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Deltech Fitness LS2580 User's Manual

1. NOTE 1 When the unit is located in a corrosive environment coat sockethead cap screws with a corrosion resistant compound Figure 4 6 INLET AND PURGE EXHAUST SWITCHING VALVE LS1000 Maintenance and Repair 4 11 3 Switching Valve Components 4 1 1 1 1 1 1 3 1 4 2 1 1 2 2 2 1 1 1 4 1 4 2 Sockethead Cap Screw Valve Cover O Ring Bonnet Cylinder Locknut Piston Seal Valve Piston O Ring Poppet Shaft Rod Seal Guide Sleeve O Ring Valve Bonnet O Ring Rod Scraper Valve Poppet Poppet Shaft Poppet Shaft Valve Bonnet Sockethead Cap Screw Valve Body Sockethead Cap Screw O Ring 60 00 03 4 9 3 Inlet Switching Valve Maintenance Models LS1250 and LS1500 WARNING Ensure that the dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage Note Removal of valve body 21 from the dryer manifold is not required unless replacement of O rings 23 or valve body is necessary Clean and inspect all valve hardware upon disassem bly Replace all software and any hardware which appears damaged or abnormally worn Clean and inspect valve seat located inside the valve body 21 As previously noted this can be accom plished w
2. 10 20 30 40 50 60 70 80 90 100 110 PURGE GAS FLOW RATE SCFM Figure C 8 Critical Orifice Calibration Curve LSC630 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers 100 90 80 70 60 50 40 30 20 PURGE PRESSURE P PSIG HYDROBLOC LSC PURGE CURVES Orifice Dia 359 Gas Air Temp 100 F 6 65 20 30 40 50 60 70 80 90 100 110 120 130 PURGE GAS FLOW RATE SCFM Figure C 9 Critical Orifice Calibration Curve LSC760 100 90 80 70 60 50 40 30 20 10 PURGE PRESSURE P1 PSIG HYDROBLOC LSC PURGE CURVES Orifice Dia 406 Gas Air Temp 100 F 6 65 20 30 40 50 60 70 80 90 100 110 120 130 PURGE GAS FLOW RATE SCFM Figure C 10 Critical Orifice Calibration Curve LSC1000 LSC 1250 100 90 80 70 60 50 40 30 20 10 PURGE PRESSURE P PSIG HYDROBLOC LSC PURGE CURVES Orifice Dia 500 Gas Air Temp 100 F 6 65 20 40 60 80 100 120 140 160 180 200 220 PURGE GAS FLOW RATE SCFM Figure C 11 Critical Orifice Calibration Curve LSC1500 100 90 80 70 60 50 40 30 20 10 PURGE PRESSURE P PSIG
3. Note If correct setting is unknown refer to the Calculation of Purge Pressure Setting in structions in Appendix A Purge or Outlet Check Valve seat is worn damaged or fouled allowing slight pressure leakage to enter regenerating chamber 1 CHECKS AND REMEDY Shutdown and Depressurize Dryer Refer to the Inlet Switch ing Valve and Purge Exhaust Switching Valve Maintenance pro cedures which are applicable to your specific dryer model Dis assemble clean and inspect the Inlet Switching Valves and Purge Exhaust Switching Valves Replace all worn or damaged components as noted Verify power is being supplied to dryer Replace timer if necessary Check for pilot gas pressure at inlet valve s pilot tubing connec tions If there is pilot pressure at the off stream chamber s pilot tubing connection and no pilot pressure at the on stream chamber s pilot tubing connection refer to the Inlet Switching Valve Mainte nance procedure which is applicable to your specific dryer model Shutdown and Depressurize Dryer Disassemble clean and inspect the Inlet Switching Valve Replace all worn or damaged parts as noted Repeat check 2 If there is no pilot gas pressure present at the off stream chamber s pilot gas tubing connection check voltage to solenoid valve voltage is present De energize Dryer Power Supply Re place solenoid valve If voltage is not present replace timer Check for pilot
4. Soenrodvve 2 12608 SolenoidCol jf 2 jose Pee POW es ef S EAR eS SNE I ae a Prefiter Replacement Element twitter 1276881 1 1276889 1 1276881 2 1276889 2 1276889 3 Afterfiter Replacement Element ayfter 1276885 1 1276885 1 1276885 2 1276893 2 1276893 3 eee aa a ee eee a ae SARS SPERM ME EN CNS CER Nb aa __ __ 1268706 OPD 4 1508 6 container 1 oO 260706 OPD 4 350R 8504 container atyidyer 2 3 3 5 2 288707 oro 42000 2000 container yayo oq 1 J 1260708 OPD 25 150 1504 container awayenl 1 Quantity required indicates spares recommended for stocking and maintenance Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers C 21 DELTECH A United Dominion Company Flair Engineered Products 4647 SW 40th Avenue Ocala FL 34474 5799 Telephone 352 873 5700 Fax 352 873 5744 WEB ADDRESS www udi flair com deltech E MAIL deltech udi flair com U S FACILITIES New Castle Delaware Ocala Florida Stanley North Carolina CANADIAN FACILITIES Brockville Ontario Tel 800 893 5247 Fax 800 318 0952 EUROPEAN FACILITIES Horndean Hants England Dortmund Germany Killarn
5. A 4 Purge Curves 5 A HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 156 Gas Air Temp 100 F G 65 PURGE GAS FLOW RATE SCFM Figure A 2 Critical Orifice Calibration Curve LS110 Purge Curves 100 90 80 70 60 50 40 30 20 10 PURGE PRESSURE P PSIG HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 172 Gas Air Temp 100 F G 65 100 90 80 70 60 50 40 30 PURGE PRESSURE P1 PSIG 20 10 PURGE GAS FLOW RATE SCFM Figure A 3 Critical Orifice Calibration Curve LS130 A 6 Purge Curves 7 A HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 203 Air 100 65 15 20 25 30 35 PURGE GAS FLOW RATE SCFM Figure A 4 Critical Orifice Calibration Curve LS185 Purge Curves 100 90 80 70 60 50 40 30 20 10 PURGE PRESSURE P PSIG HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 257 Gas Air Temp 100 F 6 65 100 90 80 70 60 50 40 30 PURGE PRESSURE P1 PSIG 20 10 10 15 20 25 30 35 40 45 50 55 60 65 PURGE GAS FLOW RATE SCFM Figure A 5 Critical Orifice Calibration Curve L
6. Close the Pilot Gas Filters Bleed Valve Close any manual vent or drain valves installed in prefilter and afterfilter assemblies Close the System Outlet Isolation Valve customer supplied Energize the dryer s electrical power supply Supply pressure to system by slowly opening the System Inlet Isolation Valve customer supplied Both desiccant chamber Inlet Switching Valves will open and both Purge Exhaust Switching Valves will close The desiccant chambers will immediately be gin pressurizing to system pressure as indicated by chamber pressure Fully open the Moisture Indicator Supply Valve The Moisture Indicator s if dryer so equipped bleed valve is installed directly into the back of the indicator s body Adjust the Moisture Indicator s Bleed Valve until a very slight continuous gas bleed is felt exhausting from the bleed valve s exhaust port Ensure that the granular indicator crystals remain motionless after final adjustment PARTIALLY open the System Outlet Isolation Valve customer supplied while monitoring the outlet pres sure gauge Do not permit the Dryer s Outlet Pres sure gauge to exceed a 5 drop in pressure while pressurizing downstream piping Close the System Bypass Valve if gas system has been so equipped Refer to Appendix A Appendix C for 100 F pdp of this manual and calculate your dryer model s purge pressure setting as instructed Locate the Purge Adjusting Valve Slowly rotate
7. HYDROBLOC LSC PURGE CURVES Orifice Dia 563 Gas Air Temp 100 F 6 65 40 60 80 100 120 140 160 180 200 220 240 260 PURGE GAS FLOW RATE SCFM Figure C 12 Critical Orifice Calibration Curve LSC2070 100 90 80 70 60 50 40 30 20 PURGE PRESSURE P PSIG HYDROBLOC LSC PURGE CURVES Orifice Dia 688 Gas Air Temp 100 F C 65 D 100 90 80 70 60 50 40 PURGE PRESSURE P PSIG 30 20 10 75 100 125 150 175 200 225 250 275 300 325 350 PURGE GAS FLOW RATE SCFM Figure C 13 Critical Orifice Calibration Curve LSC2580 C 18 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers HYDROBLOC LSC REPLACEMENT PARTS Description Quantity Model Model Model Model Model Required 0 LSC110 LSC130 LSC185 0 1283853 1283853 1283853 1283853 1283853 Relief Valve 1124704 1124704 1124704 1124704 1124704 1125546 1125546 1125546 1125546 6 AQUADEX Repair Kit 1207278 1207278 1207278 1207278 1207278 Inlet Exhaust Valve Packing Kit 1283204 1283204 1283214 1283214 1283222 Purge Valve Packing Kit 1283207 1283207 1283207 1283207 1283233 inlet Exhaust Valve Repair Kit 1283203 1283203 1283213 1283213 1283221 Purge Valve Repair Kit 1283206 1283206 1283206 1283206 1283232 Purge Orifice 1198603
8. Note Exploded view illustrates one half of switching valve only Disassembly of opposite half not shown ex ploded is identical Clean and inspect all valve hardware upon disassem bly Replace all software and any hardware which appears damaged or abnormally worn Clean and inspect valve seat located inside the valve body 16 As previously noted this can be accom plished without removing the valve body 16 from the dryer manifold Apply an ultra thin film of O ring lubricant to items 3 5 8 11 and 17 before reassembly Do not ap ply lubricant to the valve seat seal 13 The U cup piston seal 5 has been fitted with a cut O ring Ensure that the U cup piston seal is installed on the valve piston 4 as shown The open side of the U cup piston seal 5 must face the valve cover 2 upon reassembly Apply a light coat of lubricant to the sockethead cap screws items 1 and 18 Hand tighten screws until snug Torque to 245 in lbs 14 Maintenance and Repair 1 4 NOTE 1 When the unit is located in a corrosive environment coat sockethead cap screws with a corrosion resis tant compound Figure 4 8 2 PURGE EXHAUST LS1250 Maintenance and Repair 4 15 3 Switching Valve Components 8 2 2 2 2 2 2 4 2 4 2 2 2 2 2 2 2 1 2 4 Sockethead Cap Screw Valve Cover O Ring Bonnet Cylinder Locknut Piston Seal Valve Piston O Ring Poppet Shaft Rod Seal Guide Sle
9. bly Replace all software and any hardware which ap Backup Ring 2 Clean and inspect valve seat located inside the valve Compression Spring Purge Exhaust Washer body 1 ody 1 O Ring Valve Cover 3 Apply an ultra thin film of O ring lubricant to items 14 Tetraseal 16 17 and 21 before reassembly Piston Seal Ring Inl 4 The U cup piston seal 16 has been fitted with a cut A Screw O ring Ensure that the U cup piston seal is installed Locknut on the valve pistons 4 and 5 as shown in Figure 4 3 Shaft WARNING Ensure that the Dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any Dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage 60 00 gt 5 5 Apply a light coat of lubricant to the 5006617680 cap O Ring Shaft screws items 1 and 18 Hand tighten screws until Pin snug Torque as follows Torque 1 4 20 screws to 40 in lbs Torque 5 16 18 screws to 135 in lbs Piston sea 16 sl on inlet valve piston 4 Typical both sides TEN Y ooo RT Piston seal 16 orientation on purge exhaust valve piston 5 Typical both sides Figure 4 5 4 10 Maintenance and Repair
10. 2 10 Instrumentation The following instrumentation helps in monitoring dryer op eration and performance Instruments which are available as options are so noted Fixed Cycle Electronic Timer Control Power ON Light r N Left Chamber Right Chamber DRYING Light oe DRYING Light Y fol H m A Sen rs mong te cael a 4 Figure 2 2 Hydrobloc LS Series Electronic Timer Control Indicating Panel Power ON Light The power ON light on the control panel indicates when the dryer is turned on and operating Left Chamber DRYING Light The Left Chamber DRYING light on the control panel indi cates when the left chamber is drying Right Chamber DRYING Light The Right Chamber DRYING light on the control panel indi cates when the right chamber is drying 2 6 Installation 2 7 Installation When the Energy Management System LED indicator is OFF the dryer either does not have the Compu Save En ergy Management System option or that the sensor has determined that the relative humidity in the on line chamber has reached the predetermined set point At next switchover that chamber will regenerate using purge air When the Energy Management System LED indicator is flashing a high humidity condition may exist or there is an Energy Management System failure Left Chamber DRYING Light The Left Chamber DRYING light on the DEC control
11. D Continue tightening nut for an additional 1 2 turn l SNE N E Remove subassembly from the vice Install the cotter pin CONTACT Note Orifice stroke adjustment is critical to the op 1 eration of the flow restrictor DISASSEMBLY ASSEMBLY INSTRUCTIONS SLIGHT CONTACT SHAFT SUBASSEMBLY im a 1 Disassemble Build the shaft subassembly in the order shown by the Shaft Subassembly Diagram Figure 4 16 2 Preload the orifice spring A Tighten nut until slight contact is made with SHAFT SUBASSEMBLY washer and orifice spring B Continue tightening nut an additional 3 turns Total C Install cotter pin Poppet Shatt Note Preloading of the orifice spring is critical to the Orifice Plate operation of the flow restrictor Orifice Spring Washer Slotted Nut Cotter Pin SHAFT SUBASSEMBLY Figure 4 16 Figure 4 17 4 16 Purge Adjusting Valve Models LS2070 and LS2580 WARNING Ensure that the dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage Note Removal of valve body 4 is not required unless replacement of valve body is necessary 1 Clean and inspect all valve hardware upon disassembly Replace all so
12. Remove the nut from the bottom of the bowl 4 5 Automatic Drain Valve 6 Turn the bowl upside down Disassembly and Servicing 7 Inspect the drain for damage Replace if necessary vents to clean the drain valve as they may damage the tomatic drain valve valve CAUTION Do not disassemble the drain valve timer or 8 Hold the bowl upright and drop in the new or cleaned attempt to repair electrical parts Replace timer if defec drain so that the drain stem is through hole at the tive bottom of the filter The automatic drain valve discharges condensate through 9 Replace the nut and hand tighten a full port drain opening The valve body may need to be cleaned under conditions of gross particulate contamina CAUTION Do not use a pipe wrench to tighten the tion filter bowl to the head To disassemble the automatic drain valve body for cleaning 10 Reattach bowl to head and hand tighten or other maintenance refer to Figure 4 1 11 Reattach drain lines if applicable 1 Disconnect main power supply to dryer 12 Close service valve 2 Lock out and tag power supply in accordance with OSHA requirements 13mm NUT CORE HOUSING O SPRING WASHER TIMER ASSEMBLY O RING SOLENOID COIL SOLENOID COIL HOUSING SOLENOID COIL T ASSEMBLY SPRING RUBBER ASSEMBLY CONNECTOR WITH POWER CORD VALVE BODY VALVE BODY BRASS DIAPHRAGM WASHER 2 ARROW INDICATES FLOW DIRECTION Figure 4 1 AUTOMATIC DRAIN VALVE COMPON
13. mum recommended inlet temperature 120 F For capacity at inlet tem perature higher than 100 F consult your local distributor DETAIL SPECIFICATIONS 6 minutes 3 minutes 3 minutes DE 4 Activated Alumina NEMA Cycle Drying Regeneration Type ASME Section VIII DIV 1 Stamped 175 psig minimum 450 F Automatic 5 TO 5 psid 100 psig and 100 F Dryer Outlet UTILITIES NEMA 4X 115V 60 HZ 1 PH 40 WATTS Design Pressure Design Temperature Operation Pressure Drop Purge Source NEMA Type Input Power Consumption Dryer Cycle Dryer Adsorbent Pressure Vessels Dryer Electrical HYDROBLOC LS SERIES SPECIFICATIONS MODEL PREFILTER AFTERFILTER LS60 D 0100 CF D 0100 PF LS110 D 0175 CF D 0100 PF LS130 D 0175 CF D 0170 PF LS185 D 0250 CF D 0170 PF LS240 D 0250 CF D 0300 PF LS270 D 0400 CF D 0300 PF LS360 D 0400 CF D 0405 PF LS505 D 0600 CF D 0510 PF LS630 D 0600 CF D 0850 PF LS760 D 0750 CF D 0850 PF LS1000 D 1000 CF D 1020 PF LS1250 D 1200 CF D 1225 CF LS1500 D 1500 CF D 1500 PF LS2070 D 2000 CF D 2000 PF LS2580 D 3000 CF D 3000 PF 1 General Information CAUTION Each component of a Deltech Hydrobloc LS Series heaterless regenerative desiccant dryer system has been selected to compliment the performance of the other components of the system Therefore use of unauthorized parts or supplies o
14. 3 Initial Start Up For Dryers With Fixed Cycle Electronic Timer Controls Models LS60 through LS1000 only r trrrttrrstirrstrrsttacstcrrstarretrcrcrrstcrretrrrree 3 4 Initial Start Up For Dryers With DEC Controller Dryer Models LS60 through LS1000 Dryer Models LS1250 and LS1500 pp 3 5 Normal Start Up or Restart For Dryers With Fixed Cycle Electronic Timer Control Models LS60 through LS1000 only e eee eeceeeneeeeeeeeeeeeeeeeeeneeeaeeteaeeseaeeeseeseaeessatesieeeeeetias 3 6 Normal Start Up or Restart For Dryers With DEC Controller Dryer Models LS60 through LS1000 0 0 Dryer Models LS1250 and LS1500 pp Dryer Models LS2070 and LS2580 pp 3 7 Normal Operational Checks pp 3 8 Dryer Shutdown iTi eile cee a a ee E a eee EEN GEE Contents Maintenance and Repair Preventative Maintenance Schedule pp Weekly E E E E E E A E E T Quae aussie res rr rinse rie 5 tes hii ee ee Desiccant Charging Procedures pp 7 Dryer Models LS60 through LS1250 0 Dryer Models LS1500 through LS2580 pp Servicing The Internal Float Drain Valve If Equipped Automatic Drain Valve Disassembly and Servicing pp Moisture Indicator Recharging Procedure pp Inlet and Purge Exhaust Switching Valve Maintenance S60 60 Inlet and Purge Exhaust Switching Valve Maintenance LS1000 pp 3 Inlet Switching Valve Maintenance Models LS1250 and
15. DEVICES ONLY AT A STATIC FREE WORK STATION USE ONLY ANTISTATIC TYPE SOLDER SUCKERS USE ONLY GROUNDED TIP SOLDERING IRONS Se 1 o 12 Installation Y 4 Se ee saan AA 2 1 Remote alarm terminals A1 A2 A3 located on the Remote Alarm Terminal Block are provided for con nection of a customer supplied remote alarm circuit if desired Should an alarm situation or loss of the dryer s power supply occur the remote alarm relay will de energize to transfer contact from A3 to A2 for remote alarm actuation Note A customer supplied separate power source of sufficient voltage not to exceed 120 VAC must be connected to terminal A1 for remote alarm actuation CAUTION The total current rating of all customer supplied remote alarm equipment MUST NOT exceed 6 amperes inductive and 10 amperes resistive Do not make any additional wiring connections to termi nals A1 A2 and A3 2 9 Equipment Check 1 _ Vibration during shipment can cause loosening of fit tings and fasteners Therefore inspect the dryer for alignment connection and tightness of all subassem blies etc 2 Remove shipping plugs from desiccant chamber fill ports 2 Apply TFE tape to threads and install relief valves 2 Note Pressure relief valves are offered as accesso ries and are shipped separately 3 On Models LS60 through LS1500 desiccant is nor mally installed pr
16. For dryers equipped with the Hydrobloc DEC control ler refer to the Dryer Specification Label located on the inside cover of the dryer control enclosure for your specific dryer model s electrical input require ments ENSURE THAT THE INTENDED POWER SOURCE CONFORMS TO THESE REQUIRE MENTS Installation 2 3 PREFILTER BLOCK VALVE AFTERFILTER VALVE AIR OUTLET q SERVICE Figure 2 1 RECOMMENDED PIPING LAYOUT 2 5 Purge Exhaust Restrictor The dryer s Purge Exhaust Restrictor quiets the gas flow and prevents desiccant bed fluidization by controlling slowing the rate of depressurization On dryer models LS60 through LS1000 the Purge Exhaust Restrictor is designed into the Purge Exhaust Valve On dryer models LS1250 through LS2580 the Purge Ex haust Restrictor must remain attached to the purge ex haust switching valve body to operate properly 2 6 Purge Exhaust Muffler The dryer s Purge Exhaust Muffler quiets the gas flow to atmosphere during depressurization and regeneration purge cycles On models LS2070 and LS2580 the purge exhaust muffler must be piped BY THE CUSTOMER to a remote location A removable section of pipe should be provided at the Purge Exhaust Restrictor for ease of maintenance and the muffler should be mounted in a self draining position Note The pipe run from the dryer to the muffler should not exceed 100 equivalent feet of pipe using a pipe size equal to or larger th
17. LS1500 eee 2 Purge Exhaust Switching Valve Maintenance Model LS1250 only pp 3 Purge Exhaust Switching Valve Maintenance Model LS1500 only pp Purge and Outlet Check Valve Maintenance Models LS60 through LS760 2 2 22 arcirrrocorotrrrotarcocaroocrocaroorrrotrrrocarotrrroes 3 Purge and Outlet Check Valve Maintenance Models LS1000 through LS1500 pp Remote Flow Restrictor Maintenance Model LS1250 only pp Flow Restrictor Maintenance Models LS1500 through LS2580 pp Purge Adjusting Valve Models LS2070 and LS2580 pp Pilot Gas Filter Maintenance Models LS2070 and LS2580 pp Troubleshooting Guide Purge Curves Replacement Parts Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers Section 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14 4 15 4 16 4 17 Section 5 Appendix A Appendix B Appendix C HYDROBLOC LS SERIES SPECIFICATIONS STANDARD DESIGN OPERATING CONDITIONS MODEL FLOW CAPACITY scfm Operating Pressure 60 psig minimum 150 psig maximum Operating Temperature 40 F minimum 120 F maximum Inlet Moisture Content Saturated at specified inlet pressure Outlet Moisture Content 40 F Dew Point line pressure LS60 LS110 LS130 LS185 LS240 LS270 LS360 LS505 LS630 LS760 LS1000 LS1250 LS1500 LS2070 LS2580 1 Based on 100 F inlet air temperature and 40 F pressure dew point Maxi
18. Switching Valve has failed to valve s pilot tubing connection close due to fouled or worn valve internals If pilot pressure is present Shutdown and Depressurize Dryer Disassemble clean and inspect the Switching Valve Replace all worn or damaged parts as noted Valve Failure Alarm with excessive pressure exhausting through muffler BOTH chamber pressure gauges read normal system pressure 1 During Depressurization Cycle Check indicator lights at solenoid block to determine whether Off stream chamber s Purge Exhaust Valve energized Indicator light should be lit if the solenoid coil is has failed to open due to the associated 50 energized If not open control enclosure and check MEC lenoid valve s A or D failure to energize Board for output signal to solenoid valve a If voltage is present and the indicator at the solenoid block is not lit Shutdown and Depressurize Dryer Provide a separate pilot gas source With the dryer controls de energized press the manual over ride on solenoid valve to determine if functioning If function ing mechanically the purge exhaust valve should open the solenoid valve coil is defective Replace solenoid valve coil Note The dryer MUST be depressurized to change coils on a solenoid If voltage is present and the purge exhaust valve doesn t open when manual overriding the solenoid valve the solenoid valve is defective Replace solenoid valve c If voltage is not present rep
19. dryer s Purge Adjusting Valve until the Purge Pres sure Indicator indicates the calculated purge pressure setting See following Note Note The purge pressure can only be read and ad justed when an off line desiccant chamber has de pressurized for regeneration When the off line Operation 3 7 The Start Up procedure for models LS2070 and LS2580 is now complete Proceed to the Normal Operation Checks section of this manual for final op erational checks and adjustments Normal Start Up or Restart For Dryers With Fixed Cycle Electronic Timer Control Models LS60 through LS1000 only Close the Pilot Gas Filter s Bleed Valve Close any manual vent or drain valves installed in prefilter and afterfilter assemblies Close the System Outlet Isolation Valve customer supplied Energize the dryer s electrical power supply The following indicator lights will illuminate a POWER ON b LEFT or RIGHT CHAMBER DRYING Note Should the dryer experience a power inter ruption during a normal cycle the unit will return to the same status of operation that existed at the time of the power interruption Supply pressure to system by slowly opening the System Inlet Isolation Valve customer supplied The Right Chamber Inlet Switching Valve and Left Chamber Purge Exhaust Switching Valve will close The Left Chamber will immediately begin pressurizing to system pressure as indicated by the chamber pressure gauge PARTIALLY open
20. energized valve isolated and fully depressurized before attempt ing to remove or disassemble any component or subassembly Failure to do so may result in se rious personal injury and or equipment damage 6 To depressurize dryer proceed as follows a Open customer supplied System Bypass Valve if gas system has been so equipped Operation 3 9 pressurized for regeneration When the off line chamber is pressurized the Purge Pressure Indica tor will read system pressure The Normal Start Up or Restart procedure for mod els LS2070 through LS2580 is now complete Pro ceed to the Normal Operational Checks section of this manual for final operational checks and adjust ments Normal Operational Checks Ensure that the dryer is being operated at the correct inlet pressure flow rate and inlet temperature as specified on the Dryer Specification Label located on inside cover of dryer system control enclosure If the prefilter utilizes any automatic drain device en sure that it is draining and functioning properly Ensure that the Purge Pressure Indicator gauge in dicates the pressure setting calculated during start up After an off stream desiccant chamber has depressur ized for regeneration a flow of purge gas should be felt exiting the purge exhaust muffler The regenerat ing chamber s pressure gauge MUST indicate zero 0 PSIG throughout the purging period The dryer controller should automatic
21. gas leak through the piston seal pilot gas exhaust hole located on the bottom of the valve block If a pilot gas pressure leak is present refer to the Purge Exhaust Switching Valve Maintenance procedure which is applicable to your specific dryer model Shutdown and Depressurize Dryer Disassemble clean and inspect the Purge Exhaust Switching Valve Replace all worn or damaged parts as noted Shutdown and Depressurize Dryer Refer to the Purge and Outlet Check Valve Maintenance Procedure which is applicable to your specific dryer model Disassemble clean and inspect the Purge and Outlet Check Valves Replace all worn or damaged components as noted PROBLEM POSSIBLE CAUSE Off stream chamber s Inlet Switching Valve or on stream chamber s Purge Exhaust Switching Valve seat is worn damaged or fouled allowing slight pressure leakage to enter regenerating chamber Fixed Cycle Electronic Timer Control Mod els LS60 through LS1000 ONLY Dryer chambers fail to switch Timer failure Off stream chamber s Inlet Switching Valve has failed to close due to fouled or worn valve internals Off stream chamber Inlet Switching Valve has failed to close due to the associated sole noid valve s A or B failure to energize Both chambers are at line pressure Purge Exhaust Switching Valve has failed to close due to fouled or worn valve internals Purge or Outlet Check Valve internals are worn damaged or fouled permitting b
22. locknuts 13 and 16 and compression springs 2 and 3 Replace all software and any hard ware which appears damaged or abnormally worn Note Locknuts 13 and 16 are not re usable Once removed they MUST be replaced Clean and inspect valve seat located inside the valve body 8 Apply an ultra thin film of O ring lubricant to items 10 11 15 and 23 before reassembly The U cup piston seal 23 has been fitted with a cut O ring Ensure that the U cup piston seal is installed on the valve pistons 21 and 22 as shown in Figure 4 3 Apply a light coat of lubricant to sockethead cap screw item 4 Hand tighten screws until snug Torque as follows Torque 1 4 20 screws to 40 in lbs Torque 5 16 18 screws to 135 in lbs Maintenance and Repair 8 1 4 4 9 Maintenance and Repair LS60 LS110 LS130 LS185 LS240 LS270 LS360 LS505 LS630 LS760 INLET AND PURGE EXHAUST SWITCHING VALVE Figure 4 4 compound coat sockethead cap screws with a corrosion resistant When the unit is located in a corrosive environment NOTE 1 48 _ Inlet and Purge Exhaust Switching Valve Maintenance Valve Body Valve Cover Left Side Valve Cover Right Side Valve Piston Inlet Valve Piston Purge Exhaust Valve Poppet Purge Exhaust Connect Rod Centering Rod 1 Clean and inspect all valve hardware upon disassem Spacer
23. mounting bolts pipe hangers etc have been checked tight and or prop erly secured IMPORTANT It is recommended that the System s process gas output not be consumed or used at the intended points of use until the Start Up and any re lated adjustments have been completed and the system is producing process gas of the required quality The quality of the process gas should be veri fied through test and analysis when a specific quality process gas is required Supply compressed air up to System Inlet Isolation Valve Open the Pilot Gas Supply Valve located upstream of the Pilot Gas Filter Supply pressure to system by slowly opening the System Inlet Isolation Valve customer supplied The Inlet Switching Valve will open to either left or 1 IMPORTANT Water molecules can diffuse through a pinhole size leak even though pressure inside the piping is several hundred PSIG It is not uncommon to have a minute pinhole leak in a gas line cause an increase in dew point from 40 F to 10 F at a dis tance of forty or more feet downstream of the leak SLOWLY open the customer supplied System Out let Isolation Valve while monitoring the Outlet Pres sure Gauge if dryer so equipped DO NOT permit the Dryer s Outlet Pressure Gauge to exceed a 5 drop in pressure while pressurizing downstream pip ing Close the customer supplied System Bypass Valve if installed Open and adjust the Moisture Indicator s Bleed Valve until
24. switches should only be made by a qualified Deltech Field Service Engineer 2 8 Remote Alarm Connection WARNING Most standard air and gas dryers are furnished with contacts for remote alarms These contacts should be wired to an audible alarm and or to an area where they are continuously monitored When these con tacts are not used the dryer must be visually checked every two 2 hours for existence of any possible mal function Failure to do so may result in an upset con dition that could damage the equipment Failure to protect the dryer from aerosols and liquid conden sate will void warranties DELTECH POWER ON O e O o ACTIVE WARNING Compu Save HYDROBLOC LS Figure 2 3 Hydrobloc DEC Indicating Panel Hydrobloc LS DEC Controller Hydrobloc LS Series dryers are equipped with a micropro cessor system that controls the operation of all dryer func tions The controller is programmed to operate on a 6 minute cycle for 40 F pdp dryers 4 minute for 100 F pdp dryers The controller keeps the drying chamber on line for 3 minutes 2 minutes for 100 F pdp while simulta neously regenerating the off line chamber Indicators on the controller Figure 2 3 help in monitoring dryer opera tion and performance Instruments which are available as options are so noted Deltech Compu Save Energy Management System Option B The optional DEC Compu Save Energy Management Sys tem automatically adjusts
25. that the dryer control system s enclosure cover is closed with all latches tightened to prevent entrance of moisture dust dirt etc 9 SHUTDOWN AND DEPRESSURIZE DRYER follow ing two 2 to three 3 weeks of initial operation In spect desiccant beds through fill ports for settling If settling has occurred refill chambers as necessary to bring desiccant levels to bottom of each desiccant retaining screen Do Not Tamp or Ram Desiccant 3 8 Dryer Shutdown 1 De energize the dryers electrical supply When the dryer s power supply is de energized both desiccant chambers will be automatically placed on stream 2 Close the System Outlet Isolation Valve customer supplied 3 Close the System Inlet Isolation Valve customer sup plied IMPORTANT Inlet and Outlet Isolation Valves MUST be closed to prevent moisture overloading of desiccant beds due to continuous flow without regen eration 4 Close the Moisture Indicator Supply Valve if dryer has been so equipped This MUST be done to prevent depressurization of the pilot gas supply which in turn will eventually result in dryer depressurization 5 Shutdown is now complete The dryer may be left pressurized during periods of non use if desired However if any servicing or maintenance is to be per formed ensure that the dryer is depressurized BE FORE beginning work Proceed to Step 6 for depres surization instructions WARNING Ensure that the system is de
26. the System Outlet Isolation Valve customer supplied while monitoring the outlet pres sure gauge Do not permit the Dryer s Outlet Pres sure gauge to exceed a 5 drop in pressure while pressurizing downstream piping Close the System Bypass Valve if gas system has been so equipped Refer to Appendix A Appendix C for 100 F pdp of this manual and calculate your dryer model s purge pressure setting as instructed Locate the Purge Adjusting Valve Slowly rotate dryer s Purge Adjusting Valve until the Purge Pres sure Indicator indicates the calculated purge pressure setting See following Note Note The purge pressure can only be read and ad justed when an off line desiccant chamber has de pressurized for regeneration When the off line chamber is pressurized the Purge Pressure Indica tor will read system pressure 20 3 5 The Normal Start Up or Restart procedure for mod els LS1250 through LS1500 is now complete Pro ceed to the Normal Operational Checks section of this manual for final operational checks and adjust ments 13 Dryer Models LS2070 and LS2580 Close the Pilot Gas Filters Bleed Valve Close any manual vent or drain valves installed in prefilter and afterfilter assemblies Close the System Outlet Isolation Valve customer supplied Close the Pilot Gas Supply Valve and pressurize the pilot gas system with compressed gas to line pres sure Use the Ball Valve located in the pilo
27. voltage is present and the inlet valve doesn t open models OP M15 through OP M300 or close models OP M400 and OP M500 when overriding the solenoid valve the solenoid valve is defective Replace solenoid valve c If voltage is not present replace MEC Board Shutdown and Depressurize Dryer Disassemble clean and inspect the Purge and Outlet Check Valves Replace all worn or damaged components as noted Troubleshooting Guide 5 5 PROBLEM POSSIBLE CAUSE Valve Failure Alarm with excessive pressure exhausting through muffler BOTH chamber pressure gauges read below normal system pressure During Depressurization Cycle Off stream chamber s Inlet Switching Valve has failed to close due to fouled or worn valve internals During Depressurization Cycle Dryer Models LS60 through LS1500 Chamber Inlet Switching Valve has failed to close due to the associated solenoid vale s B or C failure to energize Dryer Models LS2070 and LS2580 Off stream chamber s Inlet Switching Valve has failed to close due to the associated so lenoid valve s B or C failure to energize During Depressurization Cycle Purge or Outlet Check Valve internals are worn damaged or fouled permitting blowby of on stream chamber s pressure through faulty check valve to the off stream chamber 1 PROBLEM POSSIBLE CAUSE CHECKS AND REMEDY During Repressurization Cycle Check for pilot gas pressure at on stream chamber exhaust Purge Exhaust
28. will ALWAYS cause the control system to automatically shift to fixed cycle operation Compu Save Sensor has sensed a moisture overload condition within a desiccant bed due to the presence of one or both of the follow ing conditions Inlet flow rate SCFM is above dryer s de sign inlet flow rate as specified on the Dryer Specification Label located on the inside cover of the dryer system control enclosure Excessive flow rates will result in excessive moisture loading of the desiccant beds This overload condition would raise the Compu Save Sensor s moisture related frequency signal above the microcomputer s compara tor set point range and therefore would be interpreted as a High Humidity Warning Gas has been allowed to flow through dryer for an extended period of time with the dryer control system de energized When the con trol system is de energized one chamber is automatically placed on stream and regen eration is not conducted Without regeneration the desiccant beds will eventually be overloaded with moisture When the power supply was re energized the moisture overload condition raised the Compu Save Sensor s moisture related fre quency signal above the microcomputer s comparator set point range and therefore would be interpreted as a High Humidity Warning Purge Adjusting Valve is supplying excessive purge gas to regenerating chamber as indi cated by the Purge Pressure Indicator gauge
29. 1094 1261094 Solenoid Valve Spare 1276724 1276724 1276724 1276724 1276724 Display Panel Cable Assembly 1273367 1273367 1273367 1273367 1273367 Pressure Switch Option A amp B 1221910 1221910 1221910 1221910 1221910 Pressure Switch Cable Assy Option A and B 1262602 1262602 1262602 1262602 1262602 Pilot Filter Replacement Element 1223259 1223259 1223259 1223259 1223259 Prefilter Replacement Element 1276841 1276851 1276851 1276857 1276857 Afterfilter Replacement Element 1276843 1276843 1276847 1276847 1276861 Automatic Drain Valve 1276741 1276741 1276741 1276741 1276741 CE ose pi ge gt do 1269703 OPD 4 17 8 17 container qtydryer Tt 1269704 OPD 4 34 S 34 container tyidyer 2 83 3 5 6 1269705 OPD 4 150 150 container qtydryer 1 Quantity required indicates spares recommended for stocking and maintenance B 2 Replacement Parts HYDROBLOC LS REPLACEMENT PARTS Description Quantity Model Model Model Model Model Required 0 0 5 0 0 Mufler 1283853 1283853 1283285 1283285 1283285 Relief Valve 124704 124704 124704 124704 1124704 1125546 1125546 1125546 1125546 6 AQUADEX Repair Kit 1207278 1207278 1207278 1207278 1207278 Inlet Exhaust Valve Packing Kit 1283225 1283225 1283227 1283229 1283231 Purge Valve Packing Kit 1283233 1283233 1283235 1283235 1283235 Inlet Exhaust Valve Repair Kit 1283224 1283224 1283226 1283228 1283230 Purge Valve Repair Kit 1283232 1283232 12832
30. 1218634 1180925 1180926 1198157 Solid State Controller 1286552 1286552 1286552 1286552 1286552 Solenoid Valve 1275475 1275475 1275475 1275475 1275475 Solenoid Coil 1284506 1284506 1284506 1284506 1284506 Control Board CPU 1274947 1274947 1274947 1274947 1274947 Programmed IC 1270702 1270702 1270702 1270702 1270702 Fuse 1 2AMP 1222239 1222239 1222239 1222239 1222239 Power Supply 1261094 1261094 1261094 1261094 1261094 Solenoid Valve Spare 1276724 1276724 1276724 1276724 1276724 Display Panel Cable Assembly 1273367 1273367 1273367 1273367 1273367 Pressure Switch Option A amp B 1221910 1221910 1221910 1221910 1221910 Pressure Switch Cable Assy Option A and B 1262602 1262602 1262602 1262602 1262602 Pilot Filter Replacement Element 1223259 1223259 1223259 1223259 1223259 Prefilter Replacement Element 1276832 1276841 1276841 1276851 1276851 Afterfilter Replacement Element 1276834 1276843 1276843 1276843 1276847 Automatic Drain Valve 1276741 1276741 1276741 1276741 1276741 ee FP ESR ee 1269703 OPD 4 17 8 17 container qty dryer J Et 1269704 OPD 4 34 S 34 container aty dryer 2 3 5 6 1269705 OPD 4 150 150 container qty dye do 1 Quantity required indicates spares recommended for stocking and maintenance Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers C 19 HYDROBLOC LSC REPLACEMENT PARTS Description Q
31. 1276847 1276861 1276861 1276869 1276871 Automatic Drain Valve 1276741 1276741 1276741 1276741 1276741 Dosen ee ee 1269703 OPD 4 17 8 17 container qtydryer J 1 1 S S 1269704 OPD 4 34 S 34 container tyidyer J 3 4 2 1269705 OPD 4 150 150 container qty aye J 1 2 2 3 4 1 Quantity required indicates spares recommended for stocking and maintenance 6 20 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers HYDROBLOC LSC REPLACEMENT PARTS Required LS1000 LS1250 LS1500 LS2070 LS2580 a Sa ERAN ee InlevExhaust Valve Packing Kt 1 127260 Inlet Valve Packing Kit 1256169 1256169 1252986 1252985 Exhaust Valve Packing Kt 2 1256167 1256168 1252986 1252986 Outlet 8 Purge Check Valve Packing Kit 1 1256401 1256401 1256401 jInlevExhaust Valve Repair Kit 1 127268 Inlet Valve Repair Kit 1 f ea 128874 Exhaust Valve Repair Kt 1 128672 128878 Outlet Valve Repair Tt 1266418 1256413 1256413 Purge Valve Repair 1 125645 1256415 1256415 Flow Restrictor Repair 1 tot 1205908 1205911 Flow Restrictor Rebuild o 12o597 1205987 1205937 FE FER DU Purge Orifice 2 1188538 1210708 1210703 Purge Orifice 268843 1268848 Solid State Controller 1 1
32. 150 150 container qty dryer o 1 2 1269706 OPD 4 350 350 container qtydryer 2 3 3 5 f 1269707 OPD 4 2000 2000 container 0 PP 1 1269708 OPD 25 150 150 container yy _ tk Quantity required indicates spares recommended for stocking and maintenance B 4 Replacement Parts Appendix C Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers HYDROBLOC LSC SPECIFICATIONS STANDARD DESIGN OPERATING CONDITIONS MODEL FLOW CAPACITY scfm LSC60 Operating Pressure 60 psig minimum LSC110 150 psig maximum LSC130 LSC185 Operating Temperature 40 F minimum LSC240 120 F maximum LSC270 LSC360 Inlet Moisture Content Saturated at specified inlet pressure LSC505 LSC630 Outlet Moisture Content 100 F Dew Point line pressure LSC760 LSC1000 LSC1250 LSC1500 LSC2070 LSC2580 1 Based 100 F inlet air temperature and 100 F pressure dew point Maximum recommended inlet temperature 120 F For capacity at inlet temperature higher than 100 F consult your local distributor DETAIL SPECIFICATIONS Dryer Cycle NEMA Cycle 4 minutes Drying 2 minutes Regeneration 2 minutes Dryer Adsorbent Type DE 4 Activated Alumina Pressure Vessels ASME Section VIII DIV 1 Stamped Design Pressure 175 psig minimum Design Temperature 450 F Dryer Operation Automatic Pressure Drop 5 TO 5 psid 100 psig and 100 F Purge
33. 20 130 140 PURGE GAS FLOW RATE SCFM Figure A 9 Critical Orifice Calibration Curve LS630 A 12 Purge Curves HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 438 Gas Air Temp 100 F 6 65 A 13 170 Purge Curves 160 150 80 90 100 110 120 130 140 PURGE GAS FLOW RATE SCFM Figure A 10 Critical Orifice Calibration Curve LS760 70 60 100 90 80 70 60 50 40 30 20 10 PURGE PRESSURE P PSIG HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 563 Gas Air Temp 100 F 6 65 100 90 80 70 60 50 40 PURGE PRESSURE P1 PSIG 30 20 10 40 60 80 100 120 140 160 180 200 220 240 260 PURGE GAS FLOW RATE SCFM Figure A 11 Critical Orifice Calibration Curve LS1000 A 14 Purge Curves A 15 325 350 Purge Curves 300 HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 688 Gas Air Temp 100 F 6 65 100 125 150 175 200 225 250 275 PURGE GAS FLOW RATE SCFM Figure A 12 Critical Orifice Calibration Curve LS1250 LS1500 75 100 90 80 70 60 50 40 30 20 PURGE PRESSURE P PSIG HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 750 Gas Ai
34. 34 1283234 1283234 Purge Orifice 1198854 1200806 1218638 1180920 1180921 Solid State Controller 1275442 1275442 1275442 1275442 1275442 Solenoid Valve 1275475 1275475 1275475 1275475 1275475 Solenoid Coil 1284506 1284506 1284506 1284506 1284506 Control Board CPU 1274947 1274947 1274947 1274947 1274947 Programmed IC 1270702 1270702 1270702 1270702 1270702 Fuse 1 2AMP 1222239 1222239 1222239 1222239 1222239 Power Supply 1261094 1261094 1261094 1261094 1261094 Solenoid Valve Spare 1276724 1276724 1276724 1276724 1276724 Display Panel Cable Assembly 1273367 1273367 1273367 1273367 1273367 Pressure Switch Option A amp B 1221910 1221910 1221910 1221910 1221910 Pressure Switch Cable Assy Option A and B 1262602 1262602 1262602 1262602 1262602 Pilot Filter Replacement Element 1223259 1223259 1223259 1223259 1223259 Prefilter Replacement Element 1276865 1276865 1276875 1276875 1276881 Afterfilter Replacement Element 1276861 1276869 1276871 1276885 1276885 Automatic Drain Valve 1276741 1276741 1276741 1276741 1276741 CEC SCENE ee ERY 1269703 OPD 4 17 8 17 container qty dryer J 1 1269704 OPD 4 34 S 848 container aty dryery 3 4 s 2 1269705 OPD 4 150 150 container ciytdryer J 1 2 3 4 1 Quantity required indicates spares recommended for stocking and maintenance Replacement Parts B 3 HYDROBLOC LS REPLACEMENT PARTS Required LS1000 LS1250 LS1500
35. 70 LSC2580 1 01 Standard mounted filter package 2 F02 F07 Optional mounted filter packages 3 Purge Exhaust Piping is not required on Models LS60 through LS1500 However if it is necessary to have a remote mounted muffler consult with your local Deltech Sales Representative for special piping in structions On Models LS2070 and LS2580 refer to the Purge Exhaust Muffler Section of the manual for Purge Ex haust Piping instructions 1 All external piping must be supplied by the customer unless otherwise specified Refer to Table 2 1 for connection sizes Inlet and outlet manual shut off valves and a vent valve are recommended so the dry ers and filters can be isolated and depressurized for servicing Refer to Figure 2 1 for recommended pip ing layout Be sure all piping is supported Do not allow the weight of any piping to bear on the dryer or filters Installation 2 2 2 7 Electrical Connection NOTE 1 Use proper load rated components as ap proved by NEC NEMA CSA UL etc as re quired Local and municipal codes may also apply All installations and connections must be in accordance with recognized electrical codes in effect NOTE 2 Itis mandatory that each dryer be individually GROUNDED Do not use your plant s frame as a ground Use an adequate ground with the conductor sized to NEC NOTE 3 A disconnect switch is not provided as stan dard equipment and therefore must be sup plie
36. ENTS Maintenance and Repair 4 5 WARNING Ensure that the Dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any Dryer component or subassem Failure to do so may result in serious personal bly injury and or equipment damage Remove hose that connects the drain valve to the fil ter Remove screw and washer from front of drain valve Remove the power supply connector and gasket with the timer assembly if attached from the solenoid coil housing Do not damage or lose the gasket Remove 13 mm nut and spring washer from top of solenoid coil housing Lift solenoid coil housing off solenoid core in valve body Unscrew solenoid core from valve body 3 8 Once the drain valve is disassembled the following mainte nance can be performed Inspect diaphragm clean or replace as required Remove debris from the valve body Wipe solenoid core components with a clean cloth or blow out debris with compressed air from an OSHA approved air nozzle that limits the discharge pressure to 30 psig Check the small port in diaphragm assembly is clear and solenoid coil moves freely in housing Viton dia phragm seals are compatible with commonly used synthetic lubricants If timer is attached to valve body check electrical continuity across timer assembly Maintenance and Repair 1 2 3 4 6 Remove porous disc 4 and clean sight dome see followi
37. Ensure that it is not clogged and is draining properly Repair or replace as necessary if a problem is noted Shutdown and Depressurize Dryer Inspect desiccant through fill ports and replace if badly broken coated with oil or otherwise fouled Inspect prefilter if fouling is noted Soap test the dryer outlet manifold and piping downstream of dryer Repair ALL leaks noted Open bleed valve installed in moisture indicator body until a slight continuous gas bleed is felt exhausting from bleed valve s drilled exhaust port Granular indicating desiccant MUST remain motionless after final adjustment Fully open the moisture indicator supply valve Adjust indicators bleed valve as instructed in previous step 1 Refer to Moisture Indicator Recharging Procedure section of this manual for disassembly instructions Clean or replace compo nents as necessary Perform a soap bubble leak test on indicator s tubing and fit tings Tighten or repair all noted points of leakage Refer to dew point degradation section of this Troubleshooting Guide Determine and eliminate fault Important If granular indicating desiccant is discolored any color other than Light Pink to Dark Blue replace the granular indicator PROBLEM POSSIBLE CAUSE Inlet gas temperature is above the dryer s design inlet temperature specified on the Dryer Specification Label located on the in side cover of the dryer system control enclo sure Liquids en
38. Installation Operation and Maintenance Manual HYDROBLOC LS SERIES HEATLESS COMPRESSED AIR DRYER MODEL LS60 through LS2580 This instruction manual must be read by everyone who installs or works with this equipment Form No X 1183 01 2000 Printed in USA Contents HYDROBLOC LS SERIES SPECIFICATIONS Section 1 General Information 1 1 ao Kio see fist E e te at cata te Oh ee A Pr 1 2 General System Information 2 c6cucesi Tni ecard devi i Ne nd eid dotnet 1 2 1 DOP fess ti atest tes ete OT Aan eta ati es aa eee ace i Eel een as 1 2 2 Prefilter Assembly 4 26 1 2 3 Automatic Drain Valves ifsc Sethian Geta aeth inns Ae eee 1 2 4 Aitertilter Assembly cs exit tease e aden cmos ates 00205 nats bebe deed sees eE Section 2 Installation 2 1 Receiving and INSpection cccccceseceeeesceeeeeeceeeeeneeseeeeeeeeeeeeeeneneeseseeeesneeneeeeseeeeesneeenseeeeeeeaes 2 2 Equipment Handling c c4 0 st eite hee ees eee AE ca pe ee eed ad 2 3 Mechanical Ser Up 2 4 General Piping Information pp 2 5 Purge Exhaust R Strictor siidi RL Ae Ae S 2 6 Purge Exhaust Muffler scc uanaiind een E ee Ls et ao 2 7 Electrical Connection 2 8 Remote Alarm Connection pp 2 9 Equipment 0 EAEE R ETE 2 10 InStrumentatio Mis sekccszicstzesveracat a a a a e a E te caachntesdeys cbt A EaR Section 3 Operation 3 1 Row It Works ern a ieee a elie dle ne ees 3 2 Automatic Draln ValW 2 3
39. LS2070 LS2580 Re SENN ME ERS FOES HAE EEF FEAR InlevExhaust Valve Packing Kt 1 1272008 Inlet Valve Packing Kit TT 1266169 1256169 1252086 1262986 Exhaust Valve Packing Kit 1256167 1256168 1252986 1252986 Outlet 8 Purge Check Valve Packing Kt 1 1256401 1256401 1256401 jInlevExhaust Valve Repair Kit Jt 127266 POP Inlet Valve Repair Kit tz 126674 Exhaust Valve Repair kit 1 126672 126678 Outlet Valve Repair Kit 1 1266418 1256413 12563 Purge Valve Repair Kit 1 1266416 1256415 126648 Flow Restrictor Repair Kit_ 1 1208908 1205908 1205911 Flow Restrictor Rebuild 1 1206987 1205937 1206987 oN DUES PEP EE PES FART SAG Purge Orifice 1188538 1210708 1210708 Purge Orifice jf 1 1268848 1268843 CSC SSE SEER SET S EER RAR Sold State Coroner 1 127844 od Solenoid Vave tesa Solenoid Col stop 1 Prefiter Replacement Element qty fiter 1276889 1 1276897 1 1276881 2 1276889 2 1276889 3 Afterfiter Replacement Element qty fiter 1276893 1 1276901 1 1276885 2 1276893 2 1276901 3 oe OO ol leo SS Ro Cc UNSERE TEE EES SS SS 1269708 OPD 4 17 S 17 container atyidryer S 1269704 OPD 4 34 S 346 container ye 1 S 1269705 OPD 4
40. S240 A 8 Purge Curves 9 A HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 272 Gas Air Temp 100 F 6 65 15 20 25 30 35 40 45 50 55 60 65 70 PURGE GAS FLOW RATE SCFM Figure A 6 Critical Orifice Calibration Curve LS270 Purge Curves 100 90 80 70 60 50 40 30 20 10 PURGE PRESSURE P PSIG HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 290 Gas Air Temp 100 F 6 65 100 90 80 70 60 50 40 30 PURGE PRESSURE P1 PSIG 20 10 PURGE GAS FLOW RATE SCFM Figure A 7 Critical Orifice Calibration Curve LS360 A 10 Purge Curves HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 359 Gas Air Temp 100 F 6 65 100 90 80 70 60 50 40 30 20 10 20 30 40 50 60 70 80 90 100 110 120 130 PURGE GAS FLOW RATE SCFM Figure A 8 Critical Orifice Calibration Curve LS505 Purge Curves A 11 PURGE PRESSURE P PSIG HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 375 Gas Air Temp 100 F 6 65 100 90 80 70 60 50 40 PURGE PRESSURE P PSIG 30 20 10 30 40 50 60 70 80 90 100 110 1
41. SSURE P PSIG HYDROBLOC LSC PURGE CURVES Orifice Dia 203 Gas Air Temp 100 F 6 65 100 90 80 70 60 50 40 30 PURGE PRESSURE P1 PSIG 20 10 PURGE GAS FLOW RATE SCFM Figure C 5 Critical Orifice Calibration Curve LSC240 LSC270 C 10 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers C 1i HYDROBLOC LSC PURGE CURVES Orifice Dia 257 Gas Air Temp 100 F 6 65 PURGE GAS FLOW RATE SCFM Figure C 6 Critical Orifice Calibration Curve LSC360 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers 100 90 80 70 60 50 40 30 20 10 PURGE PRESSURE P PSIG HYDROBLOC LSC PURGE CURVES Orifice Dia 290 Gas Air Temp 100 F 6 65 100 90 80 70 60 50 40 PURGE PRESSURE P PSIG 30 20 10 PURGE GAS FLOW RATE SCFM Figure C 7 Critical Orifice Calibration Curve LSC505 C 12 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers C 13 HYDROBLOC LSC PURGE CURVES Orifice Dia 313 Gas Air Temp 100 F G 65
42. Source Dryer Outlet UTILITIES Electrical NEMA Type NEMA 4X Input 115V 60 HZ 1 PH Power Consumption 40 WATTS Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers C 3 HYDROBLOC LSC SPECIFICATIONS LSC110 D 0100 CF D 0100 PF LSC130 D 0100 CF D 0100 PF LSC185 D 0175 CF D 0100 PF LSC240 D 0175 CF D 0170 PF LSC270 D 0175 CF D 0170 PF LSC360 D 0250 CF D 0300 PF LSC505 D 0400 CF D 0300 PF LSC630 D 0400 CF D 0405 PF LSC760 D 0600 CF D 0510 PF LSC1000 D 0750 CF D 0850 PF LSC1250 D 1000 CF D 0850 CF LSC1500 D 1500 CF D 1500 PF LSC2070 D 2000 CF D 2000 PF LSC2580 D 3000 CF D 3000 PF C 4 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers HYDROBLOC LSC PURGE CURVES Locate the Purge Adjusting Valve Slowly rotate dryer s Purge Adjusting Valve until the Purge Pres sure Indicator indicates the calculated purge pres sure setting See following Note Note The purge pressure can only be read and ad justed when an off line desiccant chamber has de pressurized for regeneration When the off line chamber is pressurized the Purge Pressure Indica tor will read system pressure Calculation of Purge Pressure Setting Determine air pressure psig at the dryer inlet Refer to Table C 1 Determine the inlet airflow for your model and inlet air pressure To calculate purge flo
43. TOR SUBASSEMBLY Valve Flange Shaft Subassembly Spacer Mounting Plate Vibration Pad Retaining Plate Sockethead Cap Screw Lockwire Shaft Guide Compression Spring Spring Retainer Slotted Nut Cotter Pin 1 Disassemble Build the actuator subassembly in the order shown by the Actuator Subassembly Diagram Figure 4 15 A Secure the retaining plate in the jaws of a vise B Apply Loctite RC 620 to the threads of the shaft guide and thread it into the retaining plate Using a 1 combination wrench tighten with ap proximately 80 100 Ibs force Note Loctite RC 620 must be applied to the shaft guide to prevent loosening during operation 1 1 4 1 1 1 4 1 1 1 1 1 1 C Tighten cap screws to 4 5 Ibs torque D Lockwire cap screws as shown in Detail B Note Correctly applied lockwire will tend to tighten both cap screws ooy Figure 4 15 DETAIL B STEP 2 STEP 3 A NOTE AB 1 WIRE SHOULD BE TWISTED TIGHTLY AND WITHOUT BN 2 SLACK USE WIRE 2 TWISTER PLIERS 1 TWIST A amp B 2 INSERT B THROUGH CONNECTOR 1 1 TWIST amp B 1 INSERT WIRE THROUGH CONNECTOR 2 2 Adjust orifice stroke DETAIL C A Invert the actuator subassembly and place in a 4 5 vice as shown in Detail C PRESSURE B Gently press the flange to the orifice C Tighten the nut until the spring retainer slightly contacts the shaft guide Sse
44. a very slight continuous gas bleed is felt exhausting from the bleed valve s exhaust port En sure that the granular indicator crystals remain mo tionless after final adjustment Refer to Appendix A Appendix C for 100 F pdp of this manual and calculate your dryer model s purge pressure setting as instructed Locate the Purge Adjusting Valve Slowly rotate dryer s Purge Adjusting Valve until the Purge Pres sure Indicator indicates the calculated purge pressure setting See following Note Note The purge pressure can only be read and ad justed when an off stream desiccant chamber has depressurized for regeneration When the off stream chamber is pressurized the Purge Pressure Indicator will read system pressure For dryers with the Hydrobloc Compu Save Energy Management System During operation in the Energy Management Mode the off stream chamber may re main pressurized in ENERGY MANAGEMENT AC TIVE If this condition is noted proceed as follows to adjust purge pressure a Open Dryer Control System Enclosure Locate DIP switches on MEC CPU Board b Switch DIP switch position 7 to OFF position down De energize dryer s electrical power sup ply for approximately fifteen 15 seconds then re energize Dryer is now in Fixed Cycle Opera tion The off stream chamber will depressurize to atmosphere for regeneration c Calculate and set purge pressure as previously instructed d Return DIP switch p
45. ally switch the system from left to right and right to left chamber dry ing on a fixed time cycle If the system fails to switch drying chambers twice within its designated NEMA Cycle refer to the TROUBLESHOOTING GUIDE If a Hydrobloc Compu Save Energy Management System Control indicates a High Humidity Warning upon start up it should automatically shift to EN ERGY MANAGEMENT ACTIVE within twenty four 24 hours of start up If system fails to shift to EN ERGY MANAGEMENT ACTIVE within this time pe riod refer to the TROUBLESHOOTING GUIDE and conduct checks listed for HIGH HUMIDITY WARN ING See following Note Note The system will operate in a fixed cycle ac companied by a HIGH HUMIDITY WARNING until the desiccant beds have been regenerated to the extent necessary to provide a process gas supply at the dryer s rated dew point The control system will then automatically shift to ENERGY MANAGEMENT AC TIVE During normal dryer operation ENERGY MAN AGEMENT ACTIVE the off stream desiccant cham ber will depressurize and begin regenerating purging ONLY when the need for a regeneration cycle is sensed by the chamber s Compu Save Humidity Sensor Otherwise the off stream chamber will re main pressurized 3 7 58 5b b Close the Pilot Gas Supply Valve c Open the Pilot Gas Filter s Bleed Valve Allow pi lot gas system to depressurize through the Pilot Gas Filters Bleed Valve When pilot gas pres sure is suffic
46. an the Purge Exhaust Restrictor connection Consult with your local Deltech Sales Representative for requirements when the equivalent feet of pipe exceeds 100 feet Ce CAUTION 1 STATIC SENSITIVE DEVICES STATIC SENSITIVE DEVICES CAN BE DAMAGED BY ELECTROSTATIC DISCHARGE YOU CAN MINIMIZE THE CHANCES OF DESTROYING SUCH DEVICES BY KNOWING THAT THERE IS A POTENTIAL STATIC SENSITIVE PROBLEM ADHERING TO THE GUIDELINES LISTED BELOW FOR HANDLING THEM USING RECOMMENDED PACKAGING AND BENCH TECHNIQUES 1 2 3 FOLLOW THESE PRACTICES TO MINIMIZE DAMAGE TO STATIC SENSITIVE DEVICES DO NOT WELD ON THIS EQUIPMENT AND OR ASSOCIATED PIPING THE CONTROL IS SENSITIVE TO ELECTRICAL GROUND LOOP VOLTAGES DISCHARGE PERSONAL STATIC BEFORE HANDLING DEVICE USE GROUNDING WRIST STRAP MINIMIZE HANDLING HANDLE STATIC SENSITIVE DEVICES BY THE BODY ONLY DO NOT TOUCH ANY CONNECTORS USE MICROCHIP EXTRACTION AND INSERTION TOOLS KEEP PARTS IN ORIGINAL CONTAINERS UNTIL READY FOR USE DO NOT SLIDE STATIC SENSITIVE DEVICE OVER ANY SURFACE USE ANTISTATIC CONTAINERS FOR HANDLING AND TRANSPORT KEEP PLASTIC VINYL AND POLYSTYRENE FOAM OUT OF THE WORK AREA WHEN REMOVING ASSEMBLIES HANDLE ONLY BY NONCONDUCTIVE EDGES AND NEVER TOUCH OPEN CONNECTORS EXCEPT AT A STATIC FREE WORK STATION PLACING SHORTING STRIPS ON CONNECTOR USUALLY PROVIDES COMPLETE PROTECTION TO INSTALLED STATIC SENSITIVE DEVICES HANDLE STATIC SENSITIVE
47. ching Valves are closed Refer to step 9 The desiccant chambers will immediately begin pressurizing to system pressure as indicated by chamber pressure gauges When both chambers are at supply pressure open the Pilot Gas Supply Valve and disconnect the gas supply to the pilot gas system at the Start Up Ball Valve The Moisture Indicator s if dryer so equipped bleed valve is installed directly into the back of the indicator s body Close the Indicator s Bleed Valve FULLY open the Moisture Indicator Supply Valve Soap bubble test all external piping fittings and con nections Locate and repair all noted points of leak age Do not soap bubble test components lo cated inside dryer control system s enclosure Note Small leaks noted in inlet piping to the dryer will not affect operation other than a slight loss of pressure supplied to the dryer HOWEVER any gas leaks no matter how small detected at or down stream of the dryer outlet MUST BE FIXED to ensure that the dryer will provide a continuous supply of pro cess gas at specified dew point to intended points of use Operation 10 11 12 13 3 6 The Normal Start Up or Restart procedure for mod els LS60 through LS1000 is now complete Proceed to the Normal Operational Checks section of this manual for final operational checks and adjust ments Normal Start Up or Restart For Dryers With DEC Controller 3 6 Dryer Models LS60 through LS1000
48. ckethead cap screws with a corrosion resis tant compound Figure 4 9 3 PURGE EXHAUST SWITCHING VALVE LS1500 Maintenance and Repair 4 17 4 12 Purge and Outlet Check Valve Purge and Outlet Check Valve Maintenance Models 1 560 through LS760 Shoulder Bolt Sockethead Cap Screw O Ring Roll Pin O Ring Pipe Plug Purge Adjusting Valve Valve Guide Note The purge orifice 15 is specifically sized and drilled Tetraseal for your dryer If the purge orifice 5 is lost or damaged O Ring contact your local Deltech Sales Representative for the Check Ball correct replacement Valve Poppet Valve Body Pipe Plug Purge Orifice WARNING Ensure that the dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage 60 00 Note Do Not remove shoulder bolts 1 from the valve body 13 unless wear or damage necessitates replace ment If replacement is required apply Loctite RC 680 to threads upon reassembly HPD gt gt gt 1 Clean and inspect all valve hardware upon disassem bly Replace all software and any hardware which appears damaged or abnormally worn Closely in spect valve poppets 12 check balls 11 purge ad justing valve 7 and associated mating sealing sur faces for any faults w
49. ct filtration as the O ring on the element maintains a positive seal Maintenance and Repair 4 3 Table 4 1 DESICCANT REQUIREMENTS Ibs per chamber 24 42 72 72 92 For Dryer Models LS60 through LS1500 LS1000 LS1250 LS1500 LS2070 LS2580 a Fill each chamber with OPD 4 4mm bead desic cant until the specified quantity has been in stalled Light tapping on the chamber sides with a soft face mallet should yield additional free space to allow installation of the specified quan tity DO NOT TAMP OR RAM DESICCANT For Dryer Models LS2070 and LS2580 a Install the specified quantity of OPD 25 1 4 bead desiccant b Level layer of OPD 25 c Finish filling each chamber with OPD 4 4mm bead desiccant until the specified quantity has been installed Light tapping on the chamber sides with a soft face mallet should yield addi tional free space to allow installation of the specified quantity Do Not Tamp Or Ram Des iccant Note Do not be alarmed if the specified quantity of desiccant cannot be installed in each cham ber Desiccant levels will settle after approxi mately two to three weeks of normal operation Following this settling period desiccant should be added as necessary to return levels to BOT TOM of each chamber s retaining screen when installed 5 Remove the filter cover 6 Unscrew and remove cartridge retaining seal nuts 7 Remove the used element cartridges Discard th
50. cted to compliment the performance of the other components of the system Therefore use of unauthorized parts or supplies or im proper operation will degrade system performance Once the Hydrobloc LS Series Dryer System has been in stalled according to instructions it is ready to be oper ated The system is fully automatic and does not require any auxiliary controls It is designed to run continuously Operation 3 1 3 1 How It Works Incoming air or gas is first passed through the system pre filter to remove liquid water and oil contaminants The dryer then removes vaporous contaminants The dryer s cycle control system alternately cycles the compressed gas flow through the unit s twin desiccant chambers As the vapor laden gas supply enters and flows downward through a desiccant chamber the contaminant vapors are attracted to and adsorbed on the surface of the activated desiccant Adsorption is an exothermic heat releasing process the heat which later contributes to regeneration Dry gas exits the dryer to an afterfilter for particulate removal The clean and dry gas then proceeds downstream into the com pressed air system While one desiccant chamber is in the Drying Cycle previ ously described the opposite off stream chamber depres surizes and proceeds through a fixed time atmospheric pressure regeneration cycle using a portion of the dry out let process air at the design dew point This outlet air is expanded throu
51. d by the customer The dryer s electrical load is indicated on the Dryer Specification La bel located on the inside cover of the dryer con trol enclosure NOTE 4 The manufacturer is not liable for code viola tions component damage downtime or conse quential damages related to customer supplied and installed electrical components and con nections NOTE 5 Exercise CAUTION for Static Sensitive Devices before making electrical connections DRYER CONTROLS FOR HAZARDOUS LO CATIONS Optima dryer controls for hazard ous locations comply with the National Electri cal Code NEC for application in Class I Divi sion 2 Group B through D hazardous loca tions Per NEC 501 3 b all incendive devices power supply common alarm relay fuse that may release enough energy to ignite B through D gases and vapors are located in a NEMA 7 enclosure Also all non incendive devices so lenoid valves DIP switch and pressure switch contacts that do not normally release enough energy to ignite B through D gases and vapors are located in a NEMA 4 enclosure NOTE 6 1 For dryers equipped with an electronic timer the dryer is pre wired and ready to use and is fitted with a power cord Refer to the dryer mounted Specification Plate or the Dryer Specification Sheet located in the front of this manual for your specific dryer model s electrical input requirements Connect the dryer to the power supply specified on the data plate 2
52. dix A refer to Appendix C for 100 F pdp Ensure that the dryers purge flow has been properly calculated and adjusted Inlet gas pressure is below the design pres Check the dryer s inlet pressure and correct if necessary The sure specified on the Dryer Specification La efficiency of the dryer decreases as the inlet pressure de bel located on the inside cover of the dryer creases control system enclosure Inlet gas flow SCFM is above the dryer s Verify the actual flow rate through dryer Reduce flow rate if op design flow rate erating above the inlet flow rate specified on the Dryer Specifica tion Label located on the inside cover of the dryer control system enclosure Troubleshooting Guide 5 1 CHECKS AND REMEDY Check the compressor aftercooler and cooling system Adjust as necessary to bring the dryer inlet temperature to design specification Isolate and depressurize Prefilter Assembly Inspect prefilter cartridges and end seals for loosening and or damage Tighten or replace as necessary CAUTION Each component of an Deltech Air Purification Sys tem has been selected to compliment the performance of the other components of the system Therefore use of unautho rized parts or supplies or improper operation will degrade system performance Check the compressor aftercooler for tube leakage if the aftercooler uses water as the cooling medium Inspect the prefilter automatic drain valve or drain trap
53. dryer operation to compensate for changes in operating conditions Air samples are peri odically taken from within each vessel and passed over a capacitance probe which senses both temperature and relative humidity The dew point of the air within the desic cant bed is then precisely determined While the dryer continues to operate on a fixed drying cycle the regenera tion cycle will not be initiated until a predetermined set point has been reached Purge air consumption is reduced to a minimum The DEC Compu Save Energy Management System is ac tive when the Energy Management System LED indicator is ON b Close the dryer control system enclosure cover and tighten all cover latches CAUTION Do not remove the factory programmed micro computer chip or any I C chip from the logic control circuit board Improper removal will cause irreparable damage to these highly static sensitive components Damage to these components will render the dryer control system in operative until replacement is accomplished by a Deltech Field Service Engineer Do not remove the program identi fication sticker from the microcomputer chip WARNING DIP switches within the control box have been preset at the factory to conform to customer operating con ditions Any tampering with DIP switches will void warranty and may reduce the quality of the product gas Any adjustments of DIP switches should only be made by a qualified Deltech Field Service Engineer
54. e cartridges in accordance with applicable regulations Used elements typically hold contaminants such as compressor lubricants and particulate matter 8 Insert new element cartridges in filter 9 Reinstall element seal nuts Screw seal nuts on until hand tight then tighten an additional one half 1 2 turn 10 Replace filter cover 11 Reinstall bolts to secure filter cover 12 Reattach drain lines if applicable 13 Close service valve 14 Slowly open the inlet isolation valve to prevent a pres sure surge through the filter 15 Once the filter has been pressurized slowly open the outlet isolation valve 16 After both isolation valves have been opened close the system bypass valve The filter is now in service 17 Record the date of the element change in a record book or on the provided Element Change label A new element change label with the updated informa tion should be applied over the previous label each time the element is replaced 4 4 Servicing The Internal Float Drain Valve If Equipped WARNING Ensure that the Dryer and any associated Prefilters and Afterfilters are valve isolated and fully depressur ized before attempting to remove or disassemble any components or subassemblies Failure to do so may result in serious personal injury and or equip ment damage 1 Isolate the filter by opening the system bypass valve refer to Figure 2 1 page 2 2 and closing both inlet and outlet isola
55. ect your equipment and allow safe shutdown time an uninter rupted power supply is recommended Failure to do so may result in wet pilot gas entering the control enclosure and damage to the equipment Failure to provide adequate protection to the input voltage will void warranties 3 Using the conduit connection ports provided connect the electrical input and ground leads to the Power Input and Remote Alarm Terminal Block Make con nections in accordance with the lead connection in scriptions GND H N Connect ground lead GND FIRST NOTE For hazardous locations the Power Input and Re mote Alarm Terminal Block are located in the NEMA 7 en closure CAUTION Do not make any additional wiring connections to terminals H N or GND on the POWER INPUT CAUTION Do not remove the factory programmed micro computer chip or any I C chip from the logic control circuit board Improper removal will cause irreparable damage to these highly static sensitive components Damage to these components will render the dryer control system in operative until replacement is accomplished by a Deltech Field Service Engineer Do not remove the program identi fication sticker from the microcomputer chip WARNING DIP switches within the control box have been preset at the factory to conform to customer operating con ditions Any tampering with DIP switches will void warranty and may reduce the quality of the product gas Any adjustments of DIP
56. ed piping fittings FO1 Connections F02 FO7 Connections and valves as approved by ASME ANSI ASA inenes Unehes etc Separate or special requirements by local inet Outlet inlet Outlet and or municipal codes may also apply 1 NPT 34 NPT 1 NPT 1 NPT NOTE 2 The manufacturer is not liable for code viola INET 7E NET ea UAT tions downtime component failure or conse TARET Ne 7 TAPT quential damages to customer supplied com TANRI nh VET ponents and or equipment 1 NPT 1 NPT 1 NPT 1 NPT T l 1 NPT NPT NPT NOTE 3 Where it is undesirable to interrupt process 1 NPT 1V NPT 1 NPT 1 NPT flow a redundant system with block valves should be installed to permit servicing and ee ee oy ZART ANPA maintenance of the dryer and associated filter PLR R N Z NET ANET assemblies The recommended block valve 2 NPT 2 NPT 2 NPT 2 NPT MUST be of a type which will provide bubble LS1000 3 FLG 2 NPT 3 FLG 3 FLG tight shut off Ball globe or butterfly valves with LS1250 3 FLG 3 FLG 3 FLG 3 FLG soft seats are suitable for this purpose DO 0 4 FLG 4 FLG 4 FLG 4 FLG NOTE 4 All inlet and outlet connections valve and inter LS2580 4 FLG 4 FLG 4 FLG 4 FLG connecting piping MUST be of the same size as the dryer s gas inlet connection or larger FO1 Connections FO2 FO7 Connections The manufacturer and its affiliates are not liable Inches Inches for excessive pressure drops and l
57. eginning start up procedure Refer to the General Arrangement drawing as neces sary for component identification and location while conducting start up and operational procedures Note If your dryer cannot be started or fails to start due to special installation or other problems contact your local Deltech Sales Representative for assis tance Remove the Pilot Gas Filter Bowl Verify that the pi lot gas filter cartridge is installed Replace Filter Bowl ensuring that O ring is properly seated Close the filter bowl bleed valve All Prefilter and Afterfilter Assemblies are shipped WITH filter cartridges installed Verify that prefilter and afterfilter cartridges are installed Prefilter and Afterfilter cartridges are NOT interchangeable and must be installed in their respective assemblies ONLY The proper filter cartridge part number is listed on each Prefilter and Afterfilter Assembly Replace and tighten filter assembly bowls Ensure that O rings are properly seated Operation 3 5 1 right chamber Both Purge Exhaust Switching Valves will close The desiccant chambers will im mediately begin pressurizing to system pressure as indicated by chamber pressure gauges The Moisture Indicator s if dryer so equipped bleed valve is installed directly into the back of the indicator s body Close the Indicator s Bleed Valve FULLY open the Moisture Indicator Supply Valve Soap bubble test all external piping fittings a
58. enever a wet gas sample is received 3 Operation that power is supplied to the drain valve the other LED in dicates that the drain port is open The power indicator turns off when the drain port opens If either LED fails to turn on at the proper time refer to the maintenance section of this manual If the dryer is under warranty call your local representative for authorization before servicing Operation of the automatic drain valve is controlled by an electronic timer The drain opening can be set from 0 5 to 10 seconds The drain cycle can be set from 0 5 to 45 minutes To minimize air losses the timer should be adjusted to open the port just long enough to discharge accumulated condensate The timer is properly set if nothing but air vents at the end of the open period If air vents for more than a few seconds set the timer for a longer cycle or shorter drain opening If liquid is still discharging when the port closes set the timer for a shorter cycle or longer drain opening 3 3 Initial Start Up For Dryers With Fixed Cycle Electronic Timer Controls Models LS60 through LS1000 only WARNING Ensure that the dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage CAUTION Each component of a Deltech Regenerative Desiccant Dryer System has been sele
59. er to Appendix A Appendix C for 100 F pdp of this manual and calculate your dryer model s purge pressure setting as instructed Locate the Purge Adjusting Valve Slowly rotate dryer s Purge Adjusting Valve until the Purge Pres sure Indicator indicates the calculated purge pressure setting See following Note Note The purge pressure can only be read and ad justed when an off stream desiccant chamber has depressurized for regeneration When the off stream chamber is pressurized the Purge Pressure Indicator will read system pressure 10 11 12 13 14 15 16 17 IMPORTANT Water molecules can diffuse through a pinhole size leak even though pressure inside the piping is several hundred PSIG It is not uncommon to have a minute pinhole leak in a gas line cause an increase in dew point from 40 F to 10 F at a dis tance of forty or more feet downstream of the leak SLOWLY open the System Outlet Isolation Valve customer supplied while monitoring the Outlet Pressure Gauge if dryer so equipped DO NOT per mit the Dryer s Outlet Pressure Gauge to exceed a 5 drop in pressure while pressurizing downstream piping Close the System Bypass Valve if gas system has been so equipped Open and adjust the Moisture Indicator s Bleed Valve until a very slight continuous gas bleed is felt ex hausting from the bleed valve s exhaust port Ensure that the granular indicator crystals remain motionle
60. etermine the inlet airflow for your model and inlet air pressure To calculate purge flow consumption on the critical orifice curve Inlet Flow SCFM x 14 7 PSIG 115 Purge SCFM Inlet Pressure PSIG 14 7 PSIG Locate the Critical Orifice Calibration Curve that has been sized for your specific dryer model Cross the Purge Flow requirement calculated above to the same number on the Critical Orifice Calibration Curve Follow this line vertically and then horizontally once intersection is made with the curve line to find the actual purge pressure setting Table A 1 Inlet Airflow at Various Inlet Air Pressures Inlet Air Pressure psig 100 110 120 130 Average Inlet Airflow scfm LS60 LS110 LS130 LS185 LS240 LS270 LS360 LS505 LS630 LS760 LS1000 LS1250 LS1500 LS2070 LS2580 1 Maximum inlet air pressure 150 psig 2 Based on 100 F inlet air temperature and 40 F pressure dew point Maximum recommended inlet temperature 120 F For capacity at inlet temperature higher than 100 F consult your local distributor Purge Curves A 3 HYDROBLOC LS SERIES PURGE CURVES Orifice Dia 129 Gas Air Temp 100 F 6 65 100 90 80 70 60 50 40 30 PURGE PRESSURE P1 PSIG 20 10 4 5 6 7 8 9 10 11 12 13 14 15 PURGE GAS FLOW RATE SCFM Figure A 1 Critical Orifice Calibration Curve LS60
61. eve O Ring Valve Bonnet O Ring Rod Scraper Valve Poppet Machined Bolt Valve Body O Ring Sockethead Cap Screw 60 00 03 4 11 3 Purge Exhaust Switching Valve Maintenance Model LS1500 only WARNING Ensure that the dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage Note Removal of valve body 18 from the dryer manifold is not required unless replacement of O rings 19 or valve body is necessary Note Exploded view illustrates one half of exhaust switching valve only Disassembly of opposite half not shown exploded is identical Clean and inspect all valve hardware upon disassem bly Replace all software and any hardware which appears damaged or abnormally worn Clean and inspect valve seat located inside the valve body 18 As previously noted this can be accom plished without removing the valve body 18 from the dryer manifold Apply an ultra thin film of O ring lubricant to items 3 6 8 12 14 and 19 before reassembly Apply a light coat of lubricant to the sockethead cap screws items 1 and 20 Hand tighten screws until snug Torque item 1 to 20 ft lbs and item 20 to 45 ft lbs 16 Maintenance and Repair 1 4 NOTE 1 When the unit is located in a corrosive environment coat so
62. ey Ireland Etten Leur The Netherlands ASIAN FACILITIES Jaipur India Vadodara India Tokyo Japan Pusan Korea
63. ftware and any hardware which appears damaged or abnormally worn 2 Apply an ultra thin film of O ring lubricant to item 2 before reassembly on f roa Retaining Ring O ring Valve Stem Valve Body 4 17 Pilot Gas Filter Maintenance Models LS2070 and LS2580 WARNING Ensure that the dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage Note Flow through filter assembly is from outside of filter cartridge to the inside center 1 Clean and inspect all hardware upon disassembly Replace filter cartridge software and any hardware which appears damaged or abnormally worn 2 Apply an ultra thin film of O ring lubricant to filter cartridge s O ring and O ring 2 3 Close filter bleed valve 6 following reassembly Head Assembly O Ring Filter Cartridge non cleanable Filter Bowl Band Clamp Filter Bleed Valve Figure 4 18 5 Troubleshooting Guide WARNING Ensure that the Dryer and any associated Prefilters and Afterfilters are valve isolated and fully depressurized before attempting to remove or disassemble any subassemblies or components Failure to do so may result in serious personal injury and or equipment damage WARNING Some of the following troubleshooting checks require entering the Dryer Control Sy
64. ge Pressure Setting in structions in Appendix A Purge or Outlet Check Valve seat is worn damaged or fouled allowing slight pressure leakage to enter regenerating chamber Off stream chamber s Inlet Switching Valve or on stream chamber s Purge Exhaust Switching Valve seat is worn damaged or fouled allowing slight pressure leakage to enter regenerating chamber 1 Loss of power to Operating Status and Alarm Indicators no illumination Both chambers are at line pressure as indicated by the left and right chamber pressure gauges Loss of power supply to or at dryer s electri cal disconnect switch or breaker customer supplied Loose connections at customer power con nections H N GND Control system s power fuse F1 is blown Damaged components 1 CHECKS AND REMEDY Shutdown and Depressurize Dryer Inspect desiccant through fill ports and replace if badly broken dusted or fouled Note If the normally white desiccant is fouled or discolored inspect prefilter cartridges and drain valve or trap Reduce the inlet flow rate as necessary to meet the dryer s de sign flow rate Shutdown and Depressurize Dryer Drain desiccant from chamber Inspect retaining screens through fill and drain ports and clean if fouling is noted Investigate and remedy source of fouling CAUTION Desiccant may be reinstalled if it is not fouled or badly broken Shutdown and Depressurize Dryer Rep
65. gh an orifice further reducing the dew point This extremely dry purge gas in conjunction with the heat of adsorption regenerates the bed Upon completion of the regeneration cycle the desiccant chamber will repres surize and once again be placed on stream for another dry ing cycle The dryer control system utilizes its pilot gas supply to po sition the dryer s inlet and purge switching valves as re quired for the cycle at hand 3 2 Automatic Drain Valve All Hydrobloc LS Series dryers are equipped with an elec tronic drain valve that automatically discharges condensate from the prefilter The automatic drain valve has two LED indicators and a test button to help verify operation Pushing the test button causes the drain port to click open One LED indicates Power ON Light g A Right Chamber a DRYING Light VEY Left Chamber DRYING Light w A WARNING Disconnect the main power supply before removing this cover LJ TT YY Supply pressure to system by slowly opening the System Inlet Isolation Valve customer supplied The Right Chamber Inlet Switching Valve and Left Chamber Purge Exhaust Switching Valve will close The Left Chamber will immediately begin pressurizing to system pressure as indicated by the chamber pressure gauge The Moisture Indicator s if dryer so equipped bleed valve is installed directly into the bac
66. hich could prevent positive seal ing 2 Apply an ultra thin film of O ring lubricant to items 3 5 9 and 10 Do not apply lubricant to check balls 11 or valve poppets 12 IMPORTANT NOTICE Due to potential damage of screwed fasteners from over torquing fatigue and corrosion maintain the following pro cedure Inspect internal threads for conformity to ensure no dam age was caused during previous assembly and or disas sembly and remove all foreign debris Apply a light coat of Never Seize lubricant to the new sockethead cap screws provided in the repair kit Hand tighten screws until snug Torque as outlined in the sched ule below TORQUE TABLE SIZE TORQUE 1 4 0 30 40 inch Ibs 3 4 4 5 Nm 5 16 18 130 135 inch Ibs 14 7 15 3 Nm 3 8 16 240 245 inch Ibs 27 1 27 7 Nm 1 2 13 525 550 inch Ibs 59 3 62 2 Nm Nm Newton meters 4 18 Maintenance and Repair NOTE 1 When the unit is located in a corrosive environment coat items 2 and 3 with a corrosion resistant com pound 2 Torque 1 4 20 screws to 40 in lbs Torque 5 16 18 screws to 135 in lbs Figure 4 10 PURGE AND OUTLET CHECK VALVE ASSEMBLIES LS60 LS110 LS130 LS185 LS240 LS270 LS360 LS505 LS630 LS760 Maintenance and Repair 4 19 1 1 1 2 2 1 2 2 2 2 1 3 4 4 2 1 1 1 2 3 Purge and Outlet Check Valves Flow Block Check Valve Cover Valve Housing Purge Orif
67. ice Hex Plug Purge Adjusting Valve Valve Poppet Poppet Guide Valve Spring Square O Ring O Ring O Ring Sockethead Cap Screw Sockethead Cap Screw Check Ball Valve Guide O Ring Gauge Snubber Square O Ring tem OONDOABRWND 4 13 3 Purge and Outlet Check Valve Maintenance Models LS1000 through LS1500 WARNING Ensure that the Dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any Dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage Note The purge orifice 4 is specifically sized and drilled for your dryer If the purge orifice 4 is lost or damaged contact your local Deltech Sales Representative for the correct replacement Note Do not remove poppet guides 8 from the outlet check valve cover 2 unless wear or damage necessi tates replacement 1 Clean and inspect all valve hardware upon disassem bly Replace all software and any hardware which appears damaged or abnormally worn Closely in spect valve poppets 7 check balls 15 purge ad justing valve 6 and associated mating sealing sur faces for any faults which could prevent positive seal ing 2 Apply an ultra thin film of O ring lubricant to items 10 11 12 17 and 18 Do not apply lubricant to check balls 15 or valve poppets 7 4 20 Maintenance and Repair NOTE 1 When the unit is located in a c
68. iently reduced the Purge Exhaust Switching Valves will automatically open to de pressurize dryer through Purge Exhaust Muffler d SLOWLY open customer supplied depressuriza tion valve to vent the dryer internal air pressure e When all dryer pressure gauges indicate zero pressure close the depressurization valve De pressurization is complete 3 10 Operation 4 Maintenance and Repair Quarterly Check the dry gas outlet dew point A precision Dew Point Analyzer is required to read the exact dew point The ana lyzer should be connected as close to the dryer outlet as is possible Test piping or tubing used to connect the ana lyzer to the gas system must be metallic as rubber and certain plastics contain or permit moisture diffusion from the ambient air and can cause a false high dew point indi cation Alnor Beckman Shaw and several other brands of precision dew point instruments are available Semi Annually WARNING Ensure that the Dryer and any associated Prefilters and Afterfilters are valve isolated and fully depressur ized before attempting to remove or disassemble any components or subassemblies Failure to do so may result in serious personal injury and or equip ment damage CAUTION Each component of a Deltech Regenerative Desiccant Dryer System has been selected to compliment the performance of the other components of the system Therefore use of unauthorized parts or supplies or im proper operation w
69. ier is legally responsible for damage incurred during shipping Shipping damage is not covered by the dryer warranty If goods are received short or damaged notify the carrier and insist on a notation of the loss on the face of the bill of lading Otherwise no claim can be enforced against the carrier If concealed loss or damage is discovered notify the car rier at once and request an inspection The carrier will make an inspection and grant a concealed damage nota tion The carrier will not consider any claim for loss or dam age unless an inspection has been made If you give the carrier a clear receipt for goods that have been damaged or lost in transit you do so at your own risk and expense If there is any damage file a claim with the carrier contact your local distributor or the factory before attempting to in stall subject equipment 2 2 Equipment Handling Note Should questions arise concerning site selection installation operation etc please contact your local Deltech Sales Representative for assistance WARNING Use appropriate load rated lifting equipment and observe safe lifting procedures during all moves The unit should be carefully unloaded as close as is possible to final installation site to minimize chances of equipment damage Refer to the drawings en closed with this manual for equipment shipping weight 2 4 General Piping Information Table 2 1 CONNECTIONS NOTE 1 Use the proper pressure rat
70. ill degrade system performance 1 Inspect the Pilot Gas Filter Cartridge and replace if the used cartridge appears clogged dirty or exces sively corroded 2 Inspect the Prefilter Cartridges for clogging exces sive corrosion cracked or damaged end seals or high pressure drop differential pressure exceeds 10 PSID Replace cartridges if necessary 3 Inspect the Afterfilter Cartridges for clogging exces sive corrosion cracked or damaged end seals or high pressure drop differential pressure exceeds 10 PSID Replace cartridges if necessary Maintenance and Repair 4 1 Preventative Maintenance Schedule 4 1 Weekly Check the following operating conditions a Purge pressure setting during regeneration b Inlet pressure c Inlet flow rate d Inlet temperature For optimum dryer operation and performance these recorded parameters should correspond as close as is possible to the design operating conditions and specifications noted on the Dryer Specification Label located on inside cover of dryer control enclosure Visually inspect the Moisture Indicator if dryer is so equipped for a BLUE dry indication If the indicator is PINK wet in color refer to the Troubleshooting Guide and conduct checks listed for the Moisture In dicator Check the dryer s Indicator Panel for the presence of any illuminated alarm indicators If an alarm indicator is illuminated refer to the Troubleshooting Guide Check the
71. in accordance with the following instructions Dryer Models LS60 through LS1250 WARNING Ensure that the Dryer and any associated Prefilters and Afterfilters are valve isolated and fully depressur ized before attempting to remove or disassemble any components or subassemblies Failure to do so may result in serious personal injury and or equip ment damage 1 Isolate the filter by opening the system bypass valve refer to Figure 2 1 page 2 2 and closing both inlet and outlet isolation valves 2 Open the service valve to vent the filter to atmospheric pressure 3 Disconnect drain lines at manual and automatic drain valves if installed WARNING A hissing sound while the bowl is being removed indicates the filter has not been properly depressur ized DO NOT continue to remove the bowl until the filter has been completely vented to atmospheric pressure CAUTION Filter bowls may be heavy Caution should be taken when removing the bowl 4 Remove the bottom bowl by unscrewing it from the head A strap wrench may be needed 5 Remove the element from the filter head with a brisk downward pull or by working the element back and forth until it snap frees Discard the element in ac cordance with applicable regulations Used elements typically hold contaminants such as compressor lu bricants and particulate matter Note The element may be unsnapped by differential pres sure in normal operation This will not affe
72. ior to shipment unless otherwise specified by the customer On Models LS2070 and LS2580 desiccant is shipped loose Tapping on each chamber with a soft face mallet will yield a deadened sound if desiccant has been in stalled If a hollow sound is noted the chambers are empty and require installation of desiccant prior to operation Refer to the Desiccant Charging Proce dure in the Maintenance and Repair section of this manual if charging is necessary CAUTION Dryer models covered within the scope of this manual are designed to use a specific desiccant Use of any other size or type may reduce efficiency or damage the dryer CAUTION Do not hydrostatically test the dryer with desiccant installed All pressure vessels are factory tested at one and one half 1 1 2 times the design pressure Hydrostatic testing will damage the dryer s desiccant charge 4 While exercising caution for Static Sensitive Devices open the Dryer Control System Enclosure Cover and inspect as follows a Check all terminal block wiring connections Do not over tighten terminal block lug screws Installation 2 5 CAUTION Surges spikes and input voltage of less than eighty five 85 VAC or greater than one hundred and thirty two 132 VAC may cause the Dryer Con trol System to operate erratically or malfunction This malfunction may or may not be accompanied by an alarm Adequate surge spike brownout and blackout protection must be provided to prot
73. ithout removing the valve body 9 from the dryer manifold Apply an ultra thin film of O ring lubricant to items 3 6 8 12 14 and 23 before reassembly Apply a light coat of lubricant to the sockethead cap screws items 1 20 and 22 Hand tighten screws until snug Torque items 1 and 20 to 20 ft lbs and item 22 to 45 ft lbs 12 Maintenance and Repair 1 4 NOTE 1 When the unit is located in a corrosive environment coat sockethead cap screws with a corrosion resis tant compound Figure 4 7 3 INLET SWITCHING VALVE LS1250 LS1500 Maintenance and Repair 4 3 2 Switching Valve Components 8 2 4 2 2 2 2 2 2 2 2 2 2 2 2 1 2 4 Sockethead Cap Screw Valve Cover O Ring Valve Piston Piston Seal Bonnet Cylinder Valve Bonnet O Ring Rod Scraper Poppet Shaft O Ring Seal Retainer Valve Seat Seal Retaining Disc Seal Nut Valve Body Square O Ring Sockethead Cap Screw 60 00 03 4 10 2 Purge Exhaust Switching Valve Maintenance Model LS1250 only WARNING Ensure that the Dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any Dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage Note Removal of valve body 16 from the dryer manifold is not required unless replacement of square O rings 17 or valve body is necessary
74. k of the indicator s body Close the Indicator s Bleed Valve FULLY open the Moisture Indicator Supply Valve Soap bubble test all external piping fittings and con nections Locate and repair all noted points of leak age Do not soap bubble test components lo cated inside dryer control system s enclosure Note Small leaks noted in inlet piping to the dryer will not affect operation other than a slight loss of pressure supplied to the dryer HOWEVER any gas leaks no matter how small detected at or down stream of the dryer outlet MUST BE FIXED to ensure that the dryer will provide a continuous supply of pro cess gas at specified dew point to intended points of use IMPORTANT Water molecules can diffuse through a pinhole size leak even though pressure inside the piping is several hundred PSIG It is not uncommon to have a minute pinhole leak in a gas line cause an increase in dew point from 40 F to 10 F at a dis tance of forty or more feet downstream of the leak SLOWLY open the customer supplied System Outlet Isolation Valve while monitoring the Outlet Pressure Gauge if dryer so equipped DO NOT permit the Dryer s Outlet Pressure Gauge to exceed a 5 drop in pressure while pressurizing downstream piping Close the customer supplied System Bypass Valve if installed Open and adjust the Moisture Indicator s Bleed Valve until a very slight continuous gas bleed is felt exhausting from the bleed valve s exhau
75. lace MEC Board Valve Failure Alarm 1 Damaged or out of calibration pressure Shutdown and Depressurize Dryer Replace pressure sen sensor sor 5 6 Troubleshooting Guide CHECKS AND REMEDY 1a Verify the actual inlet flow rate Reduce flow rate if operating above the inlet flow rate specified on the Dryer Specification La bel If the verified inlet flow rate is not exceeding the specified de sign flow rate proceed to POSSIBLE CAUSE 1b Allow the dryer to remain energized and operating in a fixed cycle The High Humidity Alarm will de energize followed by the con trol system s return to Energy Management System EMS Ac tive AFTER the excessive moisture load has been purged from the desiccant beds 1 SLOWLY rotate Purge Adjusting Valve until correct purge pressure setting is noted on the Purge Pressure Indicator Note The purge pressure setting can only be read and ad justed when the off stream chamber has depressurized for re generation When the off stream chamber is pressurized the Purge Pressure Indicator will read system pressure Shutdown and Depressurize Dryer Refer to the Purge and Outlet Check Valve Maintenance procedure which is applicable to your specific dryer model Disassemble clean and inspect the Purge and Outlet Check Valves Replace all worn or dam aged components as noted Troubleshooting Guide 5 7 PROBLEM POSSIBLE CAUSE High Humidity Warning Note A High Humidity Warning
76. lace damaged faulty or out of calibration gauges Shutdown and Depressurize Dryer Proceed as follows a For Model LS1250 only 1 Provide adequate support for muffler and flow restrictor assembly Remove flow restrictor assembly from lower flange by equally loosening flange bolts En sure that the method of support is prepared to ac cept the Muffler s full weight when the last bolt is removed see following CAUTION CAUTION Exercise caution when lowering flow restrictor and muffler to prevent damaging control tub ing and the Purge Pressure Indicator Remove clean and inspect the spring and orifice type flow restrictor Install a new flow restrictor if damage is noted Important When installing Flow Restrictor its springs MUST be fully seated in the spring receptacle This MUST be accomplished for proper operation Reinstall muffler and flow restrictor in the reverse order of removal PROBLEM POSSIBLE CAUSE Excessive pressure drop across dryer Badly broken dusted or fouled desiccant Inlet flow rate SCFM is exceeding the dryer s design flow rate as specified on the Dryer Specification Label located on the in side cover of the dryer system control enclo sure Desiccant retaining screens are clogged or fouled Inlet and or outlet pressure gauges are out of calibration or damaged 1 4 Chamber depressurization prior to each regen eration cycle is excessively loud The purge exhau
77. ld be in Compu Save En ergy Saver Mode 14 15 16 17 18 19 Close any manual vent or drain valves installed in prefilter and afterfilter assemblies If the prefilter assembly utilized was factory equipped with an automatic drain valve or drain trap inspect for and remove pipe plug or cap which may have been installed in drain port for shipping pur poses Ensure that all associated pipe and tubing connec tions flanges unions plugs mounting bolts pipe hangers etc have been checked tight and or prop erly secured IMPORTANT It is recommended that the System s process gas output not be consumed or used at the intended points of use until the Start Up and any re lated adjustments have been completed and the system is producing process gas of the required quality The quality of the process gas should be verified through test and analysis when a specific quality process gas is required Supply compressed air up to Inlet Isolation Valve Close the Pilot Gas Supply Valve and pressurize the pilot gas system with compressed gas to line pres sure Use the Ball Valve located in the pilot gas line prior to the Pilot Gas Filter and after the Pilot Gas Supply Valve Both desiccant chamber Inlet Valves will open and both Purge Exhaust Valves will close Supply pressure to system by slowly opening the System Inlet Isolation Valve customer supplied Both Inlet Switching Valves are open Both Purge Exhaust Swit
78. libration Curve LSC60 C 6 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers 7 C HYDROBLOC LSC PURGE CURVES Orifice Dia 129 Gas Air Temp 100 F C 65 PURGE GAS FLOW RATE SCFM Figure 6 2 Critical Orifice Calibration Curve LSC110 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers 100 90 80 70 60 50 40 30 20 10 PURGE PRESSURE P PSIG HYDROBLOC LSC PURGE CURVES Orifice Dia 156 Gas Air Temp 100 F 6 65 100 90 80 70 60 50 40 30 PURGE PRESSURE P1 PSIG 20 10 4 6 8 10 12 14 16 18 20 22 24 26 PURGE GAS FLOW RATE SCFM Figure 6 3 Critical Orifice Calibration Curve LSC130 C 8 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers 9 0 HYDROBLOC LSC PURGE CURVES Orifice Dia 172 Gas Air Temp 100 F 6 65 8 10 12 14 16 18 20 22 24 26 28 PURGE GAS FLOW RATE SCFM Figure C 4 Critical Orifice Calibration Curve LSC185 Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers 100 90 80 70 60 50 40 30 20 10 PURGE PRE
79. lished for proper opera tion 3 Reinstall muffler and flow restrictor assembly in the reverse order of removal 4 22 Maintenance and Repair FLOW RESTRICTOR ASSEMBLY 1 Valve Body Actuator Subassembly Valve Flange O Ring Hex Nut Threaded Stud lt PURGE FLOW Figure 4 13 ACTUATOR SUBASSEMBLY 4 15 Flow Restrictor Maintenance Models LS1500 through LS2580 WARNING Ensure that the dryer and any associated prefilters and afterfilters are valve isolated and fully depressur ized before attempting to remove or disassemble any components or subassemblies Failure to do so may result in serious personal injury and or equipment damage 1 Clean and inspect the assembly Check operation of the assembly If a tendency to bind erratic operation damage and or excessive wear is noted disassemble and repair the assembly DISASSEMBLY ASSEMBLY INSTRUCTIONS 1 Disassemble Build the flow restrictor assembly in the order shown by the Flow Restrictor Assembly Dia gram Figure 4 14 A Hand tighten studs in sequence shown in Detail A B Tighten studs in sequence shown to 30 ft lbs torque C Leak check valve FLOW RESTRICTOR ASSEMBLY DETAIL A TORQUE SEQUENCE 1660 Oo 3 4 O O 2 Figure 4 14 Maintenance and Repair 4 23 ACTUATOR SUBASSEMBLY DISASSEMBLY ASSEMBLY INSTRUCTIONS ACTUA
80. lowby of on stream chamber s pressure through faulty check valve to the off stream chamber Troubleshooting Guide 1 2 5 8 9 5 CHECKS AND REMEDY Clean diaphragm Check and replace connector or timer assembly Check and correct power supply and connections Replace timer assembly Replace solenoid coil Clean ports Check and correct power supply and connections Replace timer assembly Troubleshooting Guide PROBLEM POSSIBLE CAUSE Automatic drain valve continually discharging or venting 1 Clogged diaphragm 2 Short in electrical component Automatic drain valve not discharging No electrical power Timer malfunction Solenoid coil malfunction Clogged ports No response when push to test button on auto matic drain valve is pressed 1 No electrical power 2 Timer malfunction Appendix A Purge Curves HYDROBLOC LS SERIES PURGE CURVES Locate the Purge Adjusting Valve Slowly rotate dryer s Purge Adjusting Valve until the Purge Pres sure Indicator indicates the calculated purge pressure setting See following Note Note The purge pressure can only be read and ad justed when an off line desiccant chamber has de pressurized for regeneration When the off line cham ber is pressurized the Purge Pressure Indicator will read system pressure Calculation of Purge Pressure Setting Determine air pressure psig at the dryer inlet Refer to Table A 1 D
81. nd Outlet Check Valves Replace all worn or dam aged components as noted Shutdown and Depressurize Dryer Refer to the Inlet Switch ing Valve and Purge Exhaust Switching Valve Maintenance pro cedures which are applicable to your specific dryer model Dis assemble clean and inspect the Inlet Switching Valves and Purge Exhaust Switching Valves Replace all worn or damaged components as noted Check power disconnect switch or breaker CLOSED If tripped breaker or blown fuse is noted investigate and remedy cause De energize Dryer Power Supply Check power supply input wiring connections H N GND De energize Dryer Power Supply Replace fuse if blown in vestigate and remedy cause For damaged solid state components and or circuit boards of microprocessor units contact your local Deltech Sales Repre sentative for assistance Troubleshooting Guide 1 PROBLEM POSSIBLE CAUSE Back pressure on a desiccant chamber during the regeneration cycle Chamber s pressure gauge indicates above zero 0 PSIG Note The presence of back pressure will result in insufficient regeneration followed by dew point degradation An off stream chamber s pressure gauge MUST indicate zero 0 PSIG throughout all regeneration cycles Purge Adjusting Valve is supplying excessive purge gas to regenerating chamber as indi cated by the Purge Pressure Indicator gauge Note If correct setting is unknown refer to the Calculation of Pur
82. nd con nections Locate and repair all noted points of leak age Do not soap bubble test components lo cated inside dryer control system s enclosure Note Small leaks noted in inlet piping to the dryer will not affect operation other than a slight loss of pressure supplied to the dryer HOWEVER any gas leaks no matter how small detected at or down stream of the dryer outlet MUST BE FIXED to ensure that the dryer will provide a continuous supply of pro cess gas at specified dew point to intended points of use IMPORTANT Water molecules can diffuse through a pinhole size leak even though pressure inside the piping is several hundred PSIG It is not uncommon to have a minute pinhole leak in a gas line cause an increase in dew point from 40 F to 10 F at a dis tance of forty or more feet downstream of the leak SLOWLY open the System Outlet Isolation Valve customer supplied while monitoring the Outlet Pressure Gauge if dryer so equipped DO NOT per mit the Dryer s Outlet Pressure Gauge to exceed a 5 drop in pressure while pressurizing downstream piping Close the System Bypass Valve if gas system has been so equipped Open and adjust the Moisture Indicator s Bleed Valve until a very slight continuous gas bleed is felt ex hausting from the bleed valve s exhaust port Ensure that the granular indicator crystals remain motionless after final adjustment Energize the dryer s electrical power supply Ref
83. ng CAUTION CAUTION Sight Dome 2 is an acrylic plastic Do Not clean with any type of solvent Replace O ring 9 and re install screw 6 in sight dome 2 Carefully pour new granular indicator into sight dome 2 Slide porous disc 4 into place Replace O ring 7 and re install sight dome assembly items 2 4 6 7 and 9 in body 8 Fully open the moisture indicator s gas supply valve not shown Adjust bleed valve 5 until only a very slight constant gas bleed valve is felt exhausting from valve s bleed port Ensure that granular indicator remains motion less after final adjustment Maintenance and Repair 4 7 4 6 Moisture Indicator 4 Recharging Procedure Note Dryer shutdown is not necessary to perform the fol lowing procedure and can be accomplished without remov 5 ing the entire assembly 1 Close the Moisture Indicator Supply Valve and en 6 sure that the Moisture Indicator has fully depressur ized through bleed valve 5 before proceeding to step 2 for disassembly See following WARNING WARNING Ensure that Moisture Indicator is fully depressur ized before attempting disassembly Failure to do so may result in serious personal injury and 9 or equipment damage 2 Remove sight dome assembly items 2 4 6 7 and 9 from body 8 by turning screw 6 counter clockwise 3 Remove screw 6 from sight dome 2 by exerting pressure on scre
84. ngs and con nections Locate and repair all noted points of leak age Do not soap bubble test components lo cated inside dryer control system s enclosure Note Small leaks noted in inlet piping to the dryer will not affect operation other than a slight loss of pressure supplied to the dryer HOWEVER any gas leaks no matter how small detected at or down stream of the dryer outlet MUST BE FIXED to en sure that the dryer will provide a continuous supply of process gas at specified dew point to intended points of use Operation 3 3 15 Refer to Appendix A Appendix C for 100 F pdp of this manual and calculate your dryer model s purge pressure setting as instructed 16 Locate the Purge Adjusting Valve Slowly rotate dryer s Purge Adjusting Valve until the Purge Pres sure Indicator indicates the calculated purge pressure setting See following Note Note The purge pressure can only be read and ad justed when an off stream desiccant chamber has de pressurized for regeneration When the off stream chamber is pressurized the Purge Pressure Indicator will read system pressure 17 The Start Up procedure for models LS60 through LS1000 is now complete Proceed to the Normal Op eration Checks section of this manual for final opera tional checks and adjustments 3 4 Initial Start Up For Dryers With DEC Controller WARNING Ensure that the dryer is de energized valve isolated and fully depressurized befo
85. ntain chemicals and or gases that are hazardous toxic and or flammable It is recom mended that all used desiccant be analyzed to deter mine content before disposal Exercise proper care and procedures during handling and storage of used materials All containers must be properly labelled and disposed of in accordance with Local State and Federal regulations 1 _ Remove the desiccant fill port plug or drain port flange installed in the top of each desiccant chamber Clean and inspect the fill port closure Note If this is an Initial Desiccant Installation Proce dure go to Procedure 8 2 Place acontainer suitable for receiving the spent des iccant under the desiccant chambers 3 Remove desiccant drain port plug or drain port flange from the bottom of each desiccant chamber When the drain port plug or drain port flange is removed the desiccant will begin draining 4 Use a flashlight to inspect each chamber through its respective fill port to ensure that all desiccant has been drained LIGHT tapping on the chamber sides with a soft face mallet will remove any desiccant that may have remained in each chamber 5 Use a wire brush to clean drain ports and drain port plug threads 6 Apply TFE tape to drain port plug threads Reinstall drain port plugs or drain port flanges into each drain port Torque drain port plugs or flange bolts to a rea sonable limit 7 Refer to Table 4 1 for the quantity of desiccant and tabular s
86. orrosive environment coat items 13 and 14 with a corrosion resistant compound Torque 5 16 18 screws to 135 in lbs Torque 3 8 16 screws to 245 in lbs N Figure 4 11 3 PURGE AND OUTLET CHECK VALVE ASSEMBLIES LS1000 LS1250 LS1500 Maintenance and Repair 4 21 Purge Exhaust Spring Orifice Assembly Flow Restrictor Assembly Figure 4 12 4 14 Remote Flow Restrictor Maintenance Model LS1250 only WARNING Ensure that the dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage 1 Remove muffler as follows a Provide adequate support for muffler and flow restrictor assembly Remove flow restrictor assembly from lower flange by equally loosening flange bolts Ensure that the method of support is prepared to accept the muffler and flow restrictor s full weight when the last bolt is removed see following CAUTION CAUTION Exercise caution when lowering muf fler and flow restrictor to prevent damaging con trol tubing and the Purge Pressure Indicator 2 Remove clean and inspect the spring and orifice type flow restrictor Install a new flow restrictor if damage is noted IMPORTANT When installing Flow Restrictor its springs must be fully seated in the spring recep tacle This must be accomp
87. osition 7 to ON position De energize the dryer s electrical power supply for approximately fifteen 15 seconds then re energize Dryer should be in Compu Save En ergy Saver Mode Operation 12 13 14 15 16 3 4 For dryers with the Hydrobloc Energy Management System During operation in the Energy Manage ment Mode the off stream chamber may remain pressurized in ENERGY MANAGEMENT ACTIVE If this condition is noted proceed as follows to adjust purge pressure a Open Dryer Control System Enclosure Locate DIP switches on MEC CPU Board b Switch DIP switch position 7 to OFF position down De energize dryers electrical power sup ply for approximately fifteen 15 seconds then re energize Dryer is now in Fixed Cycle Opera tion The off stream chamber will depressurize to atmosphere for regeneration c Calculate and set purge pressure as previously instructed d Return DIP switch position 7 to ON position De energize the dryer s electrical power supply for approximately fifteen 15 seconds then re energize Dryer should be in Compu Save En ergy Saver Mode The Start Up procedure for models LS1250 and LS1500 is now complete Proceed to the Normal Op eration Checks section of this manual for final opera tional checks and adjustments Dryer Models LS2070 and LS2580 Do not start the dryer with compressed air flow through the dryer Close customer supplied dryer shut off valves before b
88. oss of ca inlet Outlet inet Outlet pacity caused by undersized or incorrectly in 1580 2 NPT 2 NPT T NPT T NPT stalled piping and or piping components Refer eG NDT ee to Table 2 1 for inlet and outlet connection sizes for your dryer system LSC130 1 NPT 34 NPT 1 NPT 1 NPT LSC185 1 NPT 34 NPT 1 NPT 1 NPT NOTE 5 Carefully inspect all piping lengths and compo LSC240 114 NPT 1 NPT 1 NPT NPT nents BEFORE installation Remove any inter 150270 NPT 1 NPT 1 NPT 17 NPT nal oil water dirt or debris which may have 150360 1 NPT 114 NPT NPT 1 NPT accumulated during shipment and or storage LSC505 2 NPT 1 1 NPT 2 NPT NOTE 6 Leakage from piping connections and or asso LSC630 2 NPT 1 NPT 11 NPT 2 NPT ciated components installed upstream of the dryer will cause a loss of gas pressure and un necessary compressor cycling The slightest leakage from piping connections and or asso ciated components installed downstream of the dryer s outlet connection can easily cause a degradation of the dried gas dew point The use of TFE tape on all male pipe threads and the application of sufficient torque at assembly will greatly reduce chances of leakage and subsequent rework 2 NPT 2 NPT 2 NPT 2 NPT 22 NPT 2 NPT 2 NPT 3 FLG 3 FLG 3 FLG 3 FLG 3 FLG 3 FLG 3 FLG 3 FLG 4 FLG 4 FLG 4 FLG 4 FLG 4 FLG 4 FLG 4 FLG 4 FLG LSC760 2 NPT LSC1000 LSC1250 LSC1500 LSC20
89. panel indicates when the left chamber is drying Right Chamber DRYING Light The Right Chamber DRYING light on the DEC control panel indicates when the right chamber is drying Valve Switching Failure Option A amp B This alarm is triggered when the drying chambers are not in the correct pressure state The chamber pressure switch should be open on the on stream chamber and closed on the regenerating chamber If triggered the dryer control system will energize the red LED on the DEC control panel labeled VALVE FAILURE and de energize the common alarm relay The alarm automatically clears once the alarm conditions are corrected Chamber Pressure Gauges A gauge mounted on the inlet valve block models LS60 through LS1500 or panel mounted models LS2070 and LS2580 indicates which chamber is on stream and which is regenerating The gauge for the on stream chamber in dicates operating pressure the gauge for the regenerating chamber should indicate 0 psig Purge Flow Indicator A locally mounted gauge indicates purge air pressure as an approximate measure of purge air flow when used with the appropriate calibration curve found in Appendix A for 100 F pdp refer to Appendix C Moisture Indicator Option A amp B An indicator utilizing specially treated silica gel which changes color to alert personnel of a moisture problem re quiring corrective action The indicator is blue when dry but gradually changes to pink in color wh
90. peration or mainte nance Failure to follow the operating and maintenance procedures of the instruction manual could result in per sonal injury or property damage To facilitate maintenance a Recommended Spare Parts List is included in the manual for your specific dryer model Failure to maintain recommended spare parts and filter cartridges may result in EXPENSIVE and unneces sary downtime for which the manufacturer cannot be re sponsible To request a quotation or place an order for recommended or emergency spare parts please contact your local Deltech Sales Representative A Dryer Specification Label has been permanently at tached to the inside cover of the dryer control enclosure When requesting information service ordering of spare parts etc please reference all information supplied on the Specification Label All information specifications and illustrations within this manual are those in effect at the time of printing The manufacturer reserves the right to change or make im provements without incurring any obligation to make changes or add improvements to products previously sold 1 2 General System Information CAUTION The Deltech Hydrobloc LS Series heaterless regenerative desiccant dryer system is designed to se quentially remove contaminants The Prefilter removes liq uid and particulate contaminants the Dryer removes vapor ous contaminants and the Afterfilter removes any remaining particulates Bypa
91. pressure drop differential pressure across the Prefilters and Afterfilters Prefilter and afterfilter cartridges should be replaced BEFORE a differential pressure of 10 PSID is exceeded CAUTION Each component of a Deltech Regenera tive Desiccant Dryer System has been selected to compliment the performance of the other components of the system Therefore use of unauthorized parts or supplies or improper operation will degrade system performance Check operation of the prefilter s automatic drain valve This component must function properly to maintain filter efficiency and prevent premature desic cant failure induced by liquid and oil carry over from the prefilter due to a clogged or inoperative automatic drain valve 1 CAUTION Prior to installing desiccant review all appli cable Material Safety Data Sheets and container warnings Safety Data Sheets may be obtained from the manufactur ers Safety Coordinator Exercise all necessary precau tions for your health and welfare WARNING A static electric charge can build up when pouring desiccants or dry powders Proper grounding should be observed when pouring from a container bag drum etc WARNING Do not transfer desiccant under pressure Malfunc tion or improper use of equipment can propel beads with enough velocity to penetrate skin WARNING Used desiccant material must be handled with special care Desiccant is an adsorbent material Used des iccant may co
92. provided Element Change label A new element change label with the updated informa tion should be applied over the previous label each time the element is replaced Dryer Models LS1500 through LS2580 WARNING Ensure that the Dryer and any associated Prefilters and Afterfilters are valve isolated and fully depressur ized before attempting to remove or disassemble any components or subassemblies Failure to do so may result in serious personal injury and or equip ment damage 1 Isolate the filter by opening the system bypass valve refer to Figure 2 1 page 2 2 and closing both inlet and outlet isolation valves 2 Open the service valve to vent the filter to atmospheric pressure 3 Disconnect drain lines at manual and automatic drain valves if installed 4 Remove the bolts securing the filter cover to the ves sel 4 4 Maintenance and Repair ized DO NOT continue to remove the bowl until the 13 Slowly open the inlet isolation valve to prevent a pres filter has been completely vented to atmospheric sure surge through the filter ressure p 14 Once the filter has been pressurized slowly open the CAUTION Filter bowls may be heavy Caution should be outlet isolation valve taken when removing the bowl 15 After both isolation valves have been opened close 4 Remove the bottom bowl by unscrewing it from the the system bypass valve The filter is now in service head A strap wrench may be needed 5
93. r Temp 100 F 6 65 110 100 90 80 70 60 50 PURGE PRESSURE P PSIG 40 30 20 10 100 150 200 250 300 350 400 450 500 550 600 650 PURGE GAS FLOW RATE SCFM Figure A 13 Critical Orifice Calibration Curve LS20700 LS2580 A 16 Purge Curves Appendix B Replacement Parts Replacement Parts B 1 HYDROBLOC LS REPLACEMENT PARTS Description Quantity Model Model Model Model Model Required LS60 LS110 LS130 LS185 LS240 Muffler o OE 1283853 1283853 1283853 1283853 1283853 Relief Valve 1124704 1124704 1124704 1124704 1124704 1125546 1125546 1125546 1125546 6 AQUADEX Repair Kit 1207278 1207278 1207278 1207278 1207278 Inlet Exhaust Valve Packing Kit 1283204 1283204 1283214 1283214 1283222 Purge Valve Packing Kit 1283207 1283207 1283207 1283207 1283233 Inlet Exhaust Valve Repair Kit 1283203 1283203 1283213 1283213 1283221 Purge Valve Repair Kit 1283206 1283206 1283206 1283206 1283232 Purge Orifice 1218634 1180925 1180926 1198157 1218635 Solid State Controller 1275442 1275442 1275442 1275442 1275442 Solenoid Valve 1275475 1275475 1275475 1275475 1275475 Solenoid Coil 1284506 1284506 1284506 1284506 1284506 Control Board CPU 1274947 1274947 1274947 1274947 1274947 Programmed IC 1270702 1270702 1270702 1270702 1270702 Fuse 1 2AMP 1222239 1222239 1222239 1222239 1222239 Power Supply 1261094 1261094 1261094 126
94. r improper operation will degrade system performance 1 2 1 Dryer This fully automatic heaterless type dryer alternately cycles the compressed process gas flow through two des iccant filled vertical chambers where the gas s entrained vaporous moisture content is adsorbed One desiccant chamber is always on stream in a timed DRYING CYCLE throughout normal dryer operation The opposite off stream chamber is in a timed REGENERATION CYCLE for removal of the desiccant s previously adsorbed moisture content or in a static or steady state pressurized condition The dryer s fail safe design feature provides continued process gas flow through both desiccant chambers if the control system s power supply is lost or interrupted 1 2 2 Prefilter Assembly As the first line of defense against oil water contaminants a Deltech D Series Coalescing Prefilter with an automatic drain is required The Deltech D Series Coalescing Prefilter Assembly re moves oil and water aerosols as well as dirt and pipe scale from the gas stream BEFORE the gas enters the dryer Oil and liquids collected by the assembly s filter cartridges fall to the housing sump which must be periodi cally drained General Information 1 1 1 1 Foreword This manual is designed to serve as the installation opera tion and maintenance guide for your dryer system The contents of this manual should be carefully read BEFORE attempting any phase of installation o
95. re attempting to remove or disassemble any dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage CAUTION Each component of a Hydrobloc LS Series Regenerative Desiccant Dryer System has been selected to compliment the performance of the other components of the system Therefore use of unauthorized parts or sup plies or improper operation will degrade system perfor mance Once the Hydrobloc LS Series Dryer System has been in stalled according to instructions it is ready to be oper ated The system is fully automatic and does not require any auxiliary controls It is designed to run continuously Dryer Models LS60 through LS1000 Do not start the dryer with compressed air flow through the dryer Close customer supplied dryer shut off valves before beginning start up procedure 1 Refer to the General Arrangement drawing as neces sary for component identification and location while conducting start up and operational procedures Note If your dryer cannot be started or fails to start due to special installation or other problems contact your local Deltech Sales Representative for assis tance 2 All Prefilter and Afterfilter Assemblies are shipped WITH filter cartridges installed Verify that prefilter and afterfilter cartridges are installed Prefilter and The Start Up procedure for models 1560 through LS1000 is now complete Proceed to the Normal Op eration Check
96. s section of this manual for final opera tional checks and adjustments 17 Dryer Models LS1250 and LS1500 Do not start the dryer with compressed air flow through the dryer Close customer supplied dryer shut off valves before beginning start up procedure Refer to the General Arrangement drawing as neces sary for component identification and location while conducting start up and operational procedures Note If your dryer cannot be started or fails to start due to special installation or other problems contact your local Deltech Sales Representative for assis tance All Prefilter and Afterfilter Assemblies are shipped WITH filter cartridges installed Verify that prefilter and afterfilter cartridges are installed Prefilter and Afterfilter cartridges are NOT interchangeable and must be installed in their respective assemblies ONLY The proper filter cartridge part number is listed on each Prefilter and Afterfilter Assembly Replace and tighten filter assembly bowls Ensure that O rings are properly seated Close any manual vent or drain valves installed in pre filter and afterfilter assemblies If the prefilter assembly was factory equipped with an automatic drain valve inspect for and remove pipe plug or cap which may have been installed in drain port for shipping purposes Ensure isolation ball valve to automatic drain valve is open Ensure that all associated pipe and tubing connec tions flanges unions plugs
97. ss after final adjustment Energize the dryer s electrical power supply Refer to Appendix A Appendix C for 100 F pdp of this manual and calculate your dryer model s purge pressure setting as instructed SLOWLY rotate dryer s Purge Adjusting Valve until the Purge Pressure Indicator indicates the calculated purge pressure setting See following Note Note The purge pressure can only be read and ad justed when an off stream desiccant chamber has de pressurized for regeneration When the off stream chamber is pressurized the Purge Pressure Indicator will read system pressure For dryers with the Hydrobloc Compu Save Energy Management System During operation in the Energy Management Mode the off stream chamber may re main pressurized in ENERGY MANAGEMENT AC TIVE If this condition is noted proceed as follows to adjust purge pressure a Open Dryer Control System Enclosure Locate DIP switches on MEC CPU Board b Switch DIP switch position 7 to OFF position down De energize dryer s electrical power sup ply for approximately fifteen 15 seconds then re energize Dryer is now in Fixed Cycle Opera tion The off stream chamber will depressurize to atmosphere for regeneration c Calculate and set purge pressure as previously instructed d Return DIP switch position 7 to ON position De energize the dryers electrical power supply for approximately fifteen 15 seconds then re energize Dryer shou
98. ss of any component in the system compromises the whole system 1 2 3 Automatic Drain Valves As previously stated the accumulated water and oil mix ture collected by a prefilter must be periodically drained from the prefilter housing sump A Deltech Automatic Drain Valve is a recommended and reliable means of removing collected moisture oil and sludge from coalescing prefilter housings and other components requiring periodic draining 1 2 4 Afterfilter Assembly The Deltech D Series Particulate Afterfilter Assembly is another feature offered Even under the most ideal condi tions all regenerative type desiccant dryers tend to gener ate small quantities of micron sized desiccant dust par ticles This highly abrasive contaminant can erode instru ments valve seats air cylinders and pneumatic tools A Deltech D Series Particulate Afterfilter Assembly installed downstream of your desiccant dryer will remove desiccant dust pipe scale and other harmful particulates before the gas stream continues to points of use 1 2 General Information 2 Installation Dryer models LS15 through LS1500 are designed to be moved by means of forklift slotting at the base of the dryer s protective shipping framework and lifting straps in stalled on the dryer Dryer models LS2070 and LS2580 are designed to be moved by means of lifting lugs supplied on the desiccant chambers 2 3 Mechanical Set Up Important When selecting an installation si
99. ssembly was factory equipped with an automatic drain valve inspect for and remove pipe plug or cap which may have been installed in drain port for shipping purposes Ensure isolation ball valve to automatic drain valve is open Ensure that all associated pipe and tubing connec tions flanges unions plugs mounting bolts pipe hangers etc have been checked tight and or prop erly secured IMPORTANT It is recommended that the System s process gas output not be consumed or used at the intended points of use until the Start Up and any re lated adjustments have been completed and the system is producing process gas of the required quality The quality of the process gas should be veri fied through test and analysis when a specific quality process gas is required Supply compressed air up to System Inlet Isolation Valve Energize the dryer s electrical power supply Supply pressure to system by SLOWLY opening System Inlet Isolation Valve customer supplied Both desiccant chamber Inlet Switching Valves will open and both chamber Purge Exhaust Valves will close The desiccant chambers will immediately be gin pressurizing to system pressure as indicated by chamber pressure gauges The Moisture Indicator s if dryer so equipped bleed valve is installed directly into the back of the indicator s body Close the Indicator s Bleed Valve FULLY open the Moisture Indicator Supply Valve Soap bubble test all external piping fitti
100. st flow restrictor is dam aged or not fully seated Troubleshooting Guide 1 5 4 CHECKS AND REMEDY b For Models LS1500 through LS2580 WARNING Removal of the Flow restrictor should not be done un less the piping to the Purge Exhaust Muffler is ad equately supported Failure to do so may result in serious personal injury and or equipment damage 1 Remove Flow Restrictor from the line and refer to the Flow Restrictor Maintenance Procedure Disassemble clean inspect and adjust as required Replace all worn or damaged parts as noted Check for pilot gas pressure at off stream chamber inlet valve s pilot tubing connection or on stream chamber exhaust valve s pilot tubing connection If pilot pressure is present Shutdown and Depressurize Dryer Disassemble clean and inspect the Switching Valve Replace all worn or damaged parts as noted Check indicator lights at solenoid block to determine whether energized Indicator light should be lit if the solenoid coil is en ergized If not open control enclosure and check MEC Board for output signal to solenoid valve a If voltage is present and the indicator at the solenoid block is not lit De energize Dryer Power Supply Press the manual override on solenoid valve to determine if functioning If functioning mechanically the solenoid valve coil is defec tive Replace solenoid valve coil Note The dryer MUST be depressurized to change coils on a solenoid If
101. st port En sure that the granular indicator crystals remain mo tionless after final adjustment 10 11 12 13 14 Do not start the dryer with compressed air flow through the dryer Close customer supplied dryer shut off valves before beginning start up procedure Refer to the General Arrangement drawing as neces sary for component identification and location while conducting start up and operational procedures Note If your dryer cannot be started or fails to start due to special installation or other problems contact your local Deltech Sales Representative for assis tance Remove the Pilot Gas Filter Bowl Verify that the pi lot gas filter cartridge is installed Replace Filter Bowl ensuring that O ring is properly seated Close the filter bowl bleed valve All Prefilter and Afterfilter Assemblies are shipped WITH filter cartridges installed Verify that prefilter and afterfilter cartridges are installed Prefilter and Afterfilter cartridges are NOT interchangeable and must be installed in their respective assemblies ONLY The proper filter cartridge part number is listed on each Prefilter and Afterfilter Assembly Replace and tighten filter assembly bowls Ensure that O rings are properly seated Close any manual vent or drain valves installed in pre filter and afterfilter assemblies If the prefilter assembly was factory equipped with an automatic drain valve inspect for and remove pipe plug or cap
102. stem enclosure while the Dryer s Electrical Power Supply is energized THEREFORE A POTENTIAL ELECTRICAL SHOCK HAZARD EXISTS These checks should be conducted by a qualified electrical technician or a Deltech authorized field service engi neer ONLY The Dryer s Electrical Power Supply must be de energized before any electrical maintenance or re pair work is conducted CAUTION Do not open or enter the Dryer Control System without exercising proper precautions for Static Sensitive De vices Do not remove the factory programmed microcomputer chip or any I C chip from the Logic Control Circuit Board Improper removal or handling will cause irreparable damage to these highly Static Sensitive components Damage to these components will render the Dryer Control System inoperative until replacement is accomplished by a Deltech authorized field service engineer Do not remove the program identification sticker from the microcomputer chip Important Water molecules can diffuse through a pinhole size leak even though pressure inside the piping is several hun dred PSIG Itis not at all uncommon to have a minute pinhole leak in a gas line cause an increase in dew point from 40 F to 10 F at a distance of forty or more feet downstream of the leak PROBLEM POSSIBLE CAUSE CHECKS AND REMEDY Dew point degradation 1 Insufficient or excessive purge gas flow 1 Refer to the Calculation of Purge Pressure Setting instructions during regeneration in Appen
103. t Ensure that the granular indicator crystals remain motionless after final adjustment PARTIALLY open the System Outlet Isolation Valve customer supplied while monitoring the outlet pres sure gauge Do not permit the Dryer s Outlet Pres sure gauge to exceed a 5 drop in pressure while pressurizing downstream piping Close the System Bypass Valve if gas system has been so equipped Energize the dryer s electrical power supply Refer to Appendix A Appendix C for 100 F pdp of this manual and calculate your dryer model s purge pressure setting as instructed Locate the Purge Adjusting Valve Slowly rotate dryer s Purge Adjusting Valve until the Purge Pres sure Indicator indicates the calculated purge pressure setting See following Note Note The purge pressure can only be read and ad justed when an off line desiccant chamber has de pressurized for regeneration When the off line cham ber is pressurized the Purge Pressure Indicator will read system pressure Operation 10 11 12 3 8 6 If the dryer has a Moisture Indicator and the Indicator s granular indicating gel is pink at the time of dryer start up a color change to blue should be noted within twenty four 24 hours Ensure that the indicator s bleed valve has been adjusted as in structed in the start up procedure 7 Ensure that the System Inlet and Outlet Isolation Valves customer supplied have been fully opened 8 Ensure
104. t gas line prior to the Pilot Gas Filter and after the Pilot Gas Supply Valve Both desiccant chamber Inlet Valves will open and both Purge Exhaust Valves will close Supply pressure to system by slowly opening the System Inlet Isolation Valve customer supplied Both Inlet Switching Valves are open Both Purge Exhaust Switching Valves are closed see step 4 The desiccant chambers will immediately begin pres surizing to system pressure as indicated by chamber pressure gauges Fully open the Moisture Indicator Supply Valve The Moisture Indicator s if dryer so equipped bleed valve is installed directly into the back of the indicator s body Adjust the Moisture Indicator s Bleed Valve until a very slight continuous gas bleed is felt exhausting from the bleed valve s exhaust port Ensure that the granular indicator crystals remain motionless after final adjustment PARTIALLY open the System Outlet Isolation Valve customer supplied while monitoring the outlet pres sure gauge Do not permit the Dryer s Outlet Pres sure gauge to exceed a 5 drop in pressure while pressurizing downstream piping Close the System Bypass Valve if gas system has been so equipped Energize the dryer s electrical power supply Refer to Appendix A Appendix C for 100 F pdp of this manual and calculate your dryer model s purge pressure setting as instructed Locate the Purge Adjusting Valve Slowly rotate dryer s Purge Adjusting Valve un
105. te consider ation must be given to the need for adequate clearances around and above the dryer system for ease of mainte nance and accessibility Site selection should also take into account possible momentary sound levels in excess of 85 decibels during each desiccant chamber depressur ization period 1 Locate the dryer system in an area with adequate clearance for servicing of all components The recom mended clearance around the dryer system should be a minimum of four 4 feet An overhead clearance of not less than two 2 feet above each desiccant chamber is required for desiccant filling Refer to the drawings enclosed with this manual for dimension connection and weight specifications applicable to your specific dryer system 2 Remove all protective shipping framework covers pipe plugs shipping blocks etc 3 Utilizing the base plate mounting holes provided an chor the dryer to a solid level foundation designed to support the dryer s dead weight loading plus any earthquake or wind loadings as required 4 Suitable protective barriers are recommended to re duce the possibility of accidental damage if the unit is located in an open area or in close proximity to ve hicular and pedestrian traffic Installation 2 1 2 1 Receiving and Inspection Immediately upon receipt of the dryer thoroughly inspect for damage that may have occurred during shipment Since the dryer is shipped F O B Ocala Florida the carr
106. tering the dryer inlet Desiccant is badly broken or coated with oil The normally white desiccant will appear tan or brown if oil contamination has oc curred Union or other piping component leaks at dryer outlet manifold or downstream of dryer outlet 4 Moisture Indicator has changed color from BLUE dry to a PINK wet indication Moisture indicator s bleed valve is closed Moisture indicator supply valve is closed Moisture indicator is internally clogged pre venting gas from exiting through indicator s bleed valve Sample tubing to Moisture Indicator is leak ing permitting wet atmospheric air to enter tubing and contaminate dry gas sample If the previous items 1 through 4 have been checked and the Moisture Indicator fails to return to blue within 3 to 5 hours an actual dew point problem may exist Troubleshooting Guide 1 5 2 5 3 CHECKS AND REMEDY SLOWLY rotate Purge Adjusting Valve until correct purge pres sure setting is noted on the Purge Pressure Indicator Note The purge pressure setting can only be read and ad justed when the off stream chamber has depressurized for re generation When the off stream chamber is pressurized the Purge Pressure Indicator will read system pressure Shutdown and Depressurize Dryer Refer to the Purge and Outlet Check Valve Maintenance procedure which is applicable to your specific dryer model Disassemble clean and inspect the Purge a
107. til the Purge Pres sure Indicator indicates the calculated purge pres sure setting See following Note Note The purge pressure can only be read and ad justed when an off line desiccant chamber has de 10 11 12 chamber is pressurized the Purge Pressure Indica tor will read system pressure The Normal Start Up or Restart procedure for mod els LS60 through LS1000 is now complete Proceed to the Normal Operational Checks section of this manual for final operational checks and adjustments 12 Dryer Models LS1250 and LS1500 Close the Pilot Gas Filter s Bleed Valve Close any manual vent or drain valves installed in prefilter and afterfilter assemblies Close the System Outlet Isolation Valve customer supplied Open the Pilot Gas Supply Valve located upstream of the Pilot Gas Filter Supply pressure to system by slowly opening the System Inlet Isolation Valve customer supplied The Right Chamber Inlet Switching Valve and Left Chamber Purge Exhaust Switching Valve will close The Left Chamber will immediately begin pressurizing to system pressure as indicated by the chamber pressure gauge Fully open the Moisture Indicator Supply Valve The Moisture Indicator s if dryer so equipped bleed valve is installed directly into the back of the indicator s body Adjust the Moisture Indicator s Bleed Valve until a very slight continuous gas bleed is felt exhausting from the bleed valve s exhaust por
108. tion valves 2 Open the service valve to vent the filter to atmospheric pressure 3 Disconnect drain lines and automatic drain valves if installed WARNING A hissing sound while the bowl is being removed indicates the filter has not been properly depressur 6 Clean accumulated debris from the bowl with soap and water and dry thoroughly 7 LIGHTLY lubricate the new O ring with a petroleum based lubricant that is compatible with your applica tion before installing the new element 8 Insert new element snapping it into place with a firm push up into the head The element will hang from the head until the bowl is installed 9 LIGHTLY lubricate the housing O ring with a petro leum based lubricant that is compatible with your ap plication CAUTION Do not use a pipe wrench to tighten the filter bowl to the head 10 Reattach bowl to head and hand tighten As the bowl is threaded onto the head supports in the bottom of the bowl ensure a proper seal between the element and the filter head 11 Reattach drain lines if applicable 12 Close service valve 13 Slowly open the inlet isolation valve to prevent a pres sure surge through the filter 14 Once the filter has been pressurized slowly open the outlet isolation valve 15 After both isolation valves have been opened close the system bypass valve The filter is now in service 16 Record the date of the element change in a record book or on the
109. uantity Model Model Model Model Model Required 0 0 5 0 0 Muffler 0000000000 1283853 1283853 1283285 1283285 1283285 Relief Valve 1124704 1124704 1124704 1124704 1124704 1125546 1125546 1125546 1125546 6 AQUADEX Repair Kit 1207278 1207278 1207278 1207278 1207278 Inlet Exhaust Valve Packing Kit 1283225 1283225 1283227 1283229 1283231 Purge Valve Packing Kit 1283233 1283233 1283235 1283235 1283235 Inlet Exhaust Valve Repair Kit 1283224 1283224 1283226 1283228 1283230 Purge Valve Repair Kit 1283232 1283232 1283234 1283234 1283234 Purge Orifice 1198157 1218635 1200806 1180918 1218638 Solid State Controller 1286552 1286552 1286552 1286552 1286552 Solenoid Valve 1275475 1275475 1275475 1275475 1275475 Solenoid Coil 1284506 1284506 1284506 1284506 1284506 Control Board CPU 1274947 1274947 1274947 1274947 1274947 Programmed IC 1270702 1270702 1270702 1270702 1270702 Fuse 1 2AMP 1222239 1222239 1222239 1222239 1222239 Power Supply 1261094 4 1261094 1261094 4 Solenoid Valve Spare 1276724 1276724 1276724 1276724 1276724 Display Panel Cable Assembly 1273367 1273367 1273367 1273367 1273367 Pressure Switch Option A amp B 1221910 1221910 1221910 1221910 1221910 Pressure Switch Cable Assy Option A and B 1262602 1262602 1262602 1262602 1262602 Pilot Filter Replacement Element 1223259 1223259 1223259 1223259 1223259 Prefilter Replacement Element 1276851 1276857 1276865 1276865 1276875 Afterfilter Replacement Element
110. upport required for each desiccant chamber 8 Utilizing an appropriately sized funnel fill each desic cant chamber as follows Annually WARNING Ensure that the Dryer and any associated Prefilters and Afterfilters are valve isolated and fully depressur ized before attempting to remove or disassemble any components or subassemblies Failure to do so may result in serious personal injury and or equip ment damage 1 Disassemble clean and inspect the Outlet and Purge Check Valve Assemblies Replace all damaged or worn parts 2 Disassemble clean and inspect the Inlet Switching and Purge Exhaust Switching Valves Replace all damaged or worn parts 3 Remove the desiccant fill port plugs or drain port flanges from the top of each desiccant chamber Vi sually inspect the desiccant through each chamber s fill port Replace desiccant if it appears badly broken or contaminated with oil 4 2 Desiccant Charging Procedures Note Periodic desiccant replacement is necessary to maintain dryer performance The frequency of desiccant replacement is dependent on the actual operating condi tions present and will vary in all cases These conditions can be process related mechanical or accidental A rising dew point at the dryer outlet is an indication that new des iccant is required This is assuming that the dryer is func tioning properly from a mechanical and control standpoint and the dryer is not being overloaded operated abo
111. ve its maximum flow capacity Desiccant is normally installed prior to shipment unless otherwise specified by the customer Tapping on each desiccant chamber with a soft face mallet will yield a deadened sound if desiccant has been installed If a hol low sound is noted the chambers are empty and require installation of desiccant before operation WARNING Ensure that the Dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any Dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage CAUTION Dryer models covered within the scope of this manual are designed to use a specific desiccant Use of any other size or type may reduce efficiency or damage the Dryer 4 2 Maintenance and Repair 9 Clean the fill port fill port plug threads or fill port flanges on each desiccant chamber Apply TFE tape to fill port plug threads Re install the fill port plug or fill port flange in each desiccant chamber and torque drain port plugs or flange bolts to a reasonable limit 4 3 Filter Element Replacement Coalescing prefilters and particulate afterfilters are included with all Hydrobloc LS Series Dryers The filter elements should be replaced when the differential pressure gauge on top of the filter reads 7 to 10 psid or once a year which ever comes first Refer to Appendix B for the replacement element part numbers Replace elements
112. w s threaded end Drain granular indicator Figure 4 2 MOISTURE INDICATOR Switching Valve Components Machine Screw Compression Spring Purge Exhaust Compression Spring Inlet Sockethead Cap Screw Washer Washer Washer Valve Body Flange Cover O Ring Valve Cover O Ring Shaft Rod Scraper Locknut Tetraseal O Ring Inlet Locknut Valve Cover Valve Poppet Purge Exhaust Connect Rod Purge Exhaust Connect Rod Inlet Valve Piston Purge Exhaust Valve Piston Inlet Piston Seal ONNM NNHONAHONNNAN NNNHUNNA Piston seal 23 orientation on inlet valve piston 22 Typical both sides gt NEES Ne MAO 0000 00 FF ooooooo Piston seal 23 orientation on purge exhaust valve piston 21 Typical both sides Figure 4 3 60 00 03 0 gt 4 7 Inlet and Purge Exhaust Switching Valve Maintenance LS60 through LS760 WARNING Ensure that the Dryer is de energized valve isolated and fully depressurized before attempting to remove or disassemble any Dryer component or subassem bly Failure to do so may result in serious personal injury and or equipment damage Clean and inspect all valve hardware upon disassem bly Replace
113. w consumption on the critical orifice curve Inlet Flow SCFM x 14 7 PSIG x1 15 Purge SCFM Inlet Pressure PSIG 14 7 PSIG Locate the Critical Orifice Calibration Curve that has been sized for your specific dryer model Cross the Purge Flow requirement calculated above to the same number on the Critical Orifice Calibra tion Curve Follow this line vertically and then hori zontally once intersection is made with the curve line to find the actual purge pressure setting Table 6 1 Inlet Airflow at Various Inlet Air Pressures Inlet Air Pressure psig pint Air Pressure psio 60 70 so oo 10 tio 120 130 140 150 Average Inlet Airflow scfm 0 LSC110 LSC130 LSC185 LSC240 LSC270 LSC360 LSC505 LSC630 LSC760 LSC1000 LSC1250 LSC1500 LSC2070 LSC2580 1 Maximum inlet air pressure 150 psig 2 Based on 100 F inlet air temperature and 100 F pressure dew point Maximum recommended inlet temperature 120 F For capacity at inlet temperature higher than 100 F consult your local distributor Specifications Purge Curves and Replacement Parts for 100 F Pressure Dew Doint Dryers C 5 HYDROBLOC LSC PURGE CURVES Orifice Dia 094 Gas Air Temp 100 F 6 65 100 90 80 70 60 50 40 30 PURGE PRESSURE P1 PSIG 20 10 PURGE GAS FLOW RATE SCFM Figure C 1 Critical Orifice Ca
114. which may have been installed in drain port for shipping purposes Ensure isolation ball valve to automatic drain valve is open Ensure that all associated pipe and tubing connec tions flanges unions plugs mounting bolts pipe hangers etc have been checked tight and or prop erly secured IMPORTANT It is recommended that the System s process gas output not be consumed or used at the intended points of use until the Start Up and any re lated adjustments have been completed and the system is producing process gas of the required quality The quality of the process gas should be veri fied through test and analysis when a specific quality process gas is required Energize the dryers electrical power supply The following indicator lights will illuminate a POWER ON b LEFT or RIGHT CHAMBER DRYING Note Should the dryer experience a power inter ruption during a normal cycle the unit will return to the same status of operation that existed at the time of the power interruption Operation 1 3 2 Afterfilter cartridges are NOT interchangeable and must be installed in their respective assemblies ONLY The proper filter cartridge part number is listed on each Prefilter and Afterfilter Assembly Replace and tighten filter assembly bowls Ensure that O rings are properly seated Close any manual vent or drain valves installed in pre filter and afterfilter assemblies If the prefilter a

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