SPX Hankison GCU Series, Instruction Manual

Page 1: ...ssed Air Dryers Models GCU 0 5 GCU 0 75 GCU 1 0 GCU 1 5 GCU 2 0 GCU 2 5 GCU 3 5 FOR M NO 5003343 R EVI S ION 04 2015 R EAD AN D U N D E R STAN D TH I S MAN UAL PR IOR TO OPE RATI NG OR S E RVICI NG TH I S PROD UCT I N STR UCTION MAN UAL ...

Page 2: ...ly 14 3 3 Monthly 14 3 4 Annually 14 4 0 TROUBLESHOOTING GUIDE Models 0 5 0 75 15 Models 1 0 3 5 16 5 0 REFERENCE Sizing 17 Engineering Data 18 Dryer Set Point Table 19 Dryer Alarm Table 20 Controller Screen Shots Status Menu Screens 21 Setup Menu Screens 22 Network Menu Screens 23 6 0 WIRING DIAGRAMS Model 0 5 120 230 VAC 24 Model 0 75 120 230 VAC 25 Models 1 0 2 5 460 VAC 26 27 Model 3 5 460 VAC...

Page 3: ... our plant It was received in good condition by the carrier and was so acknowledged Check for Visible Loss or Damage If this shipment shows evidence of loss or damage at time of delivery to you insist that a notation of this loss or damage be made on the delivery receipt by the carrier s agent B UNPACKING Check for Concealed Loss or Damage When a shipment has been delivered to you in apparent good...

Page 4: ...is adjusted to operate in altitudes up to 4500 feet 1370 meters If dryer is installed in an altitude above this and has not been preset at the factory for this altitude contact manufacturer s Service Department F The installation of a flexible connection prior to the dryer is recommended to prevent possible damage from vibration NOTE Outdoor installation Standard units are designed for in door ins...

Page 5: ...and drain EDD which automatically discharges condensate NOTE It may be desirable to pipe the condensate from the Automatic Drain outlet to a suitable drain B Models 0 5 0 75 Separator has a knurled fitting with flexible drain tubing attached Be sure knurled fitting is tightened by turning counter clockwise before operating dryer TO CLOSE TURN COUNTERCLOCKWISE C Models 1 0 3 5 For manual draining c...

Page 6: ... Enter to accept new value f Use the Up and Down arrow buttons to set minutes 00 to 59 Press Enter to accept new value g Press Enter to accept new value Push ESC at any time to return to the Main Menu 3 Setting Schedule a Use the Up and Down arrow buttons to select desired Day of week on off Press Enter to adjust time b Use the Up and Down arrow buttons to set hour 00 to 23 Press Enter to accept n...

Page 7: ... green Compressor on light will illuminate In this mode compressor will run continuously and will not be turned on and off by the monitor MANUAL MODE will appear on interface panel Schedule Mode push Schedule On Off and Enter button SCHEDULED MODE will appear on the interface panel The compressor will then turn on or off as programmed NOTE Dryer may be returned to the Manual Mode at any time using...

Page 8: ...is off TEMP SENSOR Occurs if the temperature sensor circuit is open or shorted If open none of the LED s in the temperature display will be illuminated If shorted all the LEDs in the temperature display will be illuminated DRAIN electric drain contains a high water level alarm that activates if drain fails to discharge f Check drain operation push Drain push to test button to energize electric dra...

Page 9: ...e evaporator inlet temperature evaporator outlet temperature and dryer load These values will be written every 10 seconds to a comma separated value file stored in the root folder of the USB flash drive Each day a new comma separated value file will be created for storing the samples for that day Comma separated value files older than 60 days will be automatically deleted 2 USB Event History When ...

Page 10: ...l area network The customer can then monitor the dryer status and performance via Web Interface or ModbusTCP 1 Web Interface After assigning an IP address to the dryer the IP address can be entered into the address bar of any web browser to connect to the web interface The first page displayed is the home screen Displayed on this page are the dryers operating status operating mode current dryer lo...

Page 11: ...ous dryer set points and setup E mail alerts that will send an e mail to up to 3 different e mail addresses whenever an alarm or warning occurs on the dryer Figure 5 Settings 2 Modbus TCP The Modbus TCP connection allows you to continuously monitor the dryer from a DCS system which implements a Modbus TCP master The dryer controller implements a ModbusTCP server on port 502 The following Modbus re...

Page 12: ...served 40023 0x0016 RESERVED N A Reserved 40024 0x0017 ENERGY_COST Integer Energy cost Cost kWh 40025 0x0018 AUDIBLE_ALARM Boolean Audible Alarm 0 Disabled 1 Enabled 40026 0x0019 MODBUS_ADDRESS Integer Modbus Address 40027 0x001A FULL_POWER Watts Full load power 40028 0x001B 40029 0x001C 40030 0x001D 40031 0x001E 40032 0x001F 40033 0x0020 ALARM_MSG_1 Integer Alarm message 1 phrase id 40034 0x0021 ...

Page 13: ...7 0x0080 Phase Reversal 8 0x0100 Phase Loss 9 0x0200 Evaporator Temperature Sensor Failure 10 0x0400 Glycol Temperature Sensor Failure 11 0x0800 Evaporator Outlet Temperature Sensor Failure 12 0x1000 Discharge Temperature Sensor failure 13 0x2000 High Super Heat 14 0x4000 Reserved 15 0x8000 Reserved Dryer Warning Flags Register 40003 Bit Mask Description 0 0x0001 High Evaporator Temperature 1 0x00...

Page 14: ...0D DEMM 1000 14 0x000E DEMM 1250 15 0x000F DEMM 1500 16 0x0010 DEMM 1750 17 0x0011 DEMM 2000 18 0x0012 DEMM 2500 19 0x0013 DEMM 3000 20 0x0014 Reserved 21 0x0015 Reserved 22 0x0016 Reserved 23 0x0017 Reserved 24 0x0018 Reserved 25 0x0019 Reserved 26 0x001A Reserved 27 0x001B Reserved 28 0x001C Reserved 29 0x001D Reserved 30 0x001E Reserved 31 0x001F Reserved Dryer Mode Register s 40018 Decimal Hex...

Page 15: ...cription 0 0x0000 English 1 0x0001 Spanish 2 0x0002 French 3 0x0003 German 4 0x0004 Portuguese 5 0x0005 Italian 6 0x0006 Polish 7 0x0007 Danish 8 0x0008 Dutch 9 0x0009 Norwegian 10 0x000A Finnish 11 0x000B Swedish 12 0x000C Czech 13 0x000D Reserved 14 0x000E Reserved 15 0x000F Reserved ...

Page 16: ...ly 3 4 Annually A Replace the filter element in the moisture separator annually Also replace the cold coalescing filter element annually where applicable B Replace the drain service unit annually C Maintenance kits are available to facilitate annual maintenance Models 0 5 0 75 Head Bowl O Ring Bowl Element Float Drain Drain Line Connection Models 1 0 3 5 Head Extrusion O Ring Models 600 750 Only E...

Page 17: ...mpressor capacity and ambient air or water temperature See D below B High pressure drop across dryer 1 Excessive air flow 2 Freezing of moisture in evaporator because of refrigeration system fault 3 Separator filter element clogged Check flow rate See D below Replace filter element C Dew point indicator in red area 1 Dryer overloaded resulting in high air outlet temperature 2 Refrigeration system ...

Page 18: ... Lack of condenser cooling Air cooled Ambient temperature too high clogged condenser fins obstructed flow across condenser faulty fan motor or fan control switch Water cooled Cooling temperature too high flow too low clogged strainer faulty water regulating valve a Dryer overloaded b Refrigeration system off or not cooling sufficiently a Drain line restricted or frozen b Drain mechanism faulty a F...

Page 19: ...ed capacity of air cooled models scfm 60 Hz 50 Hz 50 42 70 58 100 83 160 133 MODEL 2 0 2 5 3 5 Rated capacity of air cooled models scfm 60 Hz 50 Hz 200 167 240 200 330 275 TABLE 2 Air capacity correction factors Multipliers INLET COMPRESSED AIR CONDITIONS INLET PRESSURES INLET TEMPERATURES 80 F 90 F 100 F 110 F 120 F psig kgf cm2 27 C 32 C 38 C 43 C 49 C 50 80 100 125 150 175 200 3 5 5 6 7 0 8 8 1...

Page 20: ...tage 115 1 60 208 230 3 60 Min Max Voltage 104 127 187 253 Input Power Rated Flow watts 875 1070 1255 1962 2680 2910 4120 Rated Load Amps 9 5 13 0 7 5 10 4 11 4 13 9 22 1 Locked Rotor Amps 44 0 70 0 51 0 66 0 75 0 88 0 115 0 Minimum Circuit Ampacity 12 8 18 0 10 5 15 9 20 0 19 7 30 4 Branch Circuit Fuse Size amps 20 25 15 20 25 30 45 Resistance ohms 4 3 S 0 6 R 1 06 S 0 42 R 1 8 1 3 1 1 1 0 0 7 No...

Page 21: ...r Disabled Enabled 2 Status Menu Scrolling Disabled Enabled 3 Reserved N A N A 4 Reserved N A N A Dryer Configuration Description Units Lower Upper Increment Default Service Interval Hours 0 9999 1 4000 Energy Cost Decimal 0 00 0 99 0 01 0 13 Total Hours Hours 0 999999 1 0 Modbus Device Address Integer 1 247 1 1 ...

Page 22: ...ton pressed Halt compressors De energize alarm relay 1 HEATER Heater switch open 1 Second Standby Alarm reset button pressed De energize alarm relay 2 DRAIN 1 Drain 1 switch open 1 Second Dryer On Alarm reset button pressed De energize alarm relay 2 DRAIN 2 Drain 2 switch open 1 Second Dryer On Alarm reset button pressed De energize alarm relay 2 SERVICE DRYER Dryer service interval 0 AND Dryer se...

Page 23: ...p Down Up Down Status Menu Total Hours 30 HRS TO SERVICE 4970 02 24 2011 09 40 MANUAL MODE VERSION 2 x DISCHARGE xxx x C xxx F EVAPORATOR IN xxx x C xxx F Up Down EVAPORATOR OUT xxx x C xxx F Up Down Hidden if evaporator outlet temperature sensor disabled ALARM MESSAGE 1 ALARM MESSAGE 2 Shown for each active alarm Up Down Up Down ...

Page 24: ...ENU ENERGY COST MAIN MENU AUTO RESTART Down Up Down Up Down Up LANGUAGE ENGLISH Enter DATE TIME 02 24 2011 09 40 Enter SCHEDULE MON ON IGNORE Enter HRS TO SERVICE 4970 Enter 02 24 2011 09 55 ALARM MESSAGE 1 Enter ENERGY COST 0 10 KWH Enter AUTO RESTART DISABLED Enter Down Up Down Up Down Up Down Up Setup Menu Down Up Network Menu MAIN MENU NETWORK MENU Enter NOTE Press hold ESC button for 3 second...

Page 25: ... MENU IP ADDRESS TYPE Network Menu IP ADDRESS TYPE DYNAMIC Enter NETWORK MENU IP ADDRESS Up Down IP ADDRESS 192 168 0 2 Enter NETWORK MENU SUBNET MASK Up Down SUBNET MASK 255 255 255 0 Enter NETWORK MENU DEFAULT GATEWAY Up Down DEFAULT GATEWAY 192 168 0 1 Enter Up Down NETWORK MENU MODBUS ADDRESS Up Down MODBUS ADDRESS 1 Enter ...

Page 26: ...ESS PE T2 T1 FAN 1 HARNESS I O PE GROUND STUD L2 L1 L2 230 VAC CUSTOMER SUPPLIED L1 PE POWER ON PILOT LIGHT T2 T2 T2 T1 T1 PE T2 T1 T1 FPS 1 FAN 1 MTR2 START RELAY SR SR L3 L3 M 6 5 S CAPACITOR 4 OVERLOAD 3 1 3 MTR1 COMPRESSOR R C S 120 VAC POWER CORD SUPPLIED ...

Page 27: ...ONT 1 PE PE L1 CONT 1 6 L2 GROUND STUD L2 L1 PE 230 VAC CUSTOMER SUPPLIED L1 L2 L2 L2 L1 L2 L1 L1 T2 T2 T1 T1 CONT 1 L1 N 4 5 5 A PE 6 FAN 1 HARNESS HEATER HARNESS PE L2 T2 T1 FPS 1 H1 H2 HEATER 1 MTR2 FAN 1 COMPRESSOR HARNESS PE 1 C 4 COMPRESSOR MTR1 120 VAC POWER CORD SUPPLIED 2NC 1NC L3 L2 L1 T3 T2 T1 O I A1 SR A2 C R S RC SC 1 2 5 ...

Page 28: ...02 L1 L3 X N FPS 1 FPS 2 COMPRESSOR HARNESS HEATER HARNESS FAN 1 HARNESS FAN 2 HARNESS PE L3 L2 L1 4 Terminal Blocks REF SHEET 01 LINE 20 REF SHEET 02 LINE 10 Optional Fan TO LINE 22 FROM LINE 21 L1 L2 L3 L3 T1 T2 T3 T1 T2 T3 T3 for 500 600 models only TB1 REF SHEET 02 LINE 11 H4 H3 H2 H1 FU2 FU3 B100 3683 5 MICRON L1 L3 H5 208V 230V H5 400V H5 460V H5 FACTORY SET TO 460V FU1 ELECTRICAL SUPPLY 480...

Page 29: ...1 HARNESS HPS LPS HPS 19 19 17 18 CONT 1 TB2 19 15 16 19 19 HPS LPS SENSOR HARNESS COMPRESSOR CONTACTOR PE RED WHITE CONT 1 7 CONNECTOR INSTRUMENT BOARD 18 17 X 4 TEST ALM 24VAC 1 PE 2 5 6 4 3 8 7 19 20 N X DRAIN 2 HARNESS 19 TB2 21 20 19 18 17 16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 22 REMOVE JUMPER IF OPTIONAL DRAIN INSTALLED 4 N 24VAC IN 24VAC IN Compressor 1 Output Chassis Gnd N A C...

Page 30: ...T 02 X N FPS 1 FPS 2 COMPRESSOR HARNESS HEATER HARNESS FAN 1 HARNESS FAN 2 HARNESS PE L3 L2 L1 4 Terminal Blocks REF SHEET 01 LINE 20 REF SHEET 02 LINE 10 TO LINE 22 FROM LINE 21 L1 L2 L3 L3 T1 T2 T3 T1 T2 T2 T3 DISCONNECT L1 L2 L3 REF SHEET 02 LINE 11 TB1 FU1 MICRON B100 3683 5 FU3 FU2 L3 L1 ELECTRICAL SUPPLY 480VAC 3PH 60HZ GND MTR1 MTR2 T1 T2 T3 L1 L2 L3 MTR3 1NC 2NC H2 CONT 1 460V 24V 120V H1 ...

Page 31: ...SS COMPRESSOR CONTACTOR PE RED WHITE CONT 1 7 CONNECTOR INSTRUMENT BOARD 18 17 X 4 TEST ALM 24VAC 1 PE 2 5 6 4 3 8 7 19 20 N X DRAIN 2 HARNESS 19 TB2 21 20 19 18 17 16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 22 REMOVE JUMPER IF OPTIONAL DRAIN INSTALLED 4 N 24VAC IN 24VAC IN Compressor 1 Output Chassis Gnd N A Compressor 1 Output Drain Test Output N A Alarm B N O Drain Test Output Alarm B C...

Page 32: ...1 X2 X3 X4 PE L3 L2 L1 TB2 FU1 M FU2 M FU3 M FU1 P FU2 P FU3 P 575V VOLTAGE OPTION 575V 460V TRANSFORMER BANK 460V CONNECTION 460 3 60 CUSTOMER CONNECTION PRIMARY FUSE ENCLOSURE 575 3 60 CONNECTION CUSTOMER 575V TRANSFORMER 1 TRANSFORMER 2 1 2 3 PE 1 2 3 PE PE 1 2 3 PE H2 H4 H1 H3 H2 H4 ...

Page 33: ...15 817 32 15 817 32 15 817 32 15 817 C 1 63 41 1 63 41 1 88 48 1 88 48 2 77 70 2 77 70 2 77 70 D 23 62 600 23 62 600 30 15 766 30 15 766 30 15 766 30 15 766 30 15 766 E 17 62 448 17 62 448 30 15 766 30 15 766 39 62 1006 39 62 1006 39 62 1006 F 19 62 498 19 62 498 32 15 817 32 15 817 41 62 1057 41 62 1057 41 62 1057 G 9 58 243 9 58 243 7 64 194 7 64 194 20 44 519 20 44 519 20 44 519 H 14 96 380 14 ...

Page 34: ... REFERENCE RIGHT REAR VIEW A covers and center support shelf removed for clarity 2 9 12 7 8 10 11 15 18 16 17 1 3 4 RIGHT FRONT VIEW B covers and center support shelf removed for clarity 7 8 10 2 9 15 13 14 19 1 6 5 LEFT REAR VIEW C covers and center support shelf removed for clarity ...

Page 35: ...5002350 5002350 5002350 10 Condenser 5002249 5002249 5002249 3232828 3232828 3232828 11 Filter Dryer 3223808 3223808 3223808 3223809 3223809 3223809 12 Fan Pressure Switch 3230761 3230761 3230761 3230761 3230761 3230761 13 Contactor N A N A N A 5002260 5002262 5002262 14 Auxiliary Contactor N A N A N A 5002261 5002263 5002263 15 Crankcase Heater N A N A N A 3223258 3223259 3223259 16 Light Assembl...

Page 36: ... VIEW ORIENTATION REFERENCE RIGHT REAR VIEW A covers and center support shelf removed for clarity 7 2 8 1 21 3 RIGHT FRONT VIEW B covers and center support shelf removed for clarity 6 4 5 8 1 7 21 10 11 12 3 9 LEFT REAR VIEW C covers and center support shelf removed for clarity ...

Page 37: ... 3159128 3159128 3159128 3159128 3159128 3159128 3159128 3159128 16 Fuse Primary 2 3223962 3223962 3223962 3223962 3223962 3223953 3223953 3223953 3223953 3223953 17 Fuse Secondary 2 4010495 4010495 4010495 4010495 4010495 4010495 4010495 4010495 4010495 4010495 18 Digital PC Board 2 3 7442633 7442633 7442633 7442633 7442633 7442633 7442633 7442633 7442633 7442633 19 Digital PC Board Fuse 2 500294...

Page 38: ...2 3 5 1 6 16 VIEW ORIENTATION REFERENCE RIGHT REAR VIEW A covers and center support shelf removed for clarity 4 2 3 1 7 5 16 RIGHT FRONT VIEW B covers and center support shelf removed for clarity 7 2 16 18 3 1 6 LEFT REAR VIEW C covers and center support shelf removed for clarity ...

Page 39: ...442633 7442633 7442633 7442633 7442633 7442633 7442633 7442633 7442633 7442633 14 Digital PC Board Fuse 2 5002943 5002943 5002943 5002943 5002943 5002943 5002943 5002943 5002943 5002943 15 Temperature Sensor 2 5007289 5007289 5007289 5007289 5007289 5007289 5007289 5007289 5007289 5007289 16 Electric Demand Drain Optional 7428268 7428268 7428268 7428268 7428268 7428268 7428268 7428268 7428268 7428...

Page 40: ...PLACEMENT CABINET PARTS Models 1 0 through 3 5 2 5 3 6 1 4 ID PARTS DESCRIPTION 1 0 1 5 2 0 2 5 3 5 1 Cabinet Panel Top 5002082 5002082 5002106 5002106 5002106 2 Cabinet Panel Front 5002083 5002083 5002107 5002107 5003092 3 Cabinet Panel Rear 5002084 5002084 5002111 5002111 5002111 4 Cabinet Panel Left 5002084 5002084 5002108 5002108 5002108 5 Cabinet Panel Right upper 5002085 5002085 5002109 5002...

Page 41: ...39 NOTES ...

Page 42: ...40 NOTES ...

Page 43: ...part THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN ORAL OR STATUTORY AND IS EXPRESSLY IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR DAMAGE BY REASON OF STRICT LIABILITY IN TORT OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN MANUFACTURE ...

Page 44: ... spx com www spx com hankison Improvements and research are continuous at SPX Specifications may change without notice ISSUED 04 2015 Form No 5003343 Revision E COPYRIGHT 2015 SPX Corporation GCU Series Refrigerated Type Compressed Air Dryers Models GCU 0 5 GCU 0 75 GCU 1 0 GCU 1 5 GCU 2 0 GCU 2 5 GCU 3 5 ...