Aircel ABP Series, Installation & Operation Manual

Page 1: ...Front Page Desiccant Air Dryers ABP Series Blower Purge 800 10 000 scfm Installation Operations Manual Effective September 2017 ...

Page 2: ... Blower Purge Desiccant Air Dryer 2 DRYER DATA SHEET Model Number Serial Number Dryer Type Date of Manufacture Ship Date Installation Date Customer Name Customer Address Customer City State Zip Accessories Other ...

Page 3: ...iccant Type Dryer Desiccant Weight Total for System Dryer Outlet Dew Point Dryer Control Time Cycle Dryer EMS Dew Point Sensor Setting for sensor outlet dew point High Dew Point Setting Demand Cycle Setting Outlet Dew Point Readout on Display Electrical Drawing Number Mechanical Drawing Number PLC Software Program Number Control Air Filter Element Number Inlet Pre Filter Element Number option Outl...

Page 4: ...nt Controlled 15 Preliminary Start Up Checklist 16 Shut Down Procedures 17 Shut Down Emergency 17 Short Term Shut Down 17 Long Term Shut Down 17 Normal Operation Setup 18 Aircel Programmable Controller APC 19 Control Menu Screen 19 Running Screen 20 Dryer Operations 21 Alarm Banner Alarm Log 29 Diagnostic Flow Diagram 30 Entry Service Screens 31 Service Screen 32 Proceed Status Screen 33 Alarm Sta...

Page 5: ...S Improper installation operation or maintenance may contribute to conditions in the work area or facility that could result in personal injury and product or property damage Check that all equipment is properly selected and sized for the intended use Consult and comply with national and local codes relating to fire or explosion and all other appropriate codes when determining the location and ope...

Page 6: ...s a risk of electrical shock and only authorized personnel with proper gear must approach it HIGH NOISE AREA All personnel are required to wear ear protectors before approaching the vicinity of the equipment HAZARDOUS FUMES GASES Personnel must wear protective gear to prevent inhaling of the gases and fumes SUSPENSION POINTS Look for these symbols before making any attempt to move or relocate your...

Page 7: ...rsonnel perform the electrical installation for this unit 3 Only use original fuses for the rated voltage and current 4 Shut down the unit in the correct recommended procedure 5 Before any work on system always depressurize the unit and remove all electrical power 6 After shut down put up warning notice to prevent the unit from being switched ON accidentally 7 Inspect all piping hoses and connecti...

Page 8: ...at least 15 minutes EYE CONTACT In case of contact immediately flush eyes with plenty of water for at least 15 minutes Call a physician SPILLS Clean accidental spills by vacuuming sweeping or flushing to a sewer treated for suspended solids Avoid creating excess dust WARNING INHALATION SKIN EYE IRRITANT The desiccant used in this equipment is not considered hazardous Contact with and disposal of d...

Page 9: ...m is designed and constructed in accordance with the rules and regulations regarding adsorption technology and industrial safety There are hazards accompanying this type of product if not operated for the intended purpose by trained and specialized personnel Inspection on Arrival All heated regenerative desiccant dryers are tested and operated before shipment However shipping vibration may cause d...

Page 10: ...ime or energy saving demand modes of operation How It Works 1 Pre filtered wet compressed air enters the bottom of the on line vessel 2 Compressed air passes upward through the desiccant bed moisture is removed lowering the dew point to 40o F 3 Dry compressed air exits the top of the vessel and flows downstream to the after filter monitored constantly via standard dew point sensor This EMS feature...

Page 11: ... must be lowered to reduce dew point and temperature spikes in the process air when the bed goes back on line This is accomplished by allowing a slipstream of dry process air controlled by an automatic valve to flow from the on line vessel into the off line vessel This slipstream is also used to re pressurize the off line vessel after it has been cooled placing the unit into standby The EMS contro...

Page 12: ...al codes when using cranes forklifts and other lifting equipment Installation Codes and Procedures This product should be operated only from the type of power source specified If unsure of the type of power supply for the desired outlet consult a local power company Failure to comply may result in personal injury and or property damage Follow proper lock out tag out procedures before performing se...

Page 13: ...locity resulting from low service pressure Failure to maintain the correct operating pressure will cause elevated dew point and premature failure of the desiccant 7 The regeneration air outlet should be piped away from all equipment and occupied spaces The pressure loss through the regeneration air outlet piping should not exceed 2 inches of water column to prevent excessive back pressure on the b...

Page 14: ... slide gate damper at blower intake The heated air is directed downward through the off line wet desiccant bed and vented from the system through the regeneration air outlet valve in the lower piping manifold When the desiccant bed is fully regenerated 175 minutes maximum heating time the electric heater is turned off The blower is then turned off 6 minutes later for heater cool down and isolated ...

Page 15: ...e Dew point Controlled mode the effluent dew point is continuously monitored to determine if the drying period can be extended or if vessel changeover is required If a high dew point is sensed at dryer outlet changeover at the end of the re pressurization results if a low dew point is sensed at dryer outlet dew point extension drying results Dew point extension drying can occur for up to 6 hours o...

Page 16: ...orrect rotation of the blower motor verified Observe the temperature of the regeneration air leaving the electric heater Adjust the blower discharge manual valve or blower intake slide gate damper until the outlet temperature is 400 F If the system has a blower discharge valve to ambient typically used on the vortex blowers on Aircel models 800 2500 the valve should be initially closed for max flo...

Page 17: ...was shut down Long Term Shutdown 1 Close the outlet valve to stop the process airflow 2 Fully regenerate both vessels 3 Leave the equipment depressurized with the system inlet and outlet valves closed and power removed 4 The complete start up procedure must be followed after a long term shutdown 5 Close both needle valves before and after the dew point sensor WARNING When the system is shutdown an...

Page 18: ...ain screen Next press the Service Menu button to activate the service screen From here press the Deactivate Service button The Service Mode that was visible on each screen will disappear and the dryer will resume normal operation 9 Check the temperature settings in the Control Main menu by pressing the Temp Settings button and verify all settings are correct as needed 10 Dew point Demand can be tu...

Page 19: ... off Green ON is dry air purge from system outlet for system cooling Red OFF is blower only cooling which will give a high dew point on switchover System On Off Button toggles system on off Green ON is system running Red OFF is system not running Dew Point Demand On Off Button toggles energy saving mode on off Green ON enables energy saving mode Red OFF disables energy saving mode enables fixed ti...

Page 20: ... and yellow buttons indicate status screens Step Time Vessel Pressures Navigate to Main Menu Note Screen button must be in Unlock position before pressing Main Menu button Outlet Dew point Read Out Screen Lock Unlock Locks or Unlocks the running screens Note Screen must be in Lock for normal operation While in Service Mode blinking Screen Unlock is only to be used to return to Main Menu Service Mo...

Page 21: ...en the step is complete STEP ONE Select Vessel 2 for Regeneration Running Operation Screen Vessel 2 is preparing for regeneration Control system energizes Solenoid SOL2 which closes Vessel 2 inlet valve K2 Vessel 1 is drying the inlet air Vessel 1 inlet valve K1 should be open and solenoid SOL1 should be energized The regeneration valves K3 K4 depressurization valves V1 V2 and re pressurization va...

Page 22: ...mperature however the blower intake manual valve or blower discharge on the smaller units should be adjusted to give the maximum regeneration flow rate and maintain the constant 400 F heater outlet temperature without the heater cycling On and Off If the regeneration outlet temperature at the purge exhaust to ambient reaches 200 F during this cycle the heater will terminate early saving additional...

Page 23: ...ice fast cycle button to allow an authorized technician to advance to the next step without waiting for the step to finish WARNING this button should not be operated unless authorized by an Aircel Service technician and the valving and operation is verified STEP SIX Vessel 2 Re pressurization Running Operation Screen Regeneration valve K4 and depressurization valve V2 will close Re pressurization ...

Page 24: ...lel flow mode operation is the last step prior to a Vessel switchover to begin drying It allows the recently regenerated vessel to further cool down with some of the inlet gas flow since it will be diverted to both vessels the inlet valves will be open during this process which helps reduce dew point and temperature spikes after switchover The parallel flow period is 10 minutes In this step Vessel...

Page 25: ... Press to Proceed button appear when the step is complete STEP EIGHT Operation Screen Vessel 2 is drying the inlet air Vessel 2 inlet valve K2 should be open Vessel 1 is preparing for regeneration The PLC control system energizes SOL3 to open the depressurization valve V1 which slowly depressurizes Vessel 1 If the pressure in Vessel 1 does not fall below 8 PSI within 240 seconds an alarm will pop ...

Page 26: ...on and the heat regeneration process now begins The heating process cycle can operate for up to a period of 172 minutes If the regeneration outlet temperature reaches 200 F during this cycle the heater will turn off the blower will remain on and the heating step will terminate early saving additional energy The PLC will automatically advance to the heater cooling cycle If in service mode the Proce...

Page 27: ...ssure dew point is dry enough to extend the drying time saving energy if the Dew point Demand has been selected On or enabled If the system has completed a full 4 hours of drying and the dew point is below the 50 F outlet dew point setting then the system can extend the drying time up to 720 minutes 12 hours additional time 16 hours total on the vessel The Energy Savings Screen will be displayed d...

Page 28: ...lel flow mode operation is the last step prior to a Vessel switchover to begin drying It allows the recently regenerated vessel to further cool down with some of the inlet gas flow since it will be diverted to both vessels the inlet valves will be open during this process which helps reduce dew point and temperature spikes after switchover The parallel flow period is 10 minutes In this step Vessel...

Page 29: ...d on the Alarm Status screen as well Alarm Reset Resets the selected alarm if the alarm condition is corrected Clear Banner Clears the banner will return to the last visible screen ALARM LOG SCREEN Shows Previous Alarms The Alarm Log screen shows previous alarm messages as well as date and time of the alarm Main Menu Navigate back to the Main Menu Running Screens Navigate to the main Operation scr...

Page 30: ...Used to verify the warning has been read and acknowledged FLOW DIAGRAM SCREEN The flow diagram screen shows the user in which direction the unit is drying as well as which vessel is regenerating Also shown are the temperatures of the regeneration outlet heater outlet cooler outlet and heater sheath The open closed status of each valve is shown as well Dryer Status Navigate to the Dryer Status scre...

Page 31: ...ater control temperature Dew Point Demand Set outlet dew point demand set point for energy management High Humidity Set high humidity alarm set point SERVICE SCREEN The service mode screen is a screen that can be used by a qualified service technician to operate the unit in a manner to troubleshoot each step to locate any problems Main Menu Navigate back to the Main Menu Running Screens Navigate t...

Page 32: ...n a reduced amount of time while also providing the ability to advance a different step in the process if required To activate the service routine function navigate to the Service Menu and press Activate Service Mode NOTE The Service icon will be visible on screen indicating service mode is active Once the service function is activated the program will not advance without the operator or service t...

Page 33: ...d to the Next Step Selects the next step for operation This is a manual operation and must be completed by the user or service tech during service mode DO NOT leave unattended during service mode STATUS SCREEN The Status screen allows the user to view the status of the unit Main Menu Navigate back to the Main Menu Running Screens Navigate to the main Operation screen Half Cycle Time Hours of Savin...

Page 34: ...for exceeding temperatures are as follows A contactor has become stuck in the closed position A thermocouple has failed high out of range A thermocouple wire has been disconnected or broken There are fail safes in place to ensure that once the heater has reached the high limit it will shut off and cool down If this alarm continues to happen the user will need to find and correct the issue The alar...

Page 35: ...control air line Valve failure Bad transducer Bad PLC input This alarm is automatically reset once corrective action has taken place Depress V2 Failure Occurs when Vessel 2 fails to depressurize within the given time allotted Possible causes are Loss of air pressure on control air line Valve failure Bad transducer Bad PLC input This alarm is automatically reset once corrective action has taken pla...

Page 36: ...ved and the panel is locked return power to the panel After the startup period of 3 to 4 minutes the PLC will be ready to communicate with the HMI Navigate to the service menu and select Activate Service Mode Once in service mode return to the operations screen and step through to the re pressurization step 6 or 12 Return to the service menu and Deactivate Service Mode Activate heatless mode by pr...

Page 37: ... weekly inspections Verify the system is leak free Verify the operation of all pressure gauges temperature indicators and dew point sensor Verify the heater outlet temperature Adjust the blower discharge valve or blower intake slide gate damper as needed See startup section for adjustment Check heat temperature settings in dryer system display QUARTERLY Repeat all monthly inspections Check filter ...

Page 38: ...e outdoors 4 Install a reducing flange on the Regeneration Air Outlet line to connect to the primary suction hose from the Shop Vac 5 Connect the Shop Vac primary suction hose to the Regeneration Air Outlet line 6 Remove the flange on the desiccant filling port on the upper head of the desiccant tower being filled Install a reducing flange to connect to the secondary suction hose 7 Immerse the sec...

Page 39: ...r property damage Personnel must stand clear as the flange on the drain port is loosened and slid over Personal injury can result from the desiccant discharge from the drain port 1 Turn electrical power OFF and lock out controller Depressurize the compressed air dryer 2 Place a bucket or a bin beneath the desiccant drain port located on the lower section of the desiccant tower 3 Loosen the bolts o...

Page 40: ...tream of the dew point sensor to be full open and the valve downstream of the sensor should be just slightly cracked open so just a slight amount of air is felt on the exhaust The dew point probe is out of calibration Shut off the air to the humidity sensor Remove the probe from the housing and return for recalibration Blower Overload Alarm The motor overload has tripped Check the motor overload t...

Page 41: ...e pressurization solenoid valve for correct operation Check the valve actuator for correct operation Vessel re pressurized but the alarm is on Check pressure sensor for correct operation Regeneration Heater Sheath Over Temperature Failure Defective or open circuit thermocouple Replace the thermocouple RESET alarm Low or no regeneration blower flow Check the manual valve on the blower Check the blo...

Page 42: ...ace as necessary The PLC has failed or is in a Fault condition Check the PLC to verify if any outputs are on or if the PLC fault alarm LED is on The PLC may require reprogramming or replacement Consult the Aircel Sales Department for assistance WARNING Prior to performing any maintenance on the system disconnect power supply properly lock out tag out electrical power supply and depressurize the sy...

Page 43: ...elds Wear chemical resistant protective gloves Wear protective clothing Eye wash fountains and safety showers must be easily accessible Potential health effects Primary routes of exposure Routes of entry for solids and liquids include eye and skin contact ingestion and inhalation Routes of entry for gases include inhalation and eye contact Skin contact may be a route of entry for liquified gases 4...

Page 44: ...fraction Safety data sheet F200 Revision date 2008 12 04 Version 3 0 Page 2 5 30286124 MDS_GEN_US EN If on skin After contact with skin wash immediately with plenty of water and soap Consult a doctor if skin irritation persists If in eyes In case of contact with the eyes rinse immediately for at least 15 minutes with plenty of water Immediate medical attention required If swallowed No hazards anti...

Page 45: ...tion Body protection must be chosen based on level of activity and exposure 9 Physical and chemical properties Safety data sheet F200 Revision date 2008 12 04 Version 3 0 Page 3 5 30286124 MDS_GEN_US EN Form Odour Colour pH value Melting point Boiling point Vapour pressure Density Bulk density Partitioning coefficient n octanol water log Pow Viscosity dynamic Solubility in water 10 Stability and r...

Page 46: ...heck for possible recycling Disposal requirements are dependent on the hazard classification and will vary by location and the type of disposal selected All waste materials should be reviewed to determine the applicable hazards testing may be necessary 14 Transport information Land transport USDOT Not classified as a dangerous good under transport regulations Sea transport IMDG Not classified as a...

Page 47: ...MATION SET FORTH OR THAT THE PRODUCTS DESIGNS DATA OR INFORMATION MAY BE USED WITHOUT INFRINGING THE INTELLECTUAL PROPERTY RIGHTS OF OTHERS IN NO CASE SHALL THE DESCRIPTIONS INFORMATION DATA OR DESIGNS PROVIDED BE CONSIDERED A PART OF OUR TERMS AND CONDITIONS OF SALE FURTHER YOU EXPRESSLY UNDERSTAND AND AGREE THAT THE DESCRIPTIONS DESIGNS DATA AND INFORMATION FURNISHED BY BASF HEREUNDER ARE GIVEN ...

Page 48: ...ABP Series Blower Purge Desiccant Air Dryer 48 SERVICE NOTES DATE SERVICE PERFORMED NOTES ...

Page 49: ...Blower Purge Desiccant Air Dryer ABP Series 49 SERVICE NOTES DATE SERVICE PERFORMED NOTES ...

Page 50: ...ABP Series Blower Purge Desiccant Air Dryer 50 SERVICE NOTES DATE SERVICE PERFORMED NOTES ...

Page 51: ...l operation and maintenance manuals are not covered under warranty Once Aircel has been given adequate opportunity to remedy any defects in material or workmanship in accordance with Aircel Warranty Policy and Procedures Aircel retains the sole option to accept return of the goods with freight paid by the purchaser and to refund the purchase price for the goods after confirming the goods are retur...

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