1 TB2 TB3 TB4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
DISPLAY BOARD
+5
COM
PE
NEU
HOT
NO
NC
EXT. CONTACT
J2
4 1 +5 ALARM AC
1 2 3 4 5 6 7 8
ALARM RESET/MANUAL CYCLE INCREMENT SWITCH

CONTACT POWER
PRESSURE SWITCH 1 + – INPUT
POWER ON/OFF SWITCH (LEFT TOWER) 85-264 VAC
DC 1 PHASE
ENERGY SAVINGS % SELECTOR SWITCH 4 1 +5 POWER 47-63 HZ
INPUT
PRESSURE SWITCH 2
ISO CLASS/MANUAL CYCLE SELECTOR SWITCH +12 11.5-28 VDC
(RIGHT TOWER)
RIGHT INLET VALVE LEFT PURGE VALVE

(SEE NOTE 5)
+12
+12
RIGHT PURGE VALVE LEFT INLET VALVE

(SEE NOTE 5)
+12
NOTES:
1. SEE FIGURE 7-5 FOR RECOMMENDED AWG CONDUCTOR SIZES.
2. CUSTOMER SUPPLIED AC (ALTERNATING CURRENT) INPUT POWER CONNECTIONS SHOULD BE MADE AT TERMINALS TB5-21, TB5-23, AND TB5-25. FOR CUSTOMER SUPPLIED DC (DIRECT CURRENT) POWER, THE
RED AND BLACK WIRES FROM THE POWER SUPPLY BOARD SHOULD BE REMOVED AND THE CUSTOMER POWER CONNECTIONS SHOULD BE MADE AT TERMINALS TB4-18 AND TB4-19.
3. IN THE “JUMPER OFF” POSITION, THE JUMPER CAN BE COMPLETELY REMOVED OR STORED ON A SINGLE PIN. IN THE “JUMPER ON” POSITION, THE JUMPER IS INSTALLED ACROSS BOTH PINS TO PROVIDE
CONTINUITY.
4. WITH THE UNIT ON AND NO ALARMS, THERE SHOULD BE CONTINUITY BETWEEN TERMINALS TB2-7 AND TB2-9.
Figure 7-3
Point-to-Point Connection Diagram - Level 1 Controller
— 28 —
7L 8L
6L 16L
5L 12L
4L 11L
3L 10L
1L
18L 17L
1PB 4PB
19L 3PB
2PB 13L 14L 15L
ENCLOSURE DOOR EXTERIOR

LEGEND
CR COMMON ALARM RELAY 12L RIGHT TWR. DRYING (GREEN) 1PB ISO CLAS/MANAUL CYCLE SELECTOR SWITCH
1L SERVICE REMINDER 3 - PREFILTERS (AMBER) 13L POWER ON LED (GREEN) 2PB POWER ON/OFF SWITCH
3L LEFT TOWER REGEN. (AMBER) 14L MAIN SERVICE REMINDER (AMBER) 3PB ALARM RESET/MANUAL CYCLE INCREMENT SWITCH
4L LEFT PURGE VALVE OPEN (GREEN) 15L COMMON ALARM (RED) 4PB ENERGY SAVINGS % SELECTOR SWITCH
5L LEFT TOWER DRYING (GREEN) 16L PRESS. SWITCH 2 - R. TWR. CLOSED (GREEN) RS232 SERIAL I/O CONNECTION
6L PRESS. SWITCH 1 - L. TWR. CLOSED (GREEN) 17L ENERGY SAVINGS % LEDS (GREEN) PS AC TO DC POWER SUPPLY
7L SERVICE REMINDER 1 - PILOT AIR FILTER (AMBER) 18L ISO CLASS (DEW POINT) CYCLE LEDS (GREEN) J2 REMOTE SWITCH TERMINALS
8L SERVICE REMINDER 2 - AFTERFILTERS (AMBER) 19L MANUAL CYCLE (TEST MODE) LED (GREEN) TB1 EXTERNAL CONTROL INPUT TERMINALS
10L R. TWR REGEN. (AMBER) CNTRLPCB CONTROL BOARD TB2 COMMON ALARM CONTACT TERMINALS
11L RIGHT PURGE VALVE OPEN (GREEN) DISPCB DISPLAY BOARD TB3 VALVE OUTPUT TERMINALS
JMP CONFIGURATION JUMPERS (MAX. OPER. PRESS., TB4 DC POWER INPUT TERMINALS
SERVICE INTERVAL, & POWER RECOVERY MODE)
TB5 AC POWER INPUT TERMINALS
Figure 7-4
Panel Layouts - Level 1 Controller
— 29 —
11.5-28 VDC 85-264 VAC
47-63 HZ
Figure 7-4
Panel Layouts - Level 1 Controller
— 30 —
CABLE DIAMETER RANGE ENCLOSURE
# OF AWG CONNECTOR HOLE DIA.
LOCATION FUNCTION MIN. DIA. MAX. DIA.
CONDUCTORS SIZE SIZE
in. mm in. mm in. mm
1 PRESSURE SWITCH - RIGHT TOWER 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
2 PRESSURE SWITCH - LEFT TOWER 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
FACTORY
3 CONNECTIONS SOLENOID - LEFT PURGE VALVE 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
4 STANDARD SOLENOID - LEFT INLET VALVE* 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
DEVICES
5 SOLENOID - RIGHT PURGE VALVE 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
6 SOLENOID - RIGHT INLET VALVE* 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
7 ALARM CONTACTS 2 16 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
8 USER REMOTE STOP / START 2 16 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
9 CONNECTIONS RS232 3 22 0.114 2.9 0.250 6.4 PG-7 0.492 12.5
10 INPUT POWER 3 14 0.230 5.8 0.395 10.0 PG-11 0.733 18.6
* STANDARD PRESSURE MODELS 116.0 & 152.9 ONLY. HIGH PRESSURE MODELS 1.1 THROUGH 12.7 ONLY.
0.87" [22 mm]

1.97" [50 mm]
2.74" [70 mm]

4.17" [106 mm]
3.45" [88 mm]
5.35" [136 mm]
6.54" [166 mm]
7.72" [196 mm]
8.90" [226 mm]
10.00" [254 mm]
Figure 7-5
Enclosure Penetrations - Level 1 Controller
— 31 —
8. Controller – Level 2 Alarm Alarm
Power Controller Alarm or Alarm
N.O. N.C.
To On or Service Relay
Contact Contact
This section provides connection, adjustment and operational Controller? Off? Reminder Coil
(TB4-39) (TB4-40)
information for the Level 2 Controller featuring the Automatic Purge No N/A N/A De-Energized Open Closed
Saving System (APSS). Similar information can be found in Section 7 Yes Off N/A Energized Closed Open
for the Level 1, Fixed Cycle Controller.
Yes On No Energized Closed Open
Yes On Yes De-Energized Open Closed
8.1 Reference Figures – Level 2 Controller
• Figure 8-1, Front Panel Overlay – Level 2 Controller Table 8-1
• Figure 8-2, Electrical Schematic – Level 2 Controller Common Alarm Relay Logic –Level 2 Controller
• Figure 8-3, Point-to-Point Diagram – Level 2 Controller
• Figure 8-4, Panel Layouts – Level 2 Controller
• Figure 8-5, Enclosure Penetrations – Level 2 Controller 8.2.3 Connections – Remote Start / Stop
Terminals TB2-17 and –18 are used to provide a 5 VDC output to a
8.2 Connections – Level 2 Controller remote switch or volt free contacts that when closed will stop the dryer
at the end of the current half cycle. The dryer will resume running
See Figure 8-5, Enclosure Penetrations for the location, size and at the beginning of the new half cycle when the remote switch or
function of the various cable and cord connectors that are provided contacts are reopened. When dryer operation is in the remote stop
on the bottom of the Level 2 enclosure. state, all four tower drying (green) and regenerating (amber) LEDs
8.2.1 Connections - Input Power flash simultaneously.
8.2.1.1 VAC Input Power Connections Note: Remote start / stop is disabled when the dryer is in the Manual
Single-phase, alternating current (AC) input power connections ranging cycle operation mode. When the dryer is in the remote stop state, the
from 85-264 VAC and 47 to 63 Hz. can be made at terminals TB6-45, only front panel and remote selector switches (see Section 8.2.4) that
-47, and -49. See reference figures for proper polarity. These terminals remain enabled are the power on/off switches.
are connected to accessory output terminals TB6-44, -46, and -48 8.2.4 Connections – Remote Switches
respectively. Accessory output terminals can be used to direct power The controller door is equipped with four momentary-contact, push
at the same voltage and frequency to external devices. button switches. Pressing on the appropriate icon printed on the
CAUTION: Accessory output terminals are NOT controlled by display overlay actuates these switches. The display board containing
the power on/off switch and are always energized when power the switches, display LEDs, text display, and the RPB (J2) terminal
is provided to terminals TB6-45, -47, and -49. strip is mounted on the inside of the enclosure door. The terminal strip
provides connection points for remotely mounted, NO (normally open),
8.2.1.2 VDC Power Connections momentary-contact push buttons that provide the same function as the
• The control and display boards operate on low-voltage direct board mounted switches. The terminal – switch combinations are:
current. The controller is provided pre-wired with an AC to 12 VDC • Terminals J2-1 and –2 (Remote “SELECT” switch)
power supply board. For users with AC power as described in • Terminals J2-3 and –4 (Remote “ENTER” switch)
Section 8.2.1.1, their AC input is directed to the power supply • Terminals J2-5 and –6 (Remote Power On / Off Switch)
board where it is conditioned and returned to the control board NOTE: Care must be exercised in using this remote switch to
as 12 VDC at terminals TB5-42 and -43. stop a dryer. Closing this switch will affect the same response
• For users with direct current (DC) input power ranging from 11.5 as a loss of power. Both purge-repressurization valves will close.
to 28 VDC, use of the AC to DC power supply board is not needed On standard pressure models 116.0&152.9 and high pressure
and their connections can be made at terminals TB5-42 and -43 models 1.1 through 12.7, both inlet-switching valves will open. A
by first removing the black and red leads coming from the power tower that is actively purging when the power on/off button is
supply board. See reference figures for proper polarity. actuated will be subjected to a rapid repressurization that can
8.2.2 Connections – Common Alarm Contacts lead to fluidization and subsequent abrasion of the desiccant bed.
Connections to voltage-free common alarm contacts with a minimum Ideally, dryers should only be powered off during those portions of
5-amp rating can be made at terminals TB4-39 through -41. the drying cycle when both desiccant towers are at full operating
• Terminal TB4-41 is the common contact connection. pressure. Use of the remote start/stop connections as described
• Terminal TB4-39 is the N.O. (normally open) contact in Section 8.2.3 would be preferable in most cases.
connection. • Terminals J2-7 and –8 (Remote Alarm Reset Switch)
• Terminal TB4-40 is the N.C. (normally closed) contact 8.2.5 Connections – RS232
connection. Refer to Figure 8-4, Panel Layouts – Level 2 Controller. RS232
• The alarm relay coil is energized when power is supplied to the connections can be made at the 3-pin connector labeled J3 and
controller input terminals and there are no alarms. located at the upper left-hand corner of the control board. A cable for
• The coil is de-energized when power is removed or when an this connection can be purchased through your distributor.
alarm condition exists.
• Additional information on the common alarm relay logic appears
in Table 8-1.
— 32 —
8.2.6 Connections – High humidity alarm • Purge / repressurization valve status (On = valve open; Off = valve
The normally closed dry contacts from a high humidity alarm device closed) – green
can be wired to AUX 1 terminals TB1-7 and TB1-8. A shorting jumper • Left and right tower status (regenerating) - amber
that connects the two terminals must be installed if an alarm device • Left and right tower status (drying) - green
is not wired to the terminals. When continuity between the terminals • Left and right tower pressure switch status (On = switch closed;
is broken, the controller displays an outlet dew point alarm (refer to Off = switch open) – green
Section 8.9, screens 17 and 18).
8.4.2 Front Panel Switches
The front panel contains four momentary-contact push button switches.
8.3 Control Board Jumpers – Level 2 Refer to Figure 8-1, Front panel Overlay – Level 2 Controller for the
Refer to Figure 8-3, Point to Point Connection Diagram – Level 2 appropriate icon associated with each switch. Pushing on the overlay
Controller. In the upper left hand corner of the control board there are icon actuates the switch. Switching can be affected remotely by wiring
eight two-pin jumpers labeled JP1 through JP8. Only two of the eight external push-buttons to the RPB (J2) terminals located on the rear of
jumper pairs are utilized. Pairs JP3-JP8 are not used. the display board. Refer to Section 8.2.4.
NOTE: Do not install jumpers in the ON position on pairs JP3 through 8.4.2.1 Dryer On / Off Switch
JP8. This switch is used to turn the dryer on (run) or off (stop).
The jumper is a removable bridge that is used to make or break Caution: In the event of a loss of power, either intentional or
continuity between the two pins that form a pair. When installed in unintentional, both purge-repressurization valves will close. On
the ON position, the jumper is placed on both pins of the pair and standard pressure models 116.0&152.9 and high pressure models
continuity between the pins is established. When installed in the OFF 1.1 through 12.7, both inlet-switching valves will open. A tower that
position, the jumper is removed or stored on a single pin and continuity is actively purging when the power off button is actuated will be
is broken. Jumper functions are as follows: subjected to a rapid repressurization that can lead to fluidization
8.3.1 Jumper JP1 – Maximum Operating Pressure and subsequent abrasion of the desiccant bed. Ideally, dryers
• Jumper JP1 is used to select the maximum operating pressure. should be powered off at the end of any half cycle when both
Installed in the OFF position when operating at inlet pressures desiccant towers are at full operating pressure.
of 60 to 150 psig (4.1 to 10.3 barg). Installed in the ON position Power recovery after an external loss of power is affected by the
when operating at inlet pressures of 120 to 250 psig (8.3 to programming of the auto restart mode (Program Mode – Screen 2).
17.2 barg). Refer to Section 8.7 for additional information.
• This setting will affect tower purge and repressurization times.
8.4.2.2 SELECT Switch
8.3.2 Jumper JP2 – Electric Drains This button is located to the left of the text display window.
• Jumper JP2 is installed in the ON position if one or two electric Refer to Section 8.6 for additional information.
demand drains are installed. It is installed in the OFF position
when no electric drains are installed. 8.4.2.3 ENTER Switch
• The drains can be manually tested through the Level 2 controller This button is located to the right of the text display window.
Setup Mode. Refer to Section 8.6 for additional information.
• The drains provide a digital alarm signal to the Level 2 controller, 8.4.2.4 Alarm Reset Switch
which then displays an alarm message. This switch is normally used to reset an alarm or service reminder.
• If the dryer has only 1 drain, then the alarm input terminals for Refer to Section 8.9 for additional information.
Drain 2 (TB2-25 and TB2-26) must be shorted.
8.5 Event Sequence and Component Status
8.4 Front Panel Overlay – Level 2 Controller Refer to Tables 8-2, 8-3, and 8-4 for the event sequence, timing and
Refer to Figure 8-1, Front Panel Overlay – Level 2 Controller for component status for the Level 2 Controller.
information regarding the location and function of the LEDs, switches,
and text display. 8.6 Front Panel Operation
8.4.1 Front Panel LEDs 1. There are five operating modes for the Level 2 Desiccant
• Power on – green (constant when controller is switched on; Dryer Controller.
flashing when controller is energized but switched off.) a. Program Mode
• Alarm – red b. Setup Mode
• Service/maintenance reminder – amber c. Alarm & Service Mode
• Filters (pre, after, and pilot) service/maintenance reminders d. Display Mode
- amber e. Test Mode
2. Each mode is described in the following pages.
— 33 —
Left tower pressure Filter service /
switch LED: maintenance LED
On=switch closed
Off=switch open
Filter service /
maintenance LED
Left tower drying LED
Right tower pressure

Left purge valve LED switch LED:
On=valve open On=switch closed
Off=valve closed Off=switch open
Right tower drying LED
Right purge valve LED

Left tower regenerating On=valve open
LED Off=valve closed
Right tower
Filter service / regenerating LED
maintenance LED
Vacuum Fluorescent
Text Display
Select switch
Enter switch
Power On LED
Maintenance / service
reminder LED
Communications icon
Alarm LED
Power On / Off Switch
Reset switch for alarm

Also see 7.7.3, setting
dew point alarm.
Figure 8-1
Front Panel Overlay – Level 2 Controller
— 34 —
8.7 Program Mode 8.7.4 Program Mode Screen 4 – Reset the timer for filter
service.
1. Press and hold and simultaneously for 3 seconds
to enter Program Mode. FILTER SERVICE
RESET? NO
2. Program Mode is comprised of the screens that are
described below.
• Press to toggle between NO and YES.
3. There are three ways to exit Program Mode.
• When finished, press to acknowledge the selection and
a. Press after making the selection in the final screen. move to Screen 5.
b. At any screen, press and hold for 3 seconds. 8.7.5 Program Mode Screen 5 – Reset the timer for desiccant
c. The controller automatically exits Program Mode if no service.
button is pressed within 60 seconds. DESICCANT SERVICE
4. Upon exiting Program Mode the controller will switch to RESET? NO
Display Mode.
8.7.1 Program Mode Screen 1 – Select the language. • Press to toggle between NO and YES.
• When finished, press to acknowledge the selection and
move to Screen 6.
ENGLISH
8.7.6 Program Mode Screen 6 – Reset the timer for valve
• Press to scroll through the available language service.
choices: ENGLISH, DEUTSCH, FRANCAIS, ESPANOL, and VALVE SERVICE
ITALIANO.
RESET? NO
• When finished, press to save the selection and move to
Screen 2. • Press to toggle between NO and YES.
8.7.2 Program Mode Screen 2 – Select the auto restart mode. • When finished, press to acknowledge the selection and
move to Screen 7.
AUTO RESTART
DISABLED 8.7.7 Program Mode Screen 7 – Reset the valve cycle counter.
CYCLE COUNTER
• Press to toggle between DISABLED and ENABLED. RESET? NO
• When finished, press to save the selection and move to
Screen 3. • Press to toggle between NO and YES.
8.7.3 Program Mode Screen 3 – Select the service level. • When finished, press to acknowledge the selection and
exit Program Mode.
SERVICE LEVEL
NORMAL 8.8 Setup Mode
• Press to toggle between NORMAL and SEVERE. • Press and hold for 3 seconds to enter Setup Mode.
a. NORMAL service intervals are: • Setup Mode is comprised of the screens that are described
i. 4000 hours for filters below.
ii. 8000 hours for desiccant • There are three ways to exit Setup Mode.
iii. 4000 hours for valves 1. Press after making the selection in Screen 2 (if the
b. SEVERE service intervals are: dryer does not have electric drains) or Screen 3 (if the
i. 2000 hours for filters dryer has electric drains).
ii. 4000 hours for desiccant 2. At any screen, press and hold for 3 seconds.
iii. 2000 hours for valves
• NOTE: Time continues to accumulate as long as power is 3. The controller automatically exits Setup Mode if no
supplied to the controller, whether the controller is switched button is pressed within 60 seconds.
on or off. • One of two things will happen upon exiting Setup Mode.
• When finished Press to save the selection and move to 1. The controller will switch to Display Mode if DEMAND
Screen 4 (if no filter monitors are detected) or Screen 5 (if 1 CYCLE or FIXED CYCLE was selected.
or 2 filter monitors are detected). 2. The controller will switch to Test Mode if MANUAL
CYCLE was selected.
— 35 —
8.8.1 Setup Mode Screen 1 – Select the dew point class. 2. Left or right tower, regenerating, high pressure
ISO 8573 DEW PT • Pressure switch closed while purge valve is open (after an
initial time delay)
2: -40°C/-40°F
3. Left or right tower, regenerating, low pressure
• Press to scroll through the choices: • Pressure switch open at the end of the regenerating cycle
1: -73°C/-100°F 8.9.1.2 Thermistor Alarms
2: -40°C/-40°F There are two alarms for each of the four thermistors. These alarms
3: -20°C/-4°F can only occur in the demand cycle. Following is a brief description
4: +3°C/+38°F of each alarm.
• When finished, press to save the selection and move to 1. Left or right tower, upper or lower sensor, over-range
Screen 2. • Temperature above 150°F (66°C)
• Thermistor circuit shorted
8.8.2 Setup Mode Screen 2 – Select the cycle type. 2. Left or right tower, upper or lower sensor, under-range one
CYCLE TYPE cycle
DEMAND CYCLE • Temperature below 40°F (4°C)
• Thermistor circuit open
• Press to scroll through the choices: DEMAND CYCLE,
8.9.1.3 Optional Device Alarms
FIXED CYCLE, and MANUAL CYCLE. Note: DEMAND CYCLE
1. Electric Drains with Alarm Contacts
is not available if Class 1 was selected in the previous screen.
• Each drain has alarm contacts that connect to the Level 2
• When finished, press to save the selection and move to Controller.
Screen 3 (if the dryer has electric drains) or exit Setup Mode • If the contacts open, then a drain alarm is indicated.
(if the dryer does not have electric drains). 2. Humistat (humidity sensor) - AUX 1 input
8.8.3 Setup Mode Screen 3 – Test the drains. • The humistat has alarm contacts that connect to the
Level 2 controller.
TEST DRAIN ? • If the contacts open, the outlet dew point alarm is
NO indicated.
• Press to toggle between NO and YES. When an alarm condition occurs, the controller operates as follows.
• The alarm LED blinks and the appropriate alarm message is
• Press to continue. shown on the text display.
a. If NO was selected, the controller immediately exits • The dryer continues to cycle normally (see below for exception).
Setup Mode. NOTE: The LEDs for the valves, pressure switches, and
b. If YES was selected, the controller energizes Drain 1 desiccant towers are not used for alarm indication (as in the
and Drain 2 for 4 seconds before exiting Setup Mode. Level 1 Controller).
• If the alarm condition clears for one cycle, then the alarm LED
8.9 Alarm & Service Mode stops blinking (LED on); the alarm message continues to be
Alarm & Service Mode is active when the controller is in Display Mode. displayed.
It is not active in Program Mode, Setup Mode, or Test Mode. • Exception: If the alarm is caused by the condition in Section
8.9.1.1, then the cycle stops. Once the alarm condition is
NOTE: Alarm messages have priority over Service messages. Service
corrected, the alarm LED stops blinking (LED on) and the
messages have priority over Display messages. When an alarm occurs,
cycle continues normally; the alarm message continues to be
Display Mode is disabled and only the alarm message is shown. When a
displayed.
service message is active, it takes the place of the corresponding service
• In the demand cycle, the control switches to a fixed 10 minute cycle
reminder in the Display Mode (e.g. “HOURS TO SERVICE FILTERS:
when the alarm LED begins blinking. Control switches back to
XXXX” would be replaced by “SERVICE DRYER FILTERS”).
the selected demand cycle after the alarm condition clears. This
8.9.1 Alarm messages applies to thermistor and outlet dew point alarms, but not to drain
Alarm messages are displayed on a first-out basis with one exception. alarms.
The alarm caused by an open pressure switch at the end of the • When the alarm condition is corrected, press the reset button to
regeneration cycle, takes precedence over existing alarms. See extinguish the alarm LED and to clear the alarm message from
8.9.1.1 (3). the text display.
8.9.1.1 Pressure Switch Alarms
There are three alarms for each tower that are triggered by the tower
pressure switches. These alarms can occur in either the fixed or
demand cycle. Following is a brief description of each alarm.
1. Left or right tower, drying, low pressure
• Pressure switch open during drying cycle
— 36 —
The following text display is shown for each alarm. The second line of 8.9.1.11 Alarm Mode Screen 8 - Right Tower Drying – Low
the alarm screens contains up to three messages, which are scrolled Pressure (Open Pressure Switch Circuit)
through, displaying each one for 3 seconds after the alarm condition ALARM
clears.
RIGHT TOWER
8.9.1.4 Alarm Mode Screen 1 – Left Tower Drying – Low DRYING
Pressure (Open Pressure Switch Circuit) LOW PRESSURE
ALARM
8.9.1.12 Alarm Mode Screen 9 – Right Tower Regenerating
LEFT TOWER – High Pressure (Closed Pressure Switch Circuit)
DRYING
LOW PRESSURE ALARM
RIGHT TOWER
8.9.1.5 Alarm Mode Screen 2 – Left Tower Regenerating REGENERATING
– High Pressure (Closed Pressure Switch Circuit) HIGH PRESSURE
ALARM
8.9.1.13 Alarm Mode Screen 10 – Right Tower Regenerating-
LEFT TOWER Low Pressure (Open Pressure Switch Circuit)
REGENERATING
HIGH PRESSURE ALARM
RIGHT TOWER
8.9.1.6 Alarm Mode Screen 3 – Left Tower Regenerating- Low REGENERATING
Pressure (Open Pressure Switch Circuit) LOW PRESSURE
ALARM
8.9.1.14 Alarm Mode Screen 11 – Right Tower, Upper Sensor
LEFT TOWER (Thermistor) Under-Range
REGENERATING
LOW PRESSURE ALARM
RIGHT TOWER
8.9.1.7 Alarm Mode Screen 4 – Left Tower, Upper Sensor UPPER SENSOR
(Thermistor) Under-Range UNDER-RANGE
ALARM
8.9.1.15 Alarm Mode Screen 12 – Right Tower, Upper Sensor
LEFT TOWER (Thermistor) Over-Range
UPPER SENSOR
UNDER-RANGE ALARM
RIGHT TOWER
8.9.1.8 Alarm Mode Screen 5 – Left Tower, Upper Sensor UPPER SENSOR
(Thermistor) Over-Range OVER-RANGE
ALARM
8.9.1.16 Alarm Mode Screen 13 – Right Tower, Lower Sensor
LEFT TOWER (Thermistor) Under-Range
UPPER SENSOR
OVER-RANGE ALARM
RIGHT TOWER
8.9.1.9 Alarm Mode Screen 6 – Left Tower, Lower Sensor LOWER SENSOR
(Thermistor) Under-Range UNDER-RANGE
ALARM
8.9.1.17 Alarm Mode Screen 14 – Right Tower, Lower Sensor
LEFT TOWER (Thermistor) Over-Range
LOWER SENSOR
UNDER-RANGE ALARM
RIGHT TOWER
8.9.1.10 Alarm Mode Screen 7 – Left Tower, Lower Sensor LOWER SENSOR
(Thermistor) Over-Range OVER-RANGE
ALARM
8.9.1.18 Alarm Mode Screen 15 – Alarm Drain 1
LEFT TOWER
LOWER SENSOR ALARM
OVER-RANGE DRAIN 1
8.9.1.19 Alarm Mode Screen 16 – Alarm Drain 2

ALARM
DRAIN 2
— 37 —
8.9.1.20 Alarm Mode Screen 17 – Alarm 8.9.2.3 Service Mode Screen 3 – Service valves
ALARM SERVICE DRYER
LEFT TOWER VALVES
DRYING Ensure that valves are cycling properly. Check for switching failure
OUTLET DEW POINT alarms and adjust purge pressure. Check for leaks.
8.9.1.21 Alarm Mode Screen 18 – Alarm
8.10 Display Mode
ALARM
• Display Mode is active when the user exits Program Mode or
RIGHT TOWER
Setup Mode (unless MANUAL cycle was selected in Setup Mode)
DRYING
and no alarms are active.
OUTLET DEW POINT
• The LEDs for the valves, pressure switches, and desiccant towers
8.9.2 Service messages operate in the same manner as in the Level 1 Controller, except
There are two service levels (normal and severe) as described in the case of an alarm or service reminder (see 5.b and 7.b in
in Program Mode. Each service level has preset time intervals Alarm & Service Mode).
for servicing the filters, desiccant, and valves. Time continues to • Display Mode is comprised of several screens (described
accumulate as long as power is supplied to the controller, whether below). The controller automatically scrolls through the screens,
the controller is switched on or off. displaying each one for 4 seconds. The user can override the
When a service time interval expires, the controller operates as 4 second time period and force the next screen to be displayed
follows. by pressing .
• The service LED blinks and the appropriate service message is • The screens are displayed in the following sequence: 1, 2, 3A,
shown on the text display. (See 8.9.1) 1, 2, 3B, 1, 2, 3C, 1, 2, 3D, … with the exceptions noted below.
• When the service interval for filters has expired the three filter 8.10.1 Display Mode Screen 1 – Dew point class and cycle
LEDs also blink. type.
NOTE: If the dryer has 1 or 2 filter monitors, the timer for filter
2: -40°C/-40°F
service is disabled. When the filter monitor(s) sends an alarm
signal (change filter) to the Level 2 Controller, the controller DEMAND CYCLE
displays the same LEDs and messages it would if the timer for
8.10.2 Display Mode Screen 2 – Energy savings.
filter service had expired.
This screen is not displayed if FIXED cycle is selected.
• The dryer continues to cycle normally.
NOTE: The LEDs for the valves, pressure switches, and desiccant ENERGY SAVINGS
towers are not used for service indication (as in the Level 1 XX%
Controller).
8.10.3 Display Mode Screen 3A – Service reminder (filters).
To extinguish the service LED and clear the service message from the
This screen is not displayed if 1 or 2 filter monitors are detected.
text display, go to Program Mode and reset the appropriate service
timer. If a filter monitor is installed, reset the monitor to clear the HOURS TO SERVICE
Service LED. FILTERS: XXXX
The following text display is shown for each service message. 8.10.4 Display Mode Screen 3B – Service reminder (desiccant).
Replacement or repair of the affected item may or may not be
necessary. The service reminders are used to schedule routine HOURS TO SERVICE
evaluation of the operational status of key components. DESICCANT: XXXX
8.9.2.1 Service Mode Screen 1 – Service filters 8.10.5 Display Mode Screen 3C – Service reminder (valves).
SERVICE DRYER HOURS TO SERVICE
FILTERS VALVES: XXXX
Check filter Delta-P gauges and ensure that drains are functioning
8.10.6 Display Mode Screen 3D – Valve cycle counter.
properly. Inspect pilot air filter element. Check filter monitors, if
equipped. CYCLE COUNTER
XXXXXXX
8.9.2.2 Service Mode Screen 2 – Service desiccant
SERVICE DRYER
8.11 Test Mode
DESICCANT
• Test Mode is active when the user exits Setup Mode after selecting
Check moisture indicator or outlet dew point and inspect mufflers operation in MANUAL CYCLE.
for excessive dusting. • Test Mode is comprised of eight screens. Each screen
corresponds to one of eight program steps (described in Table
8-2).
— 38 —
• Caution: Do not advance to step 5 until the right tower
• Press to advance from one screen (program step) to the
has fully pressurized.
next. Be sure to read and understand all cautions listed with the
screen (program step) descriptions. • Press to advance to screen 5.
• If the temperature is below 40°F or the thermistor circuit is open, 8.11.5 Test Mode Screen 5 – Step 5
the second line of the display will read “UNDER-RANGE” instead
TEST MODE STEP 5
of the temperature reading. (Refer to screens 2, 3, 4, 6, 7, and
8.) OK TO EXIT NOW
• If the temperature is above 150°F or the thermistor circuit is • No temperature display on this screen.
shorted, the second line of the display will read “OVER-RANGE” • Press to advance to screen 6.
instead of the temperature reading. (Refer to screens 2, 3, 4, 6,
7, and 8.) 8.11.6 Test Mode Screen 6 – Step 6
• Upon entering Test Mode, the program can be at any one of the TEST MODE STEP 6
eight steps. XX°C XXX°F
• To exit Test Mode:
• The right tower drying light is blinking to indicate the thermistor
1. Use to manually advance the program to step 1 or 5. location (upper right) that corresponds to the temperature
a) The program must be set at step 1 or 5 to exit Test display.
Mode.
b) Screen 9 is displayed for 3 seconds if the user attempts • Press to advance to screen 7.
to exit the program from step 2, 3, or 4. 8.11.7 Test Mode Screen 7 – Step 7
c) Screen 10 is displayed for 3 seconds if the user
TEST MODE STEP 7
attempts to exit the program from step 6, 7, or 8.
XX°C XXX°F
2. Press and hold for 3 seconds to exit Test Mode. The
display switches to Screen 2 of Setup Mode. • The left tower regenerating light is blinking to indicate the
thermistor location (lower left) that corresponds to the
3. Use to select DEMAND CYCLE or FIXED CYCLE. temperature display.
4. Press to accept the selection and activate Display • Press to advance to screen 8.
Mode.
8.11.8 Test Mode Screen 8 – Step 8
TEST MODE STEP 1 TEST MODE STEP 8
OK TO EXIT NOW XX°C XXX°F
• No temperature display on this screen. • The right tower drying light is blinking to indicate the thermistor
location (upper right) that corresponds to the temperature
• Press to advance to screen 2. display.
8.11.2 Test Mode Screen 2 – Step 2 • Caution: Do not advance to step 1 until the left tower
has fully pressurized.
TEST MODE STEP 2
XX°C XXX°F • Press to advance to screen 1.
• The left tower drying light is blinking to indicate the thermistor 8.11.9 Test Mode Screen 9 – Attempting to exit test mode from
location (upper left) that corresponds to the temperature step 2, 3, or 4
display. TO EXIT TEST
• Press to advance to screen 3. GO TO STEP 5
8.11.3 Test Mode Screen 3 – Step 3 • This screen is displayed for 5 seconds if the user attempts to
exit test mode from step 2, 3, or 4.
TEST MODE STEP 3
• At the end of the 5-second time period, the display returns to
XX°C XXX°F the previous screen (2, 3, or 4).
• The right tower regenerating light is blinking to indicate the
8.11.10 Test Mode Screen 10 – Attempting to exit test mode
thermistor location (lower right) that corresponds to the
from step 6, 7, or 8.
temperature display.
TO EXIT TEST
• Press to advance to screen 4.
GO TO STEP 1
• This screen is displayed for 5 seconds if the user attempts to
TEST MODE STEP 4 exit test mode from step 6, 7, or 8.
XX°C XXX°F • At the end of the 5-second time period, the display returns to
• The left tower drying light is blinking to indicate the thermistor the previous screen (6, 7, or 8).
location (upper left) that corresponds to the temperature
display.
— 39 —
Program Step 1 2 3 4 5 6 7 8
Left tower status drying drying drying drying regen. regen. regen. regen.
Right tower status regen. regen. regen. regen. drying drying drying drying
Left tower closed at start, open at start,
pressure switch open at end closed at end
Right tower closed at start, open at start,
pressure switch open at end closed at end
Left inlet solenoid
off off off off off on on on
(see Note 1)
Left purge solenoid off off off off off off on off
Right inlet solenoid
off on on on off off off off
(see Note 1)
Right purge solenoid off off on off off off off off
Inlet shuttle valve
open to left chamber open to right chamber
(see Note 2)
Left inlet valve
open open open open open closed closed closed
(see Note 1)
Left purge valve closed closed closed closed closed closed open closed
Right inlet valve
open closed closed closed open open open open
(see Note 1)
Right purge valve closed closed open closed closed closed closed closed
Temperature display -
none upper left lower right upper left none upper right lower left upper right
thermistor location
Note 1: Standard Pressure Models 116.0 & 152.9 ONLY. High Pressure Models 1.1 through 12.7 ONLY.
Note 2: Standard Pressure Models 1.1 through 84.9 ONLY.
Table 8-2
Cycle Sequence Steps
— 40 —
ISO Class 1 2 3 4 1 2 3 4
Dew Point -73°C -40°C -20°C +3°C -73°C -40°C -20°C +3°C
-100°F -40°F -4°F +38°F -100°F -40°F -4°F +38°F
Cycle Time (minutes) 4 10 16 24 4 10 16 24
Time from start of cycle Time from start of cycle
Time
(minutes : seconds) (minutes : seconds)
t0 00:00 00:00 00:00 00:00 00:00 00:00 00:00 00:00
t1 00:02 00:02 00:02 00:02 00:02 00:02 00:02 00:02
t2 00:06 00:06 00:06 00:06 00:06 00:06 00:06 00:06
t3 01:12 04:00 06:55 10:50 00:48 03:00 05:40 09:20
t4 02:00 05:00 08:00 12:00 02:00 05:00 08:00 12:00
t5 02:02 05:02 08:02 12:02 02:02 05:02 08:02 12:02
t6 02:06 05:06 08:06 12:06 02:06 05:06 08:06 12:06
t7 03:12 09:00 14:55 22:50 02:48 08:00 13:40 21:20
t8 04:00 10:00 16:00 24:00 04:00 10:00 16:00 24:00
Reference Data
01:06 03:54 06:49 10:44 00:42 02:54 05:34 09:14
[(t3-t2) or (t7-t6)]
Repress. time (min:sec)
00:48 01:00 01:05 01:10 01:12 02:00 02:20 02:40
[(t4-t3) or (t8-t7)]
Table 8-3
Fixed Cycle Timing – Level 2 Controller
NOTE: When operated in the Demand Mode, drying times t4-t0 and t8-t4 can extend to a maximum of 30 minutes each. Purge times in the
Demand Mode, regardless of the ISO Class selection, will always be equal to the purge times of the ISO Class 2 (10 min.) Fixed Cycle (3:54 for
150 psig MOP and 2:54 for 250 psig MOP).
— 41 —
Time (refer to Table 8-3)
Process valve name t0 t1 t2 t3 t4 t5 t6 t7 t8
(Process valve state
w/ de-energized Left Tower Drying Right Tower Drying
pilot solenoid valve) Right Tower Regenerating Left Tower Regenerating
Half Cycle Half Cycle
Left purge valve Pilot Energized
(normally closed) (open)
Left inlet valve (normally open)
(See NOTE 1)
Right inlet valve (normally open)
(See NOTE 1)
Right purge valve Pilot Energized
(normally closed) (open)
Normal status of pressure switches
Left tower closed for < 5 open at t7,
Right tower closed for < 5 open at t3,

Pressure switch status that causes an alarm

Left tower drying
open1 open1
Low tower pressurea
closed1
Fail to de-pressurizeb
open2
Fail to re-pressurizec
Right tower drying
open1 open1
Low tower pressured
closed1
Fail to de-pressurizee
open2
Fail to re-pressurizef
Stop cycle on
Note Comments
fault
1: Check for fault condition at 15, 25, If the fault condition is clear for 1 cycle: the alarm LED stays on (without blinking) and the alarm message continues to be
no
35,... seconds into the half-cycle displayed. Once the fault condition is clear, pressing the reset button will clear the alarm LED and message.
2: Check for fault condition just before If the fault condition clears: tower cycling resumes and the alarm LED stays on (without blinking). Once the fault condition is
yes
the end of the half-cycle clear, pressing the reset button will clear the alarm LED and message.
a: Blink the Alarm LED and display the following text message: Alarm + Left Tower Drying + Low Pressure
b: Blink the Alarm LED and display the following text message: Alarm + Left Tower Regenerating + High Pressure
c: Blink the Alarm LED and display the following text message: Alarm + Left Tower Regenerating + Low Pressure
d: Blink the Alarm LED and display the following text message: Alarm + Right Tower Drying + Low Pressure
e: Blink the Alarm LED and display the following text message: Alarm + Right Tower Regenerating + High Pressure
f: Blink the Alarm LED and display the following text message: Alarm + Right Tower Regenerating + Low Pressure
NOTE 1: Standard Pressure Models 116.0 & 152.9 ONLY. High Pressure M1.1 through 12.7 ONLY
Table 8-4
Event Sequence and Component Status – Level 2 Controller
— 42 —
Figure 8-2
Electrical Schematic – Level 2 Controller
— 43 —
ENCLOSURE
DOOR
J2 (RPB)
12345678
ENCLOSURE DOOR INTERIOR

REMOTE PUSHBUTTON
SWITCH CONNECTIONS
1 2 3 4 5 6 7 8
SELECT POWER ON / OFF
ENTER ALARM_RESET
Figure 8-3
Point-to-Point Diagram – Level 2 Controller
— 44 —
ENCLOSURE
INTERIOR
J3
J1
J4
POWER SUPPLY
BLACK CUSTOMER
J5 AC POWER
RED WHITE CONNECTIONS
85-264 VAC
J6
JP1 GRN/YEL 47-63 HZ
J8 BLK
RED
BLACK CUSTOMER
DC POWER
CONNECTIONS
JP8 11.5-28 VDC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
JUMPER
TB1 TB2 TB3 TB4
COM
NO
NC
JUMPER PINS
ALARM CONTACTS
RIGHT_BTM_THERM
TEST DRAIN 2
JUMPER BASE
RIGHT_TOP_THERM
TEST DRAIN 1
LEFT_BTM_THERM
JUMPER JUMPER LEFT PURGE VALVE
OFF ON
+12
LEFT_TOP_THERM
LEFT INLET VALVE
(SEE NOTE 5)
+12
JUMPERS REMOTE START / STOP
RIGHT PURGE VALVE
JUMPER NO. & JUMPER JUMPER +12

4 1
FUNCTION OFF ON
+5
JP1 - MAXIMUM OPERATING PRESSURE 150 PSIG 250 PSIG
LEFT TOWER PRESSURE SWITCH
JP2 - DRAIN TEST FUNCTIONAL NO YES RIGHT INLET VALVE
(SEE NOTE 5)
JP3 - (NOT USED) -- -- +12
4 1
JP4 - (NOT USED) -- -- +5
JP5 - (NOT USED) -- --
RIGHT TOWER PRESSURE SWITCH
-- -- DRAIN ALARM 2
JP6 - (NOT USED)

DRAIN ALARM 1
NOTES:
1. SEE FIGURE 8-5 FOR RECOMMENDED AWG CONDUCTOR SIZES.
2. CUSTOMER SUPPLIED AC (ALTERNATING CURRENT) INPUT POWER CONNECTIONS SHOULD BE MADE AT TERMINALS TB6-44, TB6-46 AND TB6-48. FOR CUSTOMER SUPPLIED DC (DIRECT CURRENT) POWER,
THE RED AND BLACK WIRES FROM THE POWER SUPPLY BOARD SHOULD BE REMOVED AND THE CUSTOMER POWER CONNECTIONS SHOULD BE MADE AT TERMINALS TB5-42 AND TB5-43.
3. IN THE ‘JUMPER OFF’ POSITION, THE JUMPER CAN BE COMPLETELY REMOVED OR STORED ON A SINGLE PIN. IN THE ‘JUMPER ON’ POSITION, THE JUMPER IS INSTALLED ACROSS BOTH PINS TO PROVIDE
CONTINUITY.
4. WITH UNIT ON AND NO ALARMS, THERE SHOULD BE CONTINUITY BETWEEN TERMINALS TB4-39 AND TB4-41. CONTACTS ARE RATED AT 5 AMPS.
Figure 8-3
Point-to-Point Diagram – Level 2 Controller
— 45 —
7L 8L
6L 16L
5L 12L
4L 11L
3L 10L
1L VACUUM FLOURESCENT
TEXT DISPLAY
1PB 4PB
3PB
2PB 13L 14L 15L
ENCLOSURE DOOR EXTERIOR

LEGEND
1L SERVICE REMINDER 3 - PRE FILTERS (AMBER) 15L COMMON ALARM (RED) J3 RS232 SERIAL I/O CONNECTOR
3L LEFT TOWER REGENERATING (AMBER) 16L PRESSURE SWITCH 2 (RIGHT TOWER) CLOSED (GREEN) J4 PICPROG. CONNECTOR
4L LEFT PURGE VALVE OPEN (GREEN) 1PB SELECT SWITCH J6 XILINX PROGRAM CONNECTOR
5L LEFT TOWER DRYING (GREEN) 2PB POWER ON/OFF SWITCH J7 POWER SUPPLY INPUT CONNECTOR
6L PRESSURE SWITCH 1 (LEFT TOWER) CLOSED (GREEN) 3PB ALARM RESET SWITCH PS AC TO DC POWER SUPPLY
7L SERVICE REMINDER 1 - PILOT AIR FILTER (AMBER) 4PB ENTER SWITCH RPB REMOTE SWITCH TERMINALS
8L SERVICE REMINDER 2 - AFTER FILTERS (AMBER) CNTRLPCB CONTROL BOARD TB1 ANALOG INPUT TERMINALS
10L RIGHT TOWER REGENERATING (AMBER) CR ALARM CONTROL RELAY TB2 SWITCH INPUT TERMINALS
11L RIGHT PURGE VALVE OPEN (GREEN) DISPPCB DISPLAY BOARD TB3 VALVE OUTPUT TERMINALS
12L RIGHT TOWER DRYING (GREEN) JMP CONFIGURATION JUMPERS TB4 CONTACT OUTPUT TERMINALS
13L POWER ON INDICATOR (GREEN) J1 FILTER MONITOR 2 CONNECTOR TB5 DC POWER INPUT TERMINALS
14L MAIN SERVICE REMINDER (AMBER) J2 FILTER MONITOR 1 CONNECTOR TB6 AC POWER INPUT TERMINALS
Figure 8-4
Panel Layout – Level 2 Controller
— 46 —
RPB
1 2 3 4 5 6 7 8
DISPPCB
ENCLOSURE DOOR INTERIOR

J3 J4 J6 J7
CNTRLPCB
PS
U5
C5
J3 C21
U1
R52
C6
C10
Y1
J1 L2
J1
J7
C28
L3 R16
C7
C8
J4
C9
F1
L4
R21
L5
49 L
J2
C11 R15
1
AC POWER
J5
48 L
J2 C22
47 N
46 TB6
J6
R1 JP1 N
JMP 45
R2 JP2
R3 JP3 PE
JP4 J8
44
R4
R5
JP5 C23
PE
43
R6 JP6 R30 FL9 D11
K1 DC
R31
C12
R7 JP7 R34
C36
R8
R9 R10
JP8
L6
C32
42 DC TB5
C13 Q1
R50
D16
D17
D7 F2 R49 R51
Q4
C1
CR
Q5
U2 C42 VR1
D15
C14
R11
Q6
R38
C37
U3 C46 C55
R37
D1
C2
U4
C16
R12
C24
C15 C47 C52 U12

D4
30D31300
L1
U9 L7
R39
D9
R22
C26
C27
C17
C19
C25
R23
R20
R18
C20 C18
C4 R17
R14
U8
R19
R13
R45
C54
R46
C38
C3
C29 C33 C39 C43 C48 C53 R47

U6 U7 U10 U11 Q2 Q3
R40 R41
D8
D2 D3 D5 D6 R42 R48 D13
R43 D14 K2 K3 K4
R44
R24
FL1 FL2 FL3 FL4 FL5 FL6 FL7 FL8

D10 D12
R25
C31
R27
C35
R28
C41
C45
R26
C51
R29
R32
R33
R35
R36
C40
C49
C44
C30
C50
C34
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
R PURGE
L PURGE
RPS
RPS
+12VDC
+12VDC
+12VDC
+12VDC
NO
RBTH C
NC
NC
AUX3 C
AUX2 C
AUX4 C
AUX1 C
LPS
LPS
RTTH C
CONTACTS
CONTACTS
RBTH +
AUX2 +
AUX4 +
AUX1 +
LBTH C
AUX3 +
DRAIN 2
RTTH +
DRAIN 2
DRAIN 1
DRAIN 1
LTTH C
SWITCH
SWITCH
LBTH +
R INLET
LTTH +
L INLET
CONTACTS
TB1 TB2 TB3 TB4
ENCLOSURE INTERIOR
Figure 8-4
Panel Layout – Level 2 Controller
— 47 —
CABLE DIAMETER RANGE ENCLOSURE
# OF AWG CONNECTOR HOLE DIA.
LOCATION FUNCTION MIN. DIA. MAX. DIA.
CONDUCTORS SIZE SIZE
in. mm in. mm in. mm
HUMIDITY-DEW POINT SENSOR 2
DRAIN 1 (POWER & TEST) 4
1 DRAIN 1 (ALARM) 2 22 0.230 5.8 0.395 10.0 PG-11 0.733 18.6
DRAIN 2 (POWER & TEST) 4
FACTORY
CONNECTIONS DRAIN 2 (ALARM) 2
OPTIONAL FILTER MONITOR 1 TBD
DEVICES
FILTER MONITOR 2 TBD
2 ANALOG INPUT 1 2 22 0.230 5.8 0.395 10.0 PG-11 0.733 18.6
ANALOG INPUT 2 2
ANALOG INPUT 3 2
3 THERMISTOR 1 LEFT TOWER - UPPER 2 22 0.114 2.9 0.250 6.4 PG-7 0.492 12.5
4 THERMISTOR 2 RIGHT TOWER - UPPER 2 22 0.114 2.9 0.250 6.4 PG-7 0.492 12.5
5 THERMISTOR 3 LEFT TOWER - LOWER 2 22 0.114 2.9 0.250 6.4 PG-7 0.492 12.5
6 THERMISTOR 4 RIGHT TOWER - LOWER 2 22 0.114 2.9 0.250 6.4 PG-7 0.492 12.5
FACTORY
7 CONNECTIONS PRESSURE SWITCH - RIGHT TOWER 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
8 STANDARD PRESSURE SWITCH - LEFT TOWER 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
DEVICES
9 SOLENOID - LEFT PURGE VALVE 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
10 SOLENOID - LEFT INLET VALVE* 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
11 SOLENOID - RIGHT PURGE VALVE 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
12 SOLENOID - RIGHT INLET VALVE* 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
13 ALARM CONTACTS 2 16 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
14 USER REMOTE STOP / START 2 16 0.181 4.6 0.312 7.9 PG-9 0.599 15.2
15 CONNECTIONS RS232 3 22 0.114 2.9 0.250 6.4 PG-7 0.492 12.5
16 INPUT POWER 3 14 0.230 5.8 0.395 10.0 PG-11 0.733 18.6
* STANDARD PRESSURE MODELS 116.0 & 152.9 ONLY. HIGH PRESSURE MODELS 1.1 THROUGH 12.7 ONLY.
0.87" [22 mm]

1.97" [50 mm]
1 3 5 7 9 11 13 15
2 4 6 8 10 12 14 16
1.10" [28 mm]

2.74" [70 mm]
2.20" [56 mm]
3.45" [88 mm]
3.15" [80 mm]
4.17" [106 mm]
5.35" [136 mm]
6.54" [166 mm]
7.72" [196 mm]
8.90" [226 mm]
10.00" [254 mm]
BOTTOM VIEW - HINGE LEFT
Figure 8-5
Enclosure Penetrations – Level 2 Controller
— 48 —
9. Operation 9.1.4.1 Purge Rate Pressure – Models 1.1 to 84.9
• Refer to Table 9-4 for the proper purge rate pressure setting
corresponding to the conditions listed in Section 9.1.4.
9.1 Start-up Note: For units with the Level 2 Controller and the Automatic
Purge Saving System in the demand cycle mode use the ISO
9.1.1 Controller Settings (Level 1 or Level 2 Controller)
Class 2 (10 min.) purge pressure settings only.
• Set or verify settings on the Level 1 or Level 2 Controller. General
• Adjust purge rate valve until purge pressure gauge indicates
information regarding both controllers can be found in Section 5.
the required pressure. The purge pressure adjustment valve
Detailed operational points are presented in Sections 7 and 8.
on Models 1.1 through 84.9 is a quarter-turn ball valve located
WARNING - Enclosure may have live electric parts. De-energize in the smaller bypass line of the upper piping of the dryer. Refer
dryer before opening enclosure. to Figures 4-2 or 4-3 for location. Models 1.1 through 84.9 use
a double orifice purge circuit. Equally sized orifices are located
• If a Cycle or Energy (purge) Savings % change is made while the at either end of the bypass line. The purge pressure adjustment
dryer is operating, the change will occur at the end of the current valve, and a pressure tap for the purge pressure gauge are piped
half-cycle. If it is necessary to begin a new selection immediately, between the two orifices. Looking at the front of the dryer, when
shut the unit off and then back on. the left tower is drying and the right tower is purging, purge air
Note: A tower that is actively purging when the power on/off flows from left to right through the first orifice, then the purge
button is actuated will be subjected to a rapid repressurization pressure adjustment valve, past the pressure tap for the purge
that can lead to fluidization and subsequent abrasion of the pressure gauge, through the second and final orifice and into the
desiccant bed. Ideally, dryers should only be powered off during offline tower. The pressure in the purge circuit just before the final
those portions of the drying cycle when both desiccant towers orifice controls the purge flow rate. Because the purge pressure
are at full operating pressure. tap lies between the purge pressure adjustment valve and the
• If switching to a cycle mode producing a lower dew point (e.g. 0°F orifice closest to the right hand tower, the purge pressure can
to -40°F [-17.8°C to -40°C]) while the dryer is operating, one or only be correctly read and adjusted when the purge flow is from
two days of operation may be needed before the new dew point left to right. This only occurs when the right hand tower is actively
is achieved. purging. IMPORTANT: Purge pressure adjustment must be
9.1.2 Initial Pressurization made while the RIGHT HAND TOWER AS SEEN FROM THE
• SLOWLY pressurize dryer to full line pressure. (If the dryer was FRONT OF THE UNIT is regenerating and the right hand tower
installed with inlet and outlet isolation valves, the inlet isolation is actively purging (the purge valve associated with the right
valve should be slowly opened while the outlet isolation valve tower is open and air is exhausting from its muffler). Due to
remains closed.) the symmetry of the design, identical orifices at opposite ends
• During initial start-up, check the entire system for leaks. If and the bi-directional flow characteristics of the purge pressure
necessary, de-pressurize the dryer and correct any leaks. adjustment ball valve, purge flow will be similar when towers
switch and the purge flow is from the drying tower on the right
9.1.3 Energizing the Dryer towards the regenerating tower on the left. Purge pressure as
• (Timer Based Controller) Energize the dryer using the disconnect indicated by the purge pressure gauge should be disregarded
fuse located next to the customer connections in the bottom of during this half of the operating cycle.
the control box. • The purge pressure adjustment valve should never be fully closed.
• (Level 1 or Level 2 Controller) Energize the dryer using the power Proper purge flow is required to regenerate and re-pressurize the
switch located on the control panel. offline tower. Should the tower fail to re-pressurize, a switching
• NOTE: The switching failure alarm may be activated if the unit failure alarm will be initiated, and the cycle will be stopped before
is energized before it is pressurized. To deactivate alarm, allow tower switch over.
dryer to cycle to next step and press the reset button. • After the purge pressure has been correctly set, the handle of the
9.1.4 Adjusting the Purge Rate purge pressure adjustment valve may be removed and stored to
Determine the following: prevent tampering with the setting.
• Maximum operating pressure (MOP) of dryer from the dryer serial 9.1.4.2 Purge Rate Pressure – Models 116.0 to 152.9
number tag. • Refer to Table 9-4 for the proper purge rate pressure setting
• Air pressure at inlet to dryer. corresponding to the conditions listed in Section 9.1.4.
• ISO Class cycle setting (Class 1, 2, 3, or 4). Note: For units with the Level 2 Controller and the Automatic
Note: For units with the Level 2 Controller and the Automatic Purge Saving System in the demand cycle mode use the ISO
Purge Saving System in the demand cycle mode use the ISO Class 2 (10 min.) purge pressure settings only.
Class 2 (10  min.) purge pressure settings only. • Adjust purge rate valve until purge pressure gauge indicates
• Energy (purge) Savings % setting. This setting is applicable to the required pressure. The purge pressure adjustment valve on
the Level 1 Controller only. Models 116.0 through 152.9 is a globe valve located in the smaller
by-pass line of the upper piping in the front of the dryer. Refer to
Figure 4-4. IMPORTANT: Adjustment must be made while
either tower is purging (air exhausting from muffler).
— 49 —
• The purge pressure adjustment valve should never be fully closed. 9.2.4.1 Alarms –Level 1 Controller
Proper purge flow is required to regenerate and re-pressurize the Alarm light will flash if either tower fails to pressurize or de-pressurize
offline tower. Should the tower fail to re-pressurize, a switching to the required levels at the proper time. Refer to Section 7.4.3 and
failure alarm will be initiated, and the cycle will be stopped before Table 7.4.
tower switch over. NOTE: Alarm will activate if dryer is energized without being
• After the purge pressure has been correctly set, the handle of the pressurized. If this occurs, allow dryer to cycle to next step and press
purge pressure adjustment valve may be removed and stored to reset button. Alarm light will continue to illuminate even if fault clears.
prevent tampering with the setting. To clear alarm, press reset button.
Insufficient purge air will eventually result in saturation of the desiccant If the tower being regenerated fails to re-pressurize, the dryer will not
beds and wet air downstream. Verify that maximum operating pressure switch towers. The switching failure alarm will be activated and the
mode, cycle time, energy (purge) savings percent selection, and purge dryer will remain in this mode until the tower re-pressurizes.
pressure are correctly set.
9.2.5 Tower Status LEDs
9.1.5 Bringing the Dryer Online Illuminated LEDs indicate which tower is on-line drying or off-line
Establish a normal flow through the dryer. Slowly open the outlet regenerating.
isolation valve if present. Close any dryer by-pass valves.
9.2.6 Tower Pressure Gauges
NOTE: When dew points below -40°F (-40°C) are required, the dryer
Periodically check tower pressure gauges to verify that the pressure
must be run with an inlet flow rate of less than 50% of maximum until
gauge of the online tower reads line pressure and the pressure gauge
the desired dew point is attained. Depending on the initial dryness of
of the offline tower reads below 2 psig (0.14 barg).
the desiccant, this can take as long as 2 to 3 days. This stabilization
period is required on initial startup, after the dryer has been shutdown NOTE: Read the offline tower pressure gauge when the tower is
for extended periods of time, or after dryer maintenance (desiccant purging (air exhausting from muffler).
change, etc.) has been performed. 9.2.7 Check Mufflers For Back Pressure
9.1.6 Readjusting the Purge Rate Excessive back pressure may result due to the accumulation of
With the inlet pressure to the dryer at its minimum level, readjust the desiccant fines (dust) in the muffler cartridges. This sometimes
purge pressure per the instructions in Section 9.1.4. occurs after start-up due to dusting of the desiccant during tower filling
and dryer transport. If the tower pressure gauge of the off-stream
NOTE: Adjustment must be made while the appropriate tower is
tower rises above 5 psig (3.5 barg), the muffler elements should be
purging (air exhausting from muffler).
replaced.
9.2 Operational Check Points IMPORTANT: Replace muffler cores provided with unit after
5 complete cycles following the completion of the Start-Up
9.2.1 Power to unit Procedures.
Check periodically that there is power to the unit (indicating lights
9.2.8 Process Valves
illuminated).
Determine if air control valves are operating and sequencing correctly.
9.2.2 Moisture Indicator Refer to Section 3.3 for a general description of operating sequence.
Every four hours check moisture indicator. Indicator should be green. Refer to Tables 7-3 and 7-4 for time sequences for Level 1 Controllers.
The color change moisture indicator indicates the outlet relative Refer to Tables 8-3 and 8-4 for time sequences for Level 2 Controllers.
humidity of the desiccant dryer.
9.2.8.1 Valves – Models 1.1 through 84.9
Green indicates a R.H. below 3% and yellow indicates a R.H. • Inlet/Outlet switching valves are non-lubricated shuttle valves.
above 3%. Table 9-5 cross references outlet pressure dew points Pressure differences between the online and offline desiccant
to moisture indicator changes from green to yellow at various inlet towers cause the shuttle valve to shift.
temperatures. • High Pressure Models 1.1 through 12.7 ONLY. Inlet switching
NOTE: During start-up the indicator may be yellow, however, it should valves are normally open, pneumatically piston-actuated, Y-angle
begin to change to green within four hours. poppet valves. A yellow indicator can be seen through a clear
window at the top of the actuator when the valve is in the open
9.2.3 Purge Pressure Setting position.
Every four hours check the purge pressure gauge for the proper setting • Purge/repressurization valves are normally closed, pneumatically
and adjust as required. Adjustment should be made when the inlet piston-actuated, Y-angle poppet valves. A yellow indicator can be
pressure to the dryer is at its minimum level. seen through a clear window at the top of the actuator housing
NOTE: Adjustment must be made while the appropriate tower is when the valve is in the open position.
purging (air exhausting from muffler). • 12 volt DC, normally-closed, 3-way pilot solenoid valves are wired
to the controller and are used to direct pilot air to the actuators of
9.2.4 Alarms the purge/repressurization valves.
Periodically check for flashing red alarm LED. • Purge pressure and subsequent flow is adjusted by means of
a quarter-turn ball valve located in the bypass line of the upper
piping.
— 50 —
• Models 1.1 through 84.9 are equipped with a single safety relief • De-pressurize the dryer by allowing the controller to run through
valve that has been sized at a minimum to provide overpressure tower change cycles until pressure gauges on both towers read
protection due to a fire for both desiccant towers. zero. Manual test mode may be used to speed up this process.
NOTE: Below 60 psig (4.1 barg) purge/repressurization valves
9.2.8.2 Valves – Models 116.0 through 152.9
may not open. Opening the manual drain on the pilot air filter
• Inlet switching valves are resilient seated butterfly valves with
or any mounted pre or afterfilters may bleed off remaining
double acting pneumatic rack and pinion actuators. A yellow arrow
pressure.
indicator located on the top of the actuator output shaft points
• Turn dryer off using on-off switch (indicating LEDs
to valve position indicator icons. Pilot air is directed to actuator
extinguished).
ports to open both inlet valves upon loss of power.
• Purge/repressurization valves are resilient seated butterfly valves
with spring return, fail closed, pneumatic rack and pinion actuators. 9.5 Loss of Power
A yellow arrow indicator located on the top of the actuator output Control valves are designed so that upon loss of power the air dryer
shaft points to valve position indicator icons. Pilot air is directed to is capable of drying air until the desiccant exposed to the airflow is
actuator ports to close both purge/repressurization valves upon saturated.
loss of power.
• 12 volt DC, single solenoid, 4-way pilot valves are wired to the 9.6 Operating Parameters
controller and are used to direct pilot air to the actuators of the Verify that dryer is operating within the following design parameters:
inlet switching and purge/repressurization valves.
• Two mainline outlet and two smaller purge line check valves are 9.6.1 Maximum Operating Pressure (MOP):
installed in the upper piping to control the flow of outlet and purge • 150 psig (10.3 barg) is standard.
air. Check valve sticking will result in excessive air discharge • 250 psig (17.2 barg) is optional.
through a muffler. Excessive air discharge through the muffler Refer to Dryer Serial Number Tag.
can be associated with a leaking outlet check valve on the same WARNING - Do not operate the dryer at pressures above the
side or a purge check valve of the opposite side tower. maximum operating pressure shown on the serial number tag.
• Purge pressure and subsequent flow is adjusted by means of
NOTE: Consult factory for applications requiring higher maximum
a throttling globe valve located in the bypass line of the upper
operating pressures.
piping
• Models 116.0 through 152.9 are equipped with multiple safety relief 9.6.2 Minimum Operating Pressures:
valves that have been sized to provide overpressure protection
9.6.2.1 For 150 psig (10.3 barg) MOP models -
for capacities equal to or greater than the adjusted capacity of
• 60 psig (4.1 barg) is the minimum operating pressure for dryers
the dryer at its maximum operating pressure.
operated on a 4,10,16, or 24-minute cycle.
• The tower pressure gauge of the online tower should read line
pressure. Air should not be leaking from the purge-repressurization 9.6.2.2 For 250 psig (17.2 barg) MOP models -
valve of the on-line tower. • 120 psig (8.3 barg) is the minimum operating pressure for dryers
• The tower pressure gauge of the offline tower should read below operated on a 4,10,16, or 24-minute cycle.
2 psig (0.14 barg) while that tower is purging. If excessive air is Refer to Dryer Serial Number Tag.
exhausting during the purge cycle, the inlet-switching valve on
WARNING - Do not operate the dryer at pressures below the minimum
the same side may have failed to close or a check valve may be
operating pressure shown on the serial number tag.
sticking.
NOTE: Consult factory for applications requiring lower minimum
9.3 Operating Sequence operating pressures.
9.6.3 Maximum Compressed Air Temperature at Dryer Inlet:
9.3.1 Operating sequence – Timer Based Controllers • 140°F (60°C) for all models.
The operating sequence for dryers equipped with Timer Based
Controllers appears in Tables 6.1 and 6.2. 9.6.4 Ambient Temperatures:
9.3.2 Operating sequence – Level 1 Controllers 9.6.4.1 Minimum Ambient Temperature:
The operating sequence for dryers equipped with Level 1 Controllers • Standard units: 35°F (2°C)
appears in Tables 7.3 and 7.4. • Units with optional low ambient package: -20°F ( -29°C)
9.3.3 Operating sequence – Level 2 Controllers 9.6.4.2 Maximum Ambient Temperature:
The operating sequence for dryers equipped with Level 2 Controllers • 120°F (49°C)
appears in Tables 8-2, 8-3, and 8-4.
NOTE: If dryer is installed in ambients below 35°F (2°C), low ambient
protection requiring heat tracing and insulation of the prefilter bowls,
9.4 Dryer Shut Down auto drains and/or sumps, and lower piping with inlet switching and
• If the dryer installation is equipped with dryer bypass and inlet purge/repressurization valves is necessary to prevent condensate
and outlet isolation valves, the bypass valve should be opened
and the inlet and outlet isolation valves closed.
— 51 —
from freezing. If installing heat tracing, observe electrical class code 9.9 EXAMPLE
requirements for type of duty specified. Purge mufflers and their relief • Find the maximum inlet flow, maximum purge flow, and minimum
mechanisms must be kept clear from snow and ice buildup that could outlet flow for a 60 SCFM unit with a MOP of 150 psig operated
prevent proper discharge of compressed air. with 120 psig and 100°F inlet conditions on a 10 minute cycle.
Dryer will operate with an inlet airflow of 46 SCFM.
9.7 Maximum Inlet Flow Capacity • Step 1: Find Maximum Inlet Flow at 120 psig by multiplying
• Refer to Table 9-1 for maximum inlet flow at rated conditions of Maximum Inlet Flow at Rated Conditions from Table 9-1 by Inlet
100 psig (6.9 barg) and 100°F (38°C). Pressure Correction Factor for 120 psig from Table 9-2 and Inlet
• At other conditions, multiply inlet flow from Table 9-1 by the Temperature from Table 9-3:
multipliers from Tables 9-2 and 9-3 that correspond to the pressure 60 x 1.08 x 1.00 =64.8 SCFM.
and temperature at the inlet to the dryer. • Step 2: Find Maximum Purge Flow by multiplying Maximum Inlet
Flow at Rated Conditions from Table 9-1 by Maximum Purge Flow
9.8 Purge and Outlet Flows Factor from Table 9-6:
60 x 0.162 =9.7 SCFM.
9.8.1 Maximum Purge Flow • Step 3: Find Minimum Outlet Flow available by subtracting
• Maximum Purge Flow is the amount of purge air flowing through Maximum Purge Flow (Step 2) from actual inlet flow:
the off-stream tower when the purge/repressurization valve is 46 -9.7 =36.3 SCFM.
open. After the purge/repressurization valve closes, the purge flow
will gradually decrease as the off-stream tower re-pressurizes to
line pressure.
• For maximum purge flow multiply the Inlet Flow At Rated
Conditions from Table 9-1 by Maximum Purge Flow Factor from
Table 9-6 that corresponds to the dryer MOP, Cycle Time Setting,
and air pressure at inlet to dryer.
Note: For Level 2 Controller equipped dryers supplied with the
Automatic Purge Saving System operating in the Demand Cycle
Mode, use ISO Class 2 (10 minutes) as the cycle time.
9.8.2 Average Purge Flow
• For dryers with Level 1 or 2 Controllers operating in the fixed
cycle mode, the Average Purge Flow is the actual amount of flow
used during the entire purge/repressurization cycle. It includes the
maximum purge flow for a portion of the purge/repressurization
time and the volume of air used for repressurization, averaged
over the cycle time.
• For average purge flow multiply the Inlet Flow At Rated Conditions
from Table 9-1 by Average Purge/Repressurization Flow Factor
from Table 9-7 that corresponds to the dryer MOP, Cycle Time
Setting, Energy (purge) Savings % setting, and air pressure at
inlet to dryer.
9.8.3 Minimum Outlet Air Flow
• Determine minimum outlet flow available from dryer by subtracting
Maximum Purge Flow found above from inlet flow to the dryer.
9.8.4 Average Outlet Air Flow
• For dryers with Level 1 or 2 Controllers operating in the fixed
cycle mode, the average outlet flow available from dryer can be
determined by subtracting the Average Maximum Purge Flow
found above from the inlet flow to the dryer.
— 52 —
MODEL 1.1 1.6 2.5 3.2 4.6 7.3 10.4 12.7 16.7 21.2 26.3 31.9 38.2 43.8 59.4 84.9 116.0 152.9
SCFM 40 60 90 115 165 260 370 450 590 750 930 1130 1350 1550 2100 3000 4100 5400
m3/hr 68 102 153 195 280 442 629 765 1002 1274 1580 1920 2294 2633 3568 5097 6966 9175
Table 9-1 Maximum Inlet Flow at Rated Conditions
INLET psig 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
PRESSURE barg 4.1 4.8 5.5 6.2 6.9 7.6 8.3 9.0 9.7 10.3 11.0 11.7 12.4 13.1 13.8 14.5 15.2 15.9 16.5 17.2
MULTIPLIER 0.65 0.74 0.83 0.91 1.00 1.04 1.08 1.12 1.16 1.20 1.23 1.27 1.30 1.34 1.37 1.40 1.43 1.46 1.49 1.52
Table 9-2 Inlet Pressure Correction Factors
INLET °F 100 and below 105 110 115 120 125 130 135 140
TEMPERATURE °C 38 and below 41 43 46 49 52 54 57 60
MULTIPLIER 1.00 0.98 0.96 0.93 0.89 0.85 0.81 0.76 0.70
Table 9-3 Inlet Temperature Correction Factor
DRYER MOP 150 psig (10.3 barg) 250 psig (17.2 barg)
INLET psig 60 - 100 110 120 130 140 150 120 130 140 150 160 170 180 190 200 210 220 230 240 250
PRESSURE barg 4.1 - 6.9 7.6 8.3 9.0 9.7 10.3 8.3 9.0 9.7 10.3 11.0 11.7 12.4 13.1 13.8 14.5 15.2 15.9 16.5 17.2
psig 35 33 31 29 28 27 83 80 76 74 71 69 66 64 63 61 59 58 56 55
ISO CL.1 4 min.
barg 2.4 2.3 2.1 2.0 1.9 1.9 5.7 5.5 5.2 5.1 4.9 4.8 4.6 4.4 4.3 4.2 4.1 4.0 3.9 3.8
psig 20 19 18 17 16 15 44 42 40 39 37 36 35 33 32 31 31 30 29 28
ISO CL.2 10 min.
barg 1.4 1.3 1.2 1.2 1.1 1.0 3.0 2.9 2.8 2.7 2.6 2.5 2.4 2.3 2.2 2.1 2.1 2.1 2.0 1.9
CYCLE
psig 18 17 16 15 14 13 35 33 32 30 29 28 27 26 25 25 24 23 23 22
ISO CL.3 16 min.
barg 1.2 1.2 1.1 1.0 1.0 0.9 2.4 2.3 2.2 2.1 2.0 1.9 1.9 1.8 1.8 1.7 1.7 1.6 1.6 1.5
psig 16 15 15 14 13 13 30 29 28 26 25 24 24 23 22 21 21 20 20 19
ISO CL.4 24 min.
barg 1.1 1.0 1.0 1.0 0.9 0.9 2.1 2.0 1.9 1.8 1.8 1.7 1.7 1.6 1.5 1.4 1.4 1.4 1.4 1.3
Table 9-4 Purge Pressure (Note: For units with the Level 2 Controller operating in the Demand Cycle Mode, use the ISO Class 2 (10 min.)
purge pressure settings only, regardless of ISO Class operating mode.)
INLET °F 35 40 50 60 70 80 90 100 110 120

TEMPERATURE °C 2 4 10 16 21 27 32 38 43 49
°F -34 -28 -22 -16 -10 -4 3 9 15 21
OUTLET P.D.P.
°C -37 -33 -30 -27 -23 -20 -16 -13 -9 -6
Table 9-5 Outlet Pressure Dew points at Moisture Indicator Color Change
DRYER MOP 150 psig (10.3 barg) 250 psig (17.2 barg)
INLET psig 60 - 100 110 120 130 140 150 120 130 140 150 160 170 180 190 200 210 220 230 240 250
PRESSURE barg 4.1 - 6.9 7.6 8.3 9.0 9.7 10.3 8.3 9.0 9.7 10.3 11.0 11.7 12.4 13.1 13.8 14.5 15.2 15.9 16.5 17.2
ISO CL.1 4 min. 0.249 0.239 0.230 0.222 0.214 0.208 0.361 0.348 0.337 0.326 0.317 0.308 0.300 0.293 0.286 0.279 0.273 0.268 0.262 0.257
ISO CL.2 10 min. 0.175 0.168 0.162 0.156 0.151 0.146 0.218 0.210 0.203 0.197 0.191 0.186 0.181 0.177 0.172 0.169 0.165 0.162 0.158 0.155
CYCLE
ISO CL.3 16 min. 0.161 0.154 0.148 0.143 0.138 0.134 0.182 0.175 0.169 0.164 0.159 0.155 0.151 0.147 0.144 0.141 0.138 0.135 0.132 0.129
ISO CL.4 24 min. 0.153 0.147 0.141 0.136 0.132 0.128 0.164 0.158 0.153 0.148 0.144 0.140 0.137 0.133 0.130 0.127 0.124 0.122 0.119 0.117
Table 9-6 Maximum Purge Flow Factor
— 53 —
DRYER MOP 150 psig (10.3 barg)
INLET PRESSURE (psig) 60 70 80 90 100 110 120 130 140 150
INLET PRESSURE (barg) 4.1 4.8 5.5 6.2 6.9 7.6 8.3 9.0 9.7 10.3
0% 0.147 0.149 0.151 0.153 0.155 0.151 0.148 0.145 0.143 0.141
10% 0.134 0.136 0.137 0.139 0.141 0.138 0.135 0.133 0.131 0.129
ISO CLASS 1 20% 0.120 0.122 0.124 0.125 0.127 0.124 0.122 0.120 0.119 0.118
ENERGY
4 MIN. CYCLE
(PURGE) 30% 0.106 0.108 0.110 0.112 0.114 0.111 0.110 0.108 0.107 0.106
-100°F / -73°C
SAVINGS 40% 0.093 0.095 0.096 0.098 0.100 0.098 0.097 0.096 0.095 0.095
PRESSURE
SETTING 50% 0.079 0.081 0.083 0.084 0.086 0.085 0.084 0.084 0.084 0.084
DEWPOINT
60% 0.065 0.067 0.069 0.071 0.072 0.072 0.072 0.072 0.072 0.072
70% 0.052 0.053 0.055 0.057 0.059 0.059 0.059 0.060 0.060 0.061
0% 0.141 0.142 0.143 0.143 0.144 0.139 0.135 0.131 0.128 0.125
10% 0.127 0.128 0.129 0.130 0.130 0.126 0.122 0.119 0.116 0.113
ISO CLASS 2 20% 0.114 0.114 0.115 0.116 0.117 0.113 0.110 0.107 0.104 0.102
ENERGY
10 MIN. CYCLE
(PURGE) 30% 0.100 0.101 0.101 0.102 0.103 0.100 0.097 0.095 0.092 0.091
-40°F / -40°C
SAVINGS 40% 0.086 0.087 0.088 0.088 0.089 0.087 0.084 0.082 0.081 0.079
PRESSURE
SETTING 50% 0.073 0.073 0.074 0.075 0.076 0.073 0.072 0.070 0.069 0.068
DEWPOINT
60% 0.059 0.060 0.060 0.061 0.062 0.060 0.059 0.058 0.057 0.056
70% 0.045 0.046 0.047 0.047 0.048 0.047 0.046 0.046 0.045 0.045
0% 0.140 0.140 0.140 0.141 0.141 0.136 0.132 0.128 0.124 0.121
10% 0.126 0.126 0.127 0.127 0.128 0.123 0.119 0.115 0.112 0.109
ISO CLASS 3 20% 0.112 0.113 0.113 0.113 0.114 0.110 0.106 0.103 0.100 0.098
ENERGY
16 MIN. CYCLE
(PURGE) 30% 0.098 0.099 0.099 0.100 0.100 0.097 0.094 0.091 0.089 0.087
-4°F / -20°C
SAVINGS 40% 0.085 0.085 0.086 0.086 0.087 0.084 0.081 0.079 0.077 0.075
PRESSURE
SETTING 50% 0.071 0.072 0.072 0.072 0.073 0.071 0.068 0.067 0.065 0.064
DEWPOINT
60% 0.057 0.058 0.058 0.059 0.059 0.057 0.056 0.054 0.053 0.052
70% 0.044 0.044 0.045 0.045 0.045 0.044 0.043 0.042 0.042 0.041
0% 0.139 0.139 0.139 0.140 0.140 0.135 0.130 0.126 0.122 0.119
10% 0.125 0.125 0.126 0.126 0.126 0.121 0.117 0.114 0.110 0.107
ISO CLASS 4 20% 0.111 0.112 0.112 0.112 0.112 0.108 0.105 0.101 0.098 0.096
ENERGY
24 MIN. CYCLE
(PURGE) 30% 0.098 0.098 0.098 0.098 0.099 0.095 0.092 0.089 0.087 0.084
-+38°F / +3°C
SAVINGS 40% 0.084 0.084 0.084 0.085 0.085 0.082 0.079 0.077 0.075 0.073
PRESSURE
SETTING 50% 0.070 0.071 0.071 0.071 0.071 0.069 0.067 0.065 0.063 0.062
DEWPOINT
60% 0.057 0.057 0.057 0.057 0.058 0.056 0.054 0.053 0.051 0.050
70% 0.043 0.043 0.043 0.044 0.044 0.043 0.041 0.040 0.039 0.039
DRYER MOP 250 psig (17.2 barg)

INLET PRESSURE (psig) 120 130 140 150 160 170 180 190 200 210 220 230 240 250
INLET PRESSURE (barg) 8.3 9.0 9.7 10.3 11.0 11.7 12.4 13.1 13.8 14.5 15.2 15.9 16.5 17.2
0% 0.148 0.145 0.143 0.141 0.139 0.138 0.137 0.136 0.135 0.135 0.135 0.134 0.134 0.134
10% 0.135 0.133 0.131 0.129 0.128 0.127 0.126 0.126 0.125 0.125 0.125 0.125 0.125 0.125
ISO CLASS 1 20% 0.122 0.120 0.119 0.118 0.117 0.116 0.116 0.116 0.115 0.115 0.115 0.116 0.116 0.116
ENERGY
4 MIN. CYCLE
(PURGE) 30% 0.110 0.108 0.107 0.106 0.106 0.106 0.105 0.105 0.105 0.106 0.106 0.106 0.107 0.107
-100°F / -73°C
SAVINGS 40% 0.097 0.096 0.095 0.095 0.095 0.095 0.095 0.095 0.095 0.096 0.096 0.097 0.098 0.098
PRESSURE
SETTING 50% 0.084 0.084 0.084 0.084 0.084 0.084 0.084 0.085 0.085 0.086 0.087 0.088 0.088 0.089
DEWPOINT
60% 0.072 0.072 0.072 0.072 0.073 0.073 0.074 0.075 0.075 0.076 0.077 0.078 0.079 0.080
70% 0.059 0.060 0.060 0.061 0.062 0.062 0.063 0.064 0.065 0.066 0.068 0.069 0.070 0.071
0% 0.135 0.131 0.128 0.125 0.122 0.120 0.118 0.116 0.114 0.113 0.111 0.110 0.109 0.108
10% 0.122 0.119 0.116 0.113 0.111 0.109 0.107 0.106 0.104 0.103 0.102 0.101 0.100 0.099
ISO CLASS 2 20% 0.110 0.107 0.104 0.102 0.100 0.098 0.097 0.095 0.094 0.093 0.092 0.091 0.090 0.090
ENERGY
10 MIN. CYCLE
(PURGE) 30% 0.097 0.095 0.092 0.091 0.089 0.088 0.086 0.085 0.084 0.083 0.083 0.082 0.081 0.081
-40°F / -40°C
SAVINGS 40% 0.084 0.082 0.081 0.079 0.078 0.077 0.076 0.075 0.074 0.074 0.073 0.072 0.072 0.072
PRESSURE
SETTING 50% 0.072 0.070 0.069 0.068 0.067 0.066 0.065 0.065 0.064 0.064 0.063 0.063 0.063 0.063
DEWPOINT
60% 0.059 0.058 0.057 0.056 0.056 0.055 0.055 0.054 0.054 0.054 0.054 0.054 0.054 0.054
70% 0.046 0.046 0.045 0.045 0.045 0.044 0.044 0.044 0.044 0.044 0.044 0.044 0.045 0.045
0% 0.132 0.128 0.124 0.121 0.118 0.115 0.113 0.111 0.109 0.107 0.105 0.104 0.102 0.101
10% 0.119 0.115 0.112 0.109 0.107 0.105 0.103 0.101 0.099 0.097 0.096 0.095 0.093 0.092
ISO CLASS 3 20% 0.106 0.103 0.100 0.098 0.096 0.094 0.092 0.090 0.089 0.088 0.086 0.085 0.084 0.083
ENERGY
16 MIN. CYCLE
(PURGE) 30% 0.094 0.091 0.089 0.087 0.085 0.083 0.081 0.080 0.079 0.078 0.077 0.076 0.075 0.074
-4°F / -20°C
SAVINGS 40% 0.081 0.079 0.077 0.075 0.074 0.072 0.071 0.070 0.069 0.068 0.067 0.066 0.066 0.065
PRESSURE
SETTING 50% 0.068 0.067 0.065 0.064 0.063 0.061 0.060 0.060 0.059 0.058 0.058 0.057 0.057 0.056
DEWPOINT
60% 0.056 0.054 0.053 0.052 0.051 0.051 0.050 0.049 0.049 0.048 0.048 0.048 0.047 0.047
70% 0.043 0.042 0.042 0.041 0.040 0.040 0.039 0.039 0.039 0.039 0.038 0.038 0.038 0.038
0% 0.130 0.126 0.122 0.119 0.116 0.113 0.110 0.108 0.106 0.104 0.102 0.100 0.099 0.097
10% 0.117 0.114 0.110 0.107 0.105 0.102 0.100 0.098 0.096 0.094 0.093 0.091 0.090 0.088
ISO CLASS 4 20% 0.105 0.101 0.098 0.096 0.093 0.091 0.089 0.088 0.086 0.084 0.083 0.082 0.081 0.079
ENERGY
24 MIN. CYCLE
(PURGE) 30% 0.092 0.089 0.087 0.084 0.082 0.081 0.079 0.077 0.076 0.075 0.073 0.072 0.071 0.070
+38°F / +3°C
SAVINGS 40% 0.079 0.077 0.075 0.073 0.071 0.070 0.068 0.067 0.066 0.065 0.064 0.063 0.062 0.061
PRESSURE
SETTING 50% 0.067 0.065 0.063 0.062 0.060 0.059 0.058 0.057 0.056 0.055 0.054 0.054 0.053 0.052
DEWPOINT
60% 0.054 0.053 0.051 0.050 0.049 0.048 0.047 0.047 0.046 0.045 0.045 0.044 0.044 0.043
70% 0.041 0.040 0.039 0.039 0.038 0.037 0.037 0.036 0.036 0.036 0.035 0.035 0.035 0.034
Table 9-7 Average Purge / Repressurization Flow Factors ( 150 and 250 psig MOPs)
— 54 —
10. Maintenance 10.3 Valves
• Process and pilot valves should be checked frequently for leaks
WARNING - The heatless desiccant dryer is a pressure-containing and proper operation.
device. De-pressurize before servicing. (See Section 3.3) • Purge pressure adjustment valve should be checked frequently
for proper adjustment.
Note: Level 1 and 2 Controllers are equipped with Service Reminder • Refer to section 9.2.8.
functions for filters, desiccant and valves.
10.4 Pilot Air Filter Element Replacement
10.1 Desiccant Replacement
NOTE: The use of the correct replacement desiccant is necessary 10.4.1 Frequency of replacement
for proper dryer operation. Never use hygroscopic salts of the type The pilot air filter contains a filter element that should be changed
commonly used in “deliquescent ” type dryers. yearly. Replacement may be required sooner if pressure drop across
cartridge prevents valves from actuating properly. Pilot air pressure
10.1.1 Frequency Of Desiccant Replacement should be in the range of 60 - 120 psig (4.1 - 8.3 barg) and is controlled
Desiccant should be replaced whenever the required dew point by a pressure regulator that has been set and sealed at 120 psig
cannot be maintained while the dryer is being operated within its (8.3 barg).
design conditions and there are no mechanical malfunctions. Refer
to Section 11.0 for troubleshooting hints. Warning – The pilot air filter housing is a pressure-containing
NOTE: Desiccant life is determined by the quality of the inlet air. Proper device, de-pressurize before servicing. Slowly open manual drain
filtering of the inlet air will extend the life of the desiccant. Typically valve on bottom of filter bowl by turning clockwise to verify that
desiccant life is 3 to 5 years. the housing is de-pressurized before removing bowl.
10.1.2 Procedure for Desiccant Charge Replacement 10.4.2 Procedure for element replacement
• De-pressurize and de-energize the dryer. 10.4.2.1 Models 1.1 through 84.9
• Remove the fill and drain plugs from desiccant tower and drain • Isolate dryer from air supply
the spent desiccant. Place a container at the base of the vessel • De-pressurize dryer by running dryer and allowing system
to collect the desiccant. If necessary tap the sides of the vessels pressure to purge to atmosphere. Loss of pilot pressure will
with a rubber mallet to loosen desiccant. eventually prevent purge/repressurization valves from opening.
NOTE: Use extreme care when inserting rods or other tools through Remaining pressure can be vented to atmosphere through the
the desiccant fill or drain ports to loosen packed desiccant. Internal manual vent on the pilot air filter. The system must be fully de-
flow diffusers at the ends of the desiccant beds can be damaged pressurized before removing the bowl.
or punctured by sharp instruments. These diffusers are necessary • Remove the filter bowl by turning counterclockwise and then
to distribute the airflow and keep the desiccant beads within the pulling straight down.
tower. Desiccant beads in exhaust mufflers, afterfilters, or the piping • Clean the filter bowl.
connected to the desiccant towers may indicate a perforation of a • Replace the element. Reassemble in reverse order.
diffuser. 10.4.2.2 Models 116.0 through 152.9
• Replace the drain plug using Teflon tape or another pipe thread • Isolate dryer from air supply
sealant suitable for compressed air service. • De-pressurize dryer by running dryer and allowing system
• Fill the desiccant tower as full as possible with dry desiccant. Do pressure to purge to atmosphere. Loss of pilot pressure will
not tamp or otherwise pack the desiccant. eventually prevent purge/repressurization valves from opening.
• Replace the fill plug using Teflon tape or another pipe thread Remaining pressure can be vented to atmosphere through the
sealant suitable for compressed air service. manual drain on the pilot air filter. The system must be fully de-
• Repeat this procedure for the other tower. pressurized before removing the bowl.
10.1.3 Insuring Desiccant Dryness • Remove the filter bowl by pushing up, turning counterclockwise
Replacement desiccant is shipped in airtight containers. Keep the and then pulling straight down.
covers on these containers tightly closed until use to avoid moisture • Clean the filter bowl.
contamination. If desiccant is exposed to air it can be heated in an • Replace the element – Pull off the old element and discard. Make
oven at 400°F (204°C) for four hours before use. Alternatively, if the certain O-ring inside top of replacement element is lubricated and
dryer is not refilled with dry desiccant, it may be necessary to operate in place and then push element onto filter head.
the unit with an inlet flow rate of less than 50% of maximum rated inlet • Clean and lubricate O-ring at top of bowl and reassemble in
capacity until the desiccant has regenerated fully. reverse order.
NOTE: Wave spring ends should be pointed down to prevent the wave
10.2 Purge Mufflers spring from interfering with reassembly.
• Purge mufflers should be checked regularly, changed annually.
Muffler disseminator elements become clogged with desiccant dust
over time, creating back pressure and restricted purge flow.
• Refer to section 9.2.7.
— 55 —
11. Troubleshooting
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION

11.1 Indicator lights not No power to unit. Check voltage at terminal board.
illuminated Off/On switch turned off. Turn on.
Blown fuse. Replace fuse.
Off/on switch or board malfunction. Replace board.
11.2 Moisture indica- Design conditions exceeded. Refer to Sections 4 & 9 to determine if dryer is being outside of design
tor turns yellow limitations.
(elevated outlet Spent desiccant (useful service life has ended). Replace desiccant.
dew point)
Contaminated desiccant (e.g. with oil) Take corrective action. Refer to Section 4.1 to determine proper prefiltra-
tion before changing desiccant.
Saturated desiccant (saturated with water) Refer to 11.3 for corrective action. Operation at reduced flow may reacti-
vate desiccant beds until desired outlet dew point is achieved.
11.3 Premature satura- Insufficient purge flow - Purge pressure too low Refer to Section 9 to determine correct Purge Pressure Indicator setting.
tion of desiccant Incomplete tower depressurization (tower pressure Replace muffler inserts.
greater than 2 psig) - clogged mufflers
Incomplete tower depressurization - Verify voltage to pilot solenoid valve. Check pilot air pressure (60-120 psig
Purge/repressurization valve fails to open required). Verify proper actuator operation.
Insufficient purge time - Incorrect controller settings Refer to Section 7 or 8 to determine correct controller cycle settings.
Insufficient purge time - Faulty controller Refer to Section 7 or 8 to verify proper time sequence. Replace controller
board as required.
11.4 Tower fails to Purge/repressurization valve fails to close (air loss Verify removal of voltage to pilot solenoid valve. Verify proper actuator
repressurize to line from mufflers during tower repressurization portion operation. This is a spring-assisted, normally closed valve. Check valve for
pressure of cycle) obstruction or seat damage.
Insufficient purge flow - Purge pressure too low Refer to Section 9 to determine correct Purge Pressure Indicator setting .
Purge Pressure Adjustment Valve should never be completely closed.
11.5 Excessive purge is Excessive purge flow - Purge pressure too high Refer to Section 9 to determine correct Purge Pressure Indicator setting .
discharged during Inlet switching valve fails to close. Verify voltage to pilot solenoid valve. Check pilot air pressure (60-120 psig
purge cycle required.) Verify proper actuator operation. Check valve for obstruction or
seat damage.
(M1.1 through 84.9) Shuttle Valve; or (Models Repair or replace valve(s) as needed.
116.0 through 152.9) same tower Oheck or
opposite tower Purge Check Valves fail to close
11.6 Excessive desic- Fluidization of desiccant bed - design conditions for Refer to Section 4 or 9 to determine if dryer is being operated outside of
cant dust down- maximum rated flow exceeded design limitations.
stream Fluidization of desiccant bed -
Rapid repressurization of offstream tower due to:
Faulty timer Refer to Section 7 or 8 to verify proper time sequence.
Insufficient purge flow - purge pressure too low Refer to Section 9 to determine correct Purge Pressure Indicator setting .
11.7 Switching Failure Faulty pressure switches or control board Replace components
Alarm Offstream tower did not de-pressurize in time and/or Check mufflers, check or shuttle valve(s), inlet switching and purge/
(Level 1 & Level 2 below 10 psig repressurization valves, purge pressure adjustment, and controller set-
Controllers only) tings.
Offstream tower did not re-pressurize in time and/or Check air supply to dryer, purge/repressurization valve, purge pressure
above 10 psig adjustment, and controller settings.
— 56 —
12. Notes
Information from the dryer serial number tag can be recorded in the following table. This information may be necessary when communicating with
Service representatives.
Allowable Values from Actual Values at
Serial Number Tag Fields
Serial Number Tag Installation
Model Number:
Serial Number:
Service Code:
Rated Capacity:
Maximum Operating Temperature:
Desiccant Type:
VAC (AC Voltage):
AC Phase:
AC Frequency:
AC Wattage:
AC Holding Current:
VDC (DC Voltage)
DC Wattage:
DC Holding Current:
ETO DCF- Code (If Listed, Btm RH Corner)
EC- Code (If Listed, Btm RH Corner)
Additional information that may be useful when dealing with Service:
Location of installation (address and phone number):_________________________________________________________________________
Distributor purchased from:_____________________________________________________________________________________________
Repair Parts List Number and Revision:___________________________________________________________________________________
Indoors or outdoors installation:_ ________________________________________________________________________________________
Ambient temperature range:____________________________________________________________________________________________
Prefilters:___________________________________________________________________________________________________________
Drains:_____________________________________________________________________________________________________________
Delta-P devices:_ ____________________________________________________________________________________________________
Afterfilters:__________________________________________________________________________________________________________
Delta-P devices:_ ____________________________________________________________________________________________________
Blocking or Isolation Valves:____________________________________________________________________________________________
ISO Class Operating Mode:_____________________________________________________________________________________________
Fixed or Demand Cycle Mode (Level 2 controller only):_______________________________________________________________________
Outlet pressure dew point reading:_______________________________________________________________________________________
Additional accessories or special features:_________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
— 57 —
— NOTES —
— 58 —
— NOTES —
— 59 —
WARRANTY
The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance
with the procedures and recommendations outlined in the manufacturer’s instruction manuals, to be free from defects in material or
workmanship for a period of one (1) year from the date of shipment from the manufacturer or the manufacturer’s authorized distributor,
or eighteen months from the date of shipment from the factory, whichever occurs first, provided such defect is discovered and brought to
the manufacturer’s attention the aforesaid warranty period. The manufacturer will repair or replace any product or part determined to be
defective by the manufacturer within the warranty period, provided such defect occurred in normal service and not as the result of misuse,
abuse, neglect, or accident.
The warranty covers parts and labor for the warranty period. Repair or replacement shall be made at the factory or the installation site,
at the sole option of the manufacturer. The manufacturer must first authorize any service performed on the product by anyone other than
the manufacturer. Normal maintenance items requiring routine replacement are not warranted. Unauthorized service voids the warranty
and any resulting charge or subsequent claim will not be paid.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WRITTEN, ORAL, OR STATUTORY,
AND IS EXPRESSED IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE. THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR DAMAGE BY REASON OF STRICT
LIABILITY IN TORT OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN, MANUFACTURE, OR INSPECTION OF
THE EQUIPMENT OR ITS FAILURE TO DISCOVER, REPORT, REPAIR, OR MODIFY LATENT DEFECTS INHERENT THEREIN. THE
MANUFACTURER, HIS REPRESENTATIVE OR DISTRIBUTOR SHALL NOT BE LIABLE FOR LOSS OF USE OF THE PRODUCT OR
OTHER INCIDENTAL OR CONSEQUENTIAL COSTS, EXPENSES, OR DAMAGES INCURRED BY THE BUYER, WHETHER ARISING
FROM BREACH OF WARRANTY, NEGLIGENCE OR STRICT LIABILITY IN TORT.
The manufacturer does not warranty any product, part, material, component, or accessory manufactured by others and sold or supplied
in connection with the sale of the manufacturer’s products.
AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE

MATERIAL IS RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.
SERVICE DEPARTMENT : +82-51-728-5360
HANKISON, AN SPX BRAND

SPX FLOW TECHNOLOGY KOREA CO.,LTD.
#940-1, YERIM-RI, JEONGGWAN-MYEON,
GIJANG-GUN, BUSAN, 619-961, KOREA
TEL 82 l 51 l 728 l 5360
FAX 82 l 51 l 728 l 5359
Email: [email protected]
www.hankison.co.kr
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Pressure-Swing Desiccant Type Compressed Air Dryers: Instruction Manual

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Pressure-Swing Desiccant Type Compressed Air Dryers: Instruction Manual

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Bulletin M733E

HHE, HHL and HHS SERIES

HHE-1.1 HHL-1.1 HHS-1.1 40 SCFM 1.1

SERVICE DEPARTMENT : +82-51-728-5360

1.1 Pressurized Devices 2.1 Receiving:

1.5 High Velocity Air:

3.1 Dryer Function 3.2 Automatic Purge Saving System

1. Tower Pressure Gauges 8. Safety Valve

(normally closed) valves is sequenced by the control system located

1. Tower Pressure Gauges 8. Safety Valves

1. Tower Pressure Gauges 8. Safety Valve

1. Tower Pressure Gauges 8. Safety Valve(s)

Compressor Aftercooler Separator Receiver Prefilters Desiccant Dryer Afterfilters Receiver

4.1.1 Aftercooler/Separator – 4.2 Physical Location

4.9 Piping Air Outlet

4.10 Isolation Valves Purge

PURGE PRESSURE GAUGE

FRONT VIEW RIGHT SIDE VIEW REAR VIEW

L BOTTOM RIGHT SIDE VIEW

PURGE PRESSURE DESICCANT FILL PORT

LEFT CHAMBER RIGHT CHAMBER

ASME CODE TAG

DESICCANT DRAIN PORT

FRONT VIEW RIGHT SIDE VIEW REAR VIEW

7/8” X 1-1/4” SLOT (TYP 4 PLACES)

FLOW FLOW FLOW

LIFTING LUG DESICCANT FILL PORT

PURGE PRESSURE MOISTURE INDICATOR

LEFT CHAMBER RIGHT CHAMBER PILOT AIR FILTER

PURGE EXHAUST MUFFLER

FRONT VIEW RIGHT SIDE VIEW REAR

Desiccant Dryer Controllers Timer Level 1 Level 2

AC Input Voltage: 100-240 VAC, 50-60 Hz (See Note 1) •

Left Tower Right Tower

WARNING: Disconnect the main power

VOLTAGE FUSE 5 x 20mm

NEGATIVE FROM POWER SUPPLY

EARTH POSITIVE NEGATIVE TOP

LEFT TOWER RIGHT TOWER

• Figure 7-1, Front Panel Overlay – Level 1 Controller Table 7-1

Left tower pressure

Right tower pressure

Right purge valve LED

Left tower regenerating

Operating mode LEDs

Operating mode LED

Reset switch for alarm

JUMPER NO. & JUMPER JUMPER

J1 - MAXIMUM OPERATING PRESSURE 150 PSIG 250 PSIG

ALARM RESET/MANUAL CYCLE INCREMENT SWITCH

RIGHT INLET VALVE LEFT PURGE VALVE

RIGHT PURGE VALVE LEFT INLET VALVE

2PB 13L 14L 15L

ENCLOSURE DOOR EXTERIOR

0.87" [22 mm]

2.74" [70 mm]

6.54" [166 mm]

7.72" [196 mm]

8.90" [226 mm]

10.00" [254 mm]

Right tower pressure

Right tower drying LED

Right purge valve LED

Reset switch for alarm

8.9.1.19 Alarm Mode Screen 16 – Alarm Drain 2

Right tower closed for < 5 open at t3,

Pressure switch status that causes an alarm

ENCLOSURE DOOR INTERIOR

SELECT POWER ON / OFF

RIGHT PURGE VALVE

JUMPER NO. & JUMPER JUMPER +12

JP8 - (NOT USED) -- --

2PB 13L 14L 15L

ENCLOSURE DOOR EXTERIOR

ENCLOSURE DOOR INTERIOR

C15 C47 C52 U12

DRYER MOP 250 psig (17.2 barg)