Table of Contents
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IBP Series
Blower Purge Desiccant Compressed Air Dryer
F O R M N O . : 3 1 5 8 1 4 4
R E V I S I O N : 0 7 / 2 0 1 4
RATED
MODELS
FLOW
IBP500
500 SCFM
IBP600
600 SCFM
IBP750
750 SCFM
IBP900
900 SCFM
IBP1050
1050 SCFM
IBP1300
1300 SCFM
IBP1500
1500 SCFM
IBP1800
1800 SCFM
IBP2200
2200 SCFM
IBP2600
2600 SCFM
IBP3200
3200 SCFM
IBP3600
3600 SCFM
IBP4300
4300 SCFM
R E A D A N D U N D E R S TA N D T H I S M A N UA L P R I O R TO O P E R AT I N G O R S E R V I C I N G T H I S P R O D U CT.
MODEL
REFERENCE
500
600
750
900
1050
1300
1500
1800
2200
2600
3200
3600
4300
I N S T R U CT I O N M A N UA L
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Table of Contents
Related Manuals for SPX Pneumatic Products IBP500
Summary of Contents for SPX Pneumatic Products IBP500
- Page 1 I N S T R U CT I O N M A N UA L IBP Series Blower Purge Desiccant Compressed Air Dryer F O R M N O . : 3 1 5 8 1 4 4 R E V I S I O N : 0 7 / 2 0 1 4 R E A D A N D U N D E R S TA N D T H I S M A N UA L P R I O R TO O P E R AT I N G O R S E R V I C I N G T H I S P R O D U CT.
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Page 2: Table Of Contents
Contents 1.0 General Safety Information ......1 2.0 Receiving, Storing, and Moving ..... 1 3.0 Description ............ 2 4.0 Installation ............. 2 5.0 Instrumentation ..........7 6.0 Operation ............11 7.0 Maintenance ..........28 8.0 Troubleshooting ..........30 DRAWINGS Electrical Schematic – 460VAC, 3 phase ....33 Electrical Schematic –... -
Page 3: General Safety Information
CAUTION—Hazard or unsafe practice which could result 1.0 General Safety Information in minor injury or in product or property damage. The dryer data plate, attached to the electrical control This equipment is designed and built with safety as a box, contains critical safety and identification informa- prime consideration;... -
Page 4: Description
be required upstream of the Oil Removal Filter if heavy 3.0 Description liquid or solid loads are present. To ensure downstream air purity (prevent desiccant dust 3.1 Function from traveling downstream) adequate filtration down- Blower purge type regenerative dryers are an economi- stream of the dryer is required. -
Page 5: Electrical Connections
Compressor Aftercooler Separator Receiver Prefilters Desiccant Dryer Afterfilters Receiver Figure 1 Typical System Configuration Remove all mounting bolts from blower base which Dryer bypass piping may be installed to allow uninter- MAY have been used for shipping purposes. The rupted airflow during servicing. If the downstream appli- blower is designed to vibrate freely on its vibration cation cannot tolerate unprocessed air for short periods, pad during operation. - Page 6 Dimensions and Connections – Dryer Only Figure 2 (continued on next page) (For construction purposes, contact factory to request certified drawings when mounted filters are included with order)
- Page 7 Dimensions and Connections Figure 2 (continued from previous page)
- Page 8 • For the common alarm to activate on either a dryer 3. Refer to Table 1 for desiccant quantity per tower. fault condition or a service reminder, the jumper at When using Table 1 you will find the desiccant quan- JP6 is removed.
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Page 9: Instrumentation
5.5 Dew Point Transmitter 5.0 Instrumentation This option monitors and displays outlet pressure dew points and provides an alarm signal if the dew point The following instrumentation helps in monitoring dryer exceeds user-specified set point. Recommended operation and performance. Instruments which are calibration interval is 12 months. - Page 10 ENERGY MANAGEMENT SENSOR LOCATION (OPTIONAL) PURGE INLET CHECK VALVE TOP VIEW HOT PIPE INSULATION HEATER TEMP THERMOCOUPLE (CENTER END IN PIPE) (OPPOSITE SIDE) HEATER OVERTEMP RTD PURGE ASME CODE TAG HEATER WITH INSULATION TOWER INLET PURGE SUCTION VALVE FILTER SILENCER PURGE BLOWER AND MOTOR REAR VIEW...
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Page 11: Front View
ENERGY MANAGEMENT SENSOR LOCATION (OPTIONAL) REPRESS VALVE TOP VIEW HOT PIPE INSULATION HEATER TEMP THERMOCOUPLE (CENTER END IN PIPE) PURGE INLET CHECK VALVE (OPPOSITE SIDE) HEATER OVERTEMP RTD PURGE HEATER WITH ASME CODE TAG INSULATION PURGE SUCTION CHAMBER INLET FILTER SILENCER VALVE PURGE BLOWER AND MOTOR... - Page 12 HEATER INLET ENERGY MANAGEMENT TEMPERATURE SWITCH SENSOR LOCATION (OPTIONAL) OUTLET CHECK VALVE TOP VIEW ASME RELIEF VALVE HOT PIPE INSULATION REPRESS VALVE PURGE INLET CHECK VALVE HEATER TEMP THERMOCOUPLE (CENTER END IN PIPE) (OPPOSITE SIDE) HEATER OVERTEMP RTD PURGE HEATER WITH INSULATION PURGE SUCTION FILTER SILENCER...
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Page 13: Operation
After the right tower has depressurized, the Right 6.0 Operation Purge Valve V4 is opened and the Blower M and Heater H1 are energized. The heated air flows 6.1 Controls through the Right Purge Check Valve V6, down A solid-state controller controls valve and heater opera- through the right tower, and exits through the Right tion, monitors all critical operating conditions, and indi- Purge Valve V4. - Page 14 SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEWPOINTER OPTION PR&G SET AT 100 PSIG SET @ 370°F LEFT RIGHT RTD 3 CHAMBER CHAMBER SET @ 650°F SET @ SET @ 45 PSIG 45 PSIG SET @ SET @ 5 PSIG 5 PSIG EXH.
- Page 15 6.3.1 Energy Management Control (optional) After the left tower has depressurized, the Left Purge Valve V3 is opened and the Blower M and Heater Operation of the Energy Management Control cycle is H1 are energized. The heated air flows through the identical to the fixed cycle except the cycle is extended Left Purge Check Valve V5, down through the left until the desiccant bed in the on-line tower has been fully...
- Page 16 6.4 Control Board Jumpers 7. JP7 – Download Language Text Jumper JP7 is factory installed in the OFF position In the upper left hand corner of the control board there to disable Language Text download. The jumper is are eight two-pin jumpers labeled JP1 through JP8. Only installed in the ON position to allow for language text six of the eight jumper pairs are utilized.
- Page 17 Filter Service / Left Tower Pressure Maintenance LED Switch LED: On=Tower Pressurized Filter Service / Maintenance LED Left Tower Drying LED Right Tower Pressure Left Purge Valve LED Switch LED: On=valve open On=Tower pressurized Off=valve closed Left Inlet Valve LED Right Tower Drying LED On=valve open Off=valve closed...
- Page 18 b. SEVERE Service Intervals are: Screen 7: Set Point for Dew Point Demand Control i. 2000 hours for filters (This feature is only active when JP3 is “on”) ii. 4000 hours for desiccant DPNT CNTL SETPT iii. 4000 hours for valves ±XX°C ±XXX°F 2.
- Page 19 2. When finished, press to acknowledge the selec- 5. When finished, press to acknowledge the selec- tion and scroll to the pressure set point screen. tion and move to next screen. Exit Program Mode when there are no more active screens to display. 3.
- Page 20 6.5.6 Alarm & Service Mode c. Left or Right tower, regenerating, low pressure i. Regenerating tower pressure switch is open 1. Alarm & Service Mode is active when the controller at the end of the regenerating cycle. is in Display Mode. It is not active in Program Mode, Setup Mode, or Test Mode.
- Page 21 ALARM MESSAGES LEFT TOWER ALARMS RIGHT TOWER ALARMS OTHER ALARMS ALARM LEFT TOWER ALARM RIGHT TWR ALARM HEATER DRYING DRYING OVER-TEMPERATURE LOW PRESSURE LOW PRESSURE ALARM LEFT TOWER ALARM RIGHT TWR ALARM HEATER REGENERATING REGENERATING LOW TEMPERATURE HIGH PRESSURE HIGH PRESSURE ALARM LEFT TOWER ALARM RIGHT TWR ALARM ENRGY MGNT...
- Page 22 9. Heat Low Temperature 13. Dew Point Sensor a. RTD3 is used to detect Heater Low Tempera- a. High Dewpoint Alarm ture. i. The user enters an alarm value through the Program Mode. b. Alarm if the heater temperature is less than 250°F ii.
- Page 23 6.5.7 Display Mode Service Due Messages 1. Display Mode is active when the user exits Program 14. There are two service levels (normal and severe) Mode or Setup Mode and no alarms are active as described in Program Mode. Each service level (unless MANUAL CYCLE was selected in Setup has preset time intervals for servicing the filters, Mode).
- Page 24 DRYER STATUS SCREENS LEFT TOWER DRYING RIGHT TOWER DRYING LT DRYING LT DEPRESSURIZE RT DEPRESSURIZE RT DRYING LT DRYING LT HEATING RT HEATING RT DRYING LT DRYING LT COOLING RT COOLING RT DRYING LT DRYING LT REPRESSURIZE RT REPRESSURIZE RT DRYING LT DRYING LT HOLDING RT HOLDING...
- Page 25 6.5.8 Test Mode 5. To exit Test Mode: 1. Test Mode is active when the user exits Program a. Press and hold for 3 seconds to exit Test Mode after selecting operation in MANUAL CY- Mode. The display switches to Screen 2 of Setup CLE.
- Page 26 TEST MODE SCREENS Screen 1: Step 1 Screen 7: Step 7 TEST1: LT DRYING TEST7: RT DRYING XX°C XXX°F XX°C XXX°F Screen 2: Step 2 Screen 8: Step 8 TEST2: DEPR RT TEST8: DEPR LT XX°C XXX°F XX°C XXX°F NOTE: Sequence step will not advance to HEAT until NOTE: Sequence step will not advance to HEAT until tower has fully depressurized.
- Page 27 6.6 Start-up NOTE: Read the off-line tower pressure gauge when the tower is purging (air exhausting from muffler). 6.6.1 Controller Settings 6.7.5 Process Valves Set or verify settings on Controller. Detailed operational Determine if air control valves are operating and points are presented in section 6.5.
- Page 28 Dryers are equipped with a safety relief valve that has b. Advances directly to the beginning of whichever been sized to provide overpressure protection due to a stage of HEAT or COOL it had been at when fire for both desiccant towers. power was interrupted.
- Page 29 Determining jumper positions: ASCII representation of the heater tempera- ture (°F) Each jumper 8 bits weighted by position Value ASCII representation of the left bed tempera- ture (°F) ASCII representation of the right bed tem- perature (°F) ASCII representation of the humidity sensor temperature (°F) ASCII representation of the humidity sensor relative humidity (%)
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Page 30: Maintenance
e. Utilizing an appropriate sized funnel, fill each 7.0 Maintenance desiccant tower as follows: 1) Install the required quantity of tabular support WARNING - This equipment is a pressure-containing (model 4300 only) or activated alumina in device. Depressurize before servicing. layer 1 of each tower. - Page 31 2. Procedure for element replacement a. Isolate dryer from air supply b. Depressurize dryer by running dryer and allowing system pressure to purge to atmosphere. Loss of pilot pressure will eventually prevent purge/ repressurization valves from opening. Remaining pressure can be vented to atmosphere through the manual drain on the pilot air filter.
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Page 32: Troubleshooting
8.0 Troubleshooting WARNING - A POTENTIAL ELECTRICAL SHOCK HAZARD EXISTS. Some of the troubleshooting checks may require gaining access to the dryer’s electrical enclosure(s) while the power supply is energized and should be performed by a qualified electrical technician. WARNING - Before performing any electrical or mechanical repairs or maintenance, or removing or disassembling any component, be sure to de- energize and depressurize the dryer. - Page 33 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION High Pressure Alarm 1. Faulty regenerating tower pressure 1. Check pressure switch operation using tower pressure Left Tower or Right Tower Re- switch gauge for comparison. Replace switch if defective. generating 2. Regenerating tower Depressurization 2.
- Page 34 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION Outlet Dew Point Alarm 1. Inlet air flow higher than the sizing 1. Reduce inlet flow to sizing condition. Left Tower or Right Tower condition. 2. Liquids entering the dryer inlet. 2. Check the inlet air line for liquids. Inspect prefilter and drain valve.
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Page 35: Electrical Schematic - 460Vac, 3 Phase
Electrical Schematic – 460VAC, 3 phase (Contact factory to request certified drawings) DETAIL A (2-WIRE DEWPOINT TRANSMITTER) +12VDC EXTERNALLY LOCATED DEWPOINT TRANSMITTER + 4-20MA OUT CUSTOMER PROVIDED 460VAC, 3 PHASE MOTOR (FOR FUSING AND WIRE SIZING SEE TABLE 1) 249 OHM 1/8W BLACK 1HTR... -
Page 36: Electrical Schematic - 575Vac, 3 Phase
Electrical Schematic – 575VAC, 3 phase (Contact factory to request certified drawings) DETAIL A (2-WIRE DEWPOINT TRANSMITTER) CUSTOMER PROVIDED +12VDC 575VAC, 3 PHASE EXTERNALLY LOCATED MOTOR (FOR FUSING AND WIRE DEWPOINT SIZING SEE TABLE 1) TRANSMITTER + 4-20MA OUT 1HTR 249 OHM 1/8W BLACK... -
Page 37: Electrical Data - Fusing & Wire Sizing
Electrical Data – Fusing & Wire Sizing Electrical Service: 460VAC, 3 phase Electrical Service: 575VAC, 3 phase F.L.A. SUGGESTED F.L.A. SUGGESTED MODEL COMPONENT RATING WIRE SIZE MODEL COMPONENT RATING WIRE SIZE @460VAC FUSING @575VAC FUSING HEATER 10 KW 12.6 20 AMPS #12 AWG HEATER 10 KW... -
Page 38: P&Id Schematic - Models 500 Through 600
P&ID Schematic - Models 500 through 600 (Contact factory to request certified drawings) SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEWPOINTER OPTION SET AT 100 PSIG SET @ 370°F LEFT RIGHT RTD 3 CHAMBER CHAMBER SET @ 650°F SET @ SET @ 45 PSIG... - Page 39 LEGEND INLET VALVE (V1 LEFT, V2 RIGHT) PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT) PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT) DEPRESS VALVE (V9 LEFT, V10 RIGHT) PURGE HEATER WITH INSULATION HEATER TEMPERATURE THERMOCOUPLE HEATER OVERTEMPERATURE RTD CHAMBER RTD (LEFT &...
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Page 40: P&Id Schematic - Models 750 Through 4300
P&ID Schematic - Models 750 through 4300 (Contact factory to request certified drawings) SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEWPOINTER OPTION SET AT 100 PSIG (225°F) SET @ 370°F LEFT RIGHT RTD 3 CHAMBER CHAMBER SET @ 650°F SET @ SET @ 45 PSIG... - Page 41 LEGEND INLET VALVE (V1 LEFT, V2 RIGHT) SOL 'C' FLOW CONTROL VALVE PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT) SOL 'D' PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) (NO SPRING) OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT) DEPRESS VALVE (V9 LEFT, V10 RIGHT) PURGE HEATER WITH INSULATION HEATER TEMPERATURE THERMOCOUPLE HEATER OVERTEMPERATURE RTD...
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Page 42: Replacement Parts Models 500 Through 600
Replacement Parts – Models 500 through 600 REAR VIEW LEFT CHAMBER RIGHT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: 1+ 352-873-5793 FAX: +1 352-873-5770 Email: ppc.americas.am@spx.com Web: www.spx.com/pneumatic-products... - Page 43 1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 2. All quantities for one dryer. 3. ID# correspond to P&ID legend (* Not pictured in diagrams.) Phone: 1+ 352-873-5793 FAX: +1 352-873-5770 Email: ppc.americas.am@spx.com Web: www.spx.com/pneumatic-products...
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Page 44: Models 750 Through 1800
Replacement Parts – Models 750 through 1800 MODEL 750 1 1A REAR VIEW LEFT CHAMBER RIGHT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: 1+ 352-873-5793 FAX: +1 352-873-5770 Email: ppc.americas.am@spx.com Web: www.spx.com/pneumatic-products... - Page 45 1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 2. All quantities for one dryer. 3. ID# correspond to P&ID legend (* Not pictured in diagrams.) 4. N/A - Not Applicable to this Model Size Phone: 1+ 352-873-5793 FAX: +1 352-873-5770 Email: ppc.americas.am@spx.com Web: www.spx.com/pneumatic-products...
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Page 46: Models 2200 Through 2600
Replacement Parts – Models 2200 through 2600 1 1A REAR VIEW RIGHT CHAMBER LEFT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: 1+ 352-873-5793 FAX: +1 352-873-5770 Email: ppc.americas.am@spx.com Web: www.spx.com/pneumatic-products... - Page 47 1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 2. All quantities for one dryer. 3. ID# correspond to P&ID legend (* Not pictured in diagrams.) Phone: 1+ 352-873-5793 FAX: +1 352-873-5770 Email: ppc.americas.am@spx.com Web: www.spx.com/pneumatic-products...
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Page 48: Models 3200 Through 4300
Replacement Parts – Models 3200 through 4300 42 43 1 1A REAR VIEW RIGHT CHAMBER LEFT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: 1+ 352-873-5793 FAX: +1 352-873-5770 Email: ppc.americas.am@spx.com Web: www.spx.com/pneumatic-products... - Page 49 1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 2. All quantities for one dryer. 3. ID# correspond to P&ID legend (* Not pictured in diagrams.) Phone: 1+ 352-873-5793 FAX: +1 352-873-5770 Email: ppc.americas.am@spx.com Web: www.spx.com/pneumatic-products...
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Page 51: Warranty
WARRANTY The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with the procedures and recommendations outlined in the manufacturer’s instruction manuals, to be free from defects in material or workmanship for a period of one (1) year from the date of shipment from the manufacturer or the manufacturer’s authorized distributor, or eighteen months from the date of shipment from the factory, whichever occurs first, provided such defect is discovered and brought to the manufacturer’s attention the aforesaid warranty period. - Page 52 4647 S.W. 40th Avenue Ocala, Florida 34474-5788 U.S.A. P: (352) 873-5793 F: (352) 873-5770 E: ppc.americas@spx.com www.spx.com/pneumatic-products Improvements and research are continuous at SPX. Specifications may change without notice. ISSUED 07/2014 Form No.: 3158144 Revision: I COPYRIGHT ©2014 SPX Corporation...
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