!

This dryer configuration includes equipment

options as selected (X) below:

EMS OPTION
LDP OPTION
3V OPTION

More Than Air. Answers.

Online answers: http://www.air.irco.com
Phone : 1-800-526-3615

Form: APDD 792

CCN: 38019683
Z103146 Rev. 10
 USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

FOREWORD
Reading this user manual will fully familiarize you with the Ingersoll-Rand adsorption
dryer. You will be better able to run this equipment in accordance with its intended use.
This manual contains important information for safe, proper and economic dryer
installation, start-up, operation and maintenance. Always keep it within reach where the
adsorption dryer is being used.
It is necessary to follow all instructions as written. Careful reading will avert danger,
avoid unnecessary downtime, and minimize work for yourself and wear on the
equipment.
In addition to carefully reading this technical manual in its entirety, you must understand
your National, State and local rules and regulations regarding safety in the workplace,
their necessary precautions and procedures.
Each person responsible for the set-up, start-up, operation, maintenance or repair of
this adsorption dryer must have first read and understood this user manual – including
all the safety tips.

NOTE: Ingersoll-Rand recommends that installation, start-up and maintenance

be carried out by its factory-trained technicians in a regularly scheduled,
site-dedicated program. This will ensure the safety of personnel, the
integrity of equipment and the surety of warranty coverage.

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REV 10 – 23 February 2006

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REV 10 – 23 February 2006

TABLE OF CONTENTS
1. INTRODUCTION ..................................................................................................................................................1
1.1 GENERAL.............................................................................................................................................................1
1.2 PRODUCT INFORMATION......................................................................................................................................1
1.2.1 Pressure Vessel Regulations........................................................................................................................2
1.2.2 Leak Test......................................................................................................................................................2
1.3 SAFETY INSTRUCTIONS ........................................................................................................................................2
1.3.1 Identification of Signs and Symbols in this Manual.....................................................................................2
1.3.2 General Safety Tips for Assembly, Inspection and Maintenance.................................................................3
1.4 TECHNICAL DATA SHEET ....................................................................................................................................4
1.4.1 Models TZE400 to TZE820..........................................................................................................................4
1.4.2 Models TZE1000 to TZE1800......................................................................................................................5
1.4.3 Models TZE2100 to TZE3500......................................................................................................................6
1.4.4 Dryer Flow Capacities ................................................................................................................................7
1.5 OVERLOADING ....................................................................................................................................................8
1.6 TRANSPORT .........................................................................................................................................................8
1.7 STORAGE .............................................................................................................................................................8
1.8 USE OF A PREFILTER AND AFTERFILTER ..............................................................................................................8
2. INSTALLATION....................................................................................................................................................9
2.1 GENERAL.............................................................................................................................................................9
2.2 MECHANICAL ASSEMBLY ....................................................................................................................................9
2.3 FILTER INSTALLATION .......................................................................................................................................10
2.3.1 Prefilter Installation (Shipped Loose) .......................................................................................................10
2.3.2 Afterfilter Installation (Shipped Loose) .....................................................................................................11
2.3.3 Filter Skid with 3 Valve Bypass (If Dryer Includes 3V Option).................................................................11
2.4 ELECTRICAL CONNECTION ................................................................................................................................11
2.5 EMS CONTROL CONNECTION ...........................................................................................................................12
3. EQUIPMENT OPERATION ..............................................................................................................................13
3.1 GENERAL OPERATING PRINCIPLES ....................................................................................................................13
3.1.1 Dryer Program Steps.................................................................................................................................14
3.2 OPERATOR CONTROLS / LOW-VOLTAGE CONTROL PANEL ...............................................................................16
3.2.1 Dryer Status...............................................................................................................................................18
3.2.2 Alarm Information .....................................................................................................................................19
3.2.3 Dryer Operation Modes.............................................................................................................................20
3.2.4 Heater Sheath Information ........................................................................................................................20
3.2.5 Heater Outlet Information .........................................................................................................................21
3.2.6 Regeneration Outlet Information...............................................................................................................21
3.2.7 Dryer Off, Dryer On, EMS On – 3-Position Switch..................................................................................21
3.2.8 Status Lamps..............................................................................................................................................22
3.2.9 Pressure Gages..........................................................................................................................................22
3.3 INITIAL START-UP .............................................................................................................................................22
3.3.1 Pressurizing Dryer.....................................................................................................................................22
3.3.2 Energizing Dryer Controls ........................................................................................................................23
3.3.3 Pressure Switch Adjustment.......................................................................................................................24
3.3.4 EMS Start Up.............................................................................................................................................24
3.4 SHORT-TERM SHUTDOWN .................................................................................................................................26
3.5 SHUTDOWN IN CASE OF A FAULT OR FOR MAINTENANCE .................................................................................26
3.6 RESTARTING ......................................................................................................................................................26
4. MAINTENANCE..................................................................................................................................................27
4.1 CHECKLIST ........................................................................................................................................................27
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4.1.1 Daily Check ...............................................................................................................................................27
4.1.2 Weekly Check..............................................................................................................................................27
4.1.3 Quarterly Check (Every Three Months) ....................................................................................................27
4.1.4 Annual Check.............................................................................................................................................28
4.2 CHANGING THE FILTER ELEMENT......................................................................................................................28
4.3 REPLACEMENT OF THE DESICCANT ...................................................................................................................29
5. PARTS LISTINGS ...............................................................................................................................................31
5.1 PARTS LIST FOR TZE400 TO TZE650................................................................................................................31
5.2 PARTS LIST FOR TZE820 TO TZE1225..............................................................................................................32
5.3 PARTS LIST FOR TZE1500 TO TZE2100............................................................................................................33
5.4 PARTS LIST FOR TZE2500 TO TZE3500.............................................................................................................34
6. FAULTS AND TROUBLESHOOTING.............................................................................................................38
6.1 DEWPOINT HAS DETERIORATED .............................................................................................................38
6.2 HIGH HUMIDITY ALARM OR SENSOR FAILURE ...................................................................................39
6.3 PRESSURE DROP TOO HIGH.......................................................................................................................39
6.4 SWITCHING FAILURE ALARM...................................................................................................................39
7. DRAWINGS..........................................................................................................................................................42

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1. INTRODUCTION
1.1 GENERAL
This adsorption dryer includes the latest technology and safety features. Its use,
however, can endanger life and limb and can lead to considerable damage to the
equipment and other material assets if:

• it is operated by personnel not instructed in its use,

• it is improperly used,

• it is improperly maintained or serviced.

Furthermore, ignorance of its use and proper service can result in the loss of any claim
for damage.
This adsorption dryer is designed for neutral media (such as air or nitrogen) which is
free of aggressive water, oil and solid elements. Ingersoll-Rand accepts no liability for
corrosion damage or malfunctions caused by aggressive media.
Applications other than those mentioned in this manual must be agreed to by Ingersoll-
Rand and confirmed in writing.
Ingersoll-Rand reserves the right to make changes at any time as may be necessary for
increasing safety or efficiency, or In the interests of further product development.

1.2 PRODUCT INFORMATION

The adsorption dryer is used for the purpose of drying compressed air and other gases
according to its contracted design. Depending on certain conditions at the inlet, it
provides pure, dry and oil-free compressed air or gases. The standard model of
adsorption dryer is equipped with two desiccant vessels and a prefilter and afterfilter.
This specific model of dryer includes an Energy Management System (EMS) that
provides automatic monitoring and control of the work/regeneration cycle to optimize
equipment efficiency. This manual includes references to optionally available Low Dew
Point (LDP) and 3-valve bypass (3V) systems/assemblies which may or may not be
provided. Selected options included with this dryer are indicated on the cover page by
an “X” mark in the box.

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REV 10 – 23 February 2006

1.2.1 PRESSURE VESSEL REGULATIONS

The pressure vessels are designed and built to meet the American Society of
Mechanical Engineers (ASME) standards. They fulfill the test of the certifying procedure
and carry the ASME symbols U or UM.
RANGE OF APPLICATION
Design Pressure Max: 150 psig

Max: 500 °F (260 °C)

Design Temperature
Min: -20 °F (-29 °C)

1.2.2 LEAK TEST

Each Ingersoll-Rand adsorption dryer is subjected to, and passes, a leak test prior to
shipment.

1.3 SAFETY INSTRUCTIONS

This manual contains basic tips which must be followed during set-up, operation and
servicing. It is of utmost importance that it be read by the assembly technician before
installation and start-up as well as by the specialist/operator in charge. It must always
be within reach at the place where the adsorption dryer is being used.

1.3.1 IDENTIFICATION OF SIGNS AND SYMBOLS IN THIS MANUAL

The safety tips contained in this manual, whose disregard could endanger people and
equipment, are indicated by a general danger sign and the additional markings Danger!
or Attention! or Warning!

Danger! / Attention!
Safety sign in accordance with DIN 4844 - W9

Warning – high voltage!

Safety sign in accordance with DIN 4844 - W8

Safety tips printed directly on the adsorption dryer must be heeded at all times and must
be kept completely legible.

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REV 10 – 23 February 2006

1.3.2 GENERAL SAFETY TIPS FOR ASSEMBLY, INSPECTION AND MAINTENANCE

The purchaser is to ensure that all assembly, maintenance and inspection work is
carried out by personnel qualified to do it.
The personnel involved in assembly, operation, maintenance and inspection must have
the corresponding qualifications to do this work. Areas of responsibility and supervision
of the personnel must be clearly established by the purchaser. Should the personnel
not possess the necessary knowledge, then they must be instructed. If need be, this
training may be carried out by the manufacturer/supplier at the request of the purchaser.
Further, the purchaser is to ensure that all personnel completely understand and follow
the content of this manual.
Attention!

• Never make structural changes to the adsorption dryer

• Only use recommended spare parts as listed in section 5

• Never weld on a pressure vessel or change it in any way

• Carry out maintenance only when the adsorption dryer is OFF,

depressurized and disconnected from the electric power supply.

Danger!

• Review the Material Safety Data Sheet (MSDS) provided with the
desiccant

• Wear protective clothing and goggles when working with the

desiccant

• If desiccant comes into contact with the eyes, rinse eyes

immediately with a lot of clear water

• If the desiccant is spilled, clean up without causing swirls of dust

• In case of fire, there is no restriction on the use of fire extinguishing

material; the reaction with water and foam is defined as strong

• A mask must be worn whenever handling desiccant.

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1.4 TECHNICAL DATA SHEET

1.4.1 MODELS TZE400 TO TZE820
Model TZE400 TZE500 TZE650 TZE820
Rated flow @ 100 psig &
400 scfm 500 scfm 650 scfm 820 scfm
100°F inlet conditions
Chamber Outer Diameter 18 inches 18 inches 18 inches 20 inches
Standard (no LDP option):
100% Activated Alumina
Desiccant Bed 272 350 433 660
Composition & Pounds With LDP option – Layered:
per Chamber 33% Mol Sieve (bottom), 67% Activated Alumina (top).
1st MS: 90 1st MS: 115 1st MS: 143 1st MS: 218
2nd AA: 182 2nd AA: 235 2nd AA: 290 2nd AA: 442
Inlet Connection 2-in NPT 2-in NPT 2-in NPT 3-in RF FLG
Outlet Connection 2-in NPT 2-in NPT 2-in NPT 3-in RF FLG
Recommended Prefilter HE563 HE563 HE 706 HE 1100
Recommended Afterfilter DP563 DP563 DP 706 DP 1100
Pilot Air Filter AR-0003G/B AR-0003G/B AR-0003G/B IR-DP19
Standard Electric Rqmt 460 Vac/3-phase/60 Hz
Heater 6 kW 6 kW 8 kW 12 kW
8-Hour Cycle –
Cycle Time
4 Hours Drying / 4 Hours Regeneration
Outlet Pressure Dewpoint -40°F PDP (-100°F LDP)
EMS Control Setting -40°F PDP (-100°F LDP)
High Humidity Alarm -35°F PDP (-95°F LDP)
Pressure Switch Setpoints PSL – 10 psig / PSH – 30 psig below line pressure
Purge Pressure Setting 70 psig 65 psig 55 psig 55 psig
Low Purge Alarm Setpoint 60 psig 55 psig 45 psig 45 psig
Heater Outlet Setpoint 425°F
End Heating Temperature 180°F
End Cooling Temperature 120°F
Heater Sheath Alarm 1000°F
Flow Directions Downward Drying – Upward Regeneration

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REV 10 – 23 February 2006

1.4.2 MODELS TZE1000 TO TZE1800

Model TZE1000 TZE1225 TZE1500 TZE1800
Rated flow @ 100 psig &
1000 scfm 1225 scfm 1500 scfm 1800 scfm
100°F inlet conditions
Chamber Outer Diameter 24 inches 24 inches 28 inches 28 inches
Standard (no LDP option):
100% Activated Alumina
Desiccant Bed 825 990 1055 1320
Composition & Pounds per With LDP option – Layered:
Chamber 33% Mol Sieve (bottom), 67% Activated Alumina (top).
1st MS: 272 1st MS: 327 1st MS: 348 1st MS: 436
2nd AA: 553 2nd AA: 663 2nd AA: 707 2nd AA: 884
Inlet Connection 3 in RF FLG 3 in RF FLG 3 in RF FLG 4 in RF FLG
Outlet Connection 3 in RF FLG 3 in RF FLG 3 in RF FLG 4 in RF FLG
Recommended Prefilter HE1100 HE 1380 HE 2100 HE 2100
Recommended Afterfilter DP1100 DP 1380 DP 2100 DP 2100
Pilot Air Filter IR-DP19 IR-DP19 IR-DP19 IR-DP19
Standard Electric Rqmt 460 Vac/3-phase/60 Hz
Heater 17 kW 21 kW 25 kW 28 kW
8 Hour Cycle –
Cycle Time
4 Hours Drying / 4 Hours Regeneration
Outlet Pressure Dewpoint -40°F PDP (-100°F LDP)
EMS Control Setting -40°F PDP (-100°F LDP)
High Humidity Alarm -35°F PDP (-95°F LDP)
Pressure Switch Setpoints PSL – 10 PSIG / PSH – 30 PSIG below line pressure
Purge Pressure Setting 70 psig 60 psig 65 psig 70 psig
Low Purge Alarm Setpoint 60 psig 50 psig 55 psig 60 psig
Heater Outlet Set Point 425°F
End Heating Temperature 180°F
End Cooling Temperature 120°F
Heater Sheath Alarm 1000°F
Flow Directions Downward Drying - Upward Regeneration

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REV 10 – 23 February 2006

1.4.3 MODELS TZE2100 TO TZE3500

Model TZE2100 TZE2500 TZE3000 TZE3500
Rated flow @ 100 psig &
2100 scfm 2500 scfm 3000 scfm 3500 scfm
100°F inlet conditions
Chamber Outer Diameter 30 inches 36 inches 40 inches 40 inches
Standard (no LDP option):
100% Activated Alumina
Desiccant Bed 1485 1722 2310 2805
Composition & Pounds With LDP option – Layered:
per Chamber 33% Mol Sieve (bottom), 67% Activated Alumina (top).
1st MS: 490 1st MS: 568 1st MS: 762 1st MS: 926
2nd AA: 995 2nd AA: 1154 2nd AA: 1548 2nd AA: 1879
Inlet Connection 4-in RF FLG 4-in RF FLG 6-in RF FLG 6-in RF FLG
Outlet Connection 4-in RF FLG 4-in RF FLG 6-in RF FLG 6-in RF FLG
Recommended Prefilter HE 2100 HE 2750 HE 4100 HE 4100
Recommended Afterfilter DP 2100 DP 2750 DP 4100 DP 4100
Pilot Air Filter IR-DP19 IR-DP19 IR-DP19 IR-DP19
Standard Voltage 460 Vac/3-phase/60 Hz
Heater 30 kW 36 kW 43 kW 50 kW
8-Hour Cycle –
Cycle Time
4 Hours Drying / 4 Hours Regeneration
Outlet Pressure
-40°F PDP (-100°F LDP)
Dewpoint
EMS Control Setting -40°F PDP (-100°F LDP)
High Humidity Alarm -35°F PDP (-95°F LDP)
Pressure Switch Set
PSL – 10 psig / PSH – 30 PSIG below line pressure
Points
Purge Pressure Setting 60 psig 70 psig 65 psig 60 psig
Low Purge Alarm Set
50 psig 60 psig 55 psig 50 psig
Point
Heater Outlet Set Point 425°F
End Heating
180°F
Temperature
End Cooling
120°F
Temperature
Heater Sheath Alarm 1000°F
Flow Directions Downward Drying - Upward Regeneration

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REV 10 – 23 February 2006

1.4.4 DRYER FLOW CAPACITIES

The specific size/model of your dryer was selected to meet performance requirements
based on an analysis of air supply and demand capacities. The model selection chart
provided following should confirm that this dryer remains suitable for its intended use.
The table following is based on -40oF PDP, 8-hour cycle, activated alumina and average
inlet air flow for non-LDP-equipped dryers with EMS. Consult our factory for rated air
flows on LDP-equipped dryers.
Rated inlet air flow (scfm) at given pressures (psig)
Design Inlet o
(Based upon 100 F inlet air temperature)
MODEL Air Pressure
(psig) 60 70 80 90 100 110 120 130 140
TZE400 150 220 265 310 355 400 440 480 520 550
TZE500 150 305 355 400 460 500 550 590 645 680
TZE650 150 360 435 505 580 650 705 790 850 905
TZE820 150 460 550 640 735 820 905 990 1070 1150
TZE1000 150 615 715 805 920 1000 1140 1255 1325 1420
TZE1225 150 690 825 955 1100 1225 1360 1490 1610 1735
TZE1500 150 785 960 1150 1275 1500 1600 1730 1875 2010
TZE1800 150 1010 1210 1405 1610 1800 1995 2190 2375 2535
TZE2100 150 1095 1345 1600 1835 2100 2275 2500 2700 2890
TZE2500 150 1480 1735 1985 2270 2500 2820 3100 3355 3585
TZE3000 150 1685 2015 2340 2680 3000 3330 3645 3960 4235
TZE3500 150 1900 2300 2700 3095 3500 3845 4195 4570 4890

Higher pressures are optionally available. Consult factory.

To correct for an inlet temperature other than 100oF, multiply dryer capacity by the
temperature correction factor listed below.
CORRECTION FACTOR FOR INLET TEMPERATURE
TEMPERATURE
DEGREES F 80 90 100 105 110 115 120
Correction Factor 1.1 1.1 1.0 0.85 0.69 0.565 0.455

Example: To size for an inlet flow of 950 SCFM @ 105 F and 110 psig.
1. Select model that produce at least 950 SCFM at 110 psig. This case would be the TZE1000 which
can dry 1140 SCFM.
2. Multiply pressure corrected flow by the temperature correction factor to obtain the flow of the dryer
corrected for pressure and temperature:
1140 X (0.85) = 969 SCFM
3. Confirm model selection. Model TZE1000 can flow 969 SCFM at the inlet conditions specified;
requirements of 950 SCFM are less: TZE1000 is correct.

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REV 10 – 23 February 2006
NOTE: Settings for EMS: Standard Dryers: EMS Control -40°F (-40°C)
High Humidity -35°F (-35°C)
LDP Dryers: EMS Control -100°F (-74°C)
High Humidity -95°F (-69°C).

1.5 OVERLOADING
Attention! Protect the adsorption dryer from overloads!
The adsorption dryer can become overloaded if:
• The flow volume of the medium to be dried increases
• The temperature of the air at entry and, correspondingly, its
humidity increases
• The minimum operating pressure decreases
• The prefiltration and separation of impurities are not sufficient or the
filter drain fails
• Introduction of oil into the air stream.

1.6 TRANSPORT
Immediately upon delivery of the adsorption dryer, it must be checked for any damage
that may have occurred during transport. If necessary, the damage must be recorded
on the shipping waybill/receipt. Liability for such damage usually rests with the shipper.
Contact Ingersoll-Rand to arrange for any required service or replacement parts.
Attention!
For transport within your company site, only the skids of the adsorption
dryer may be used. Lifting at any other points on the equipment will void
the warranty and damage the equipment.

1.7 STORAGE
If the adsorption dryer is to be stored for a long period of time, its place of storage must
be dry and free of dust. The ambient temperature cannot go below 33°F (+1°C).

1.8 USE OF A PREFILTER AND AFTERFILTER

In order to prevent droplets of condensate, oil and dirt from getting into the desiccant, a
Ingersoll-Rand prefilter must be installed upstream of the adsorption dryer. An oil film
on the desiccant reduces the drying capacity and the dewpoint. In order to prevent
breakdown in downstream consumers caused by material that has been abraded from
the desiccant bed, a Ingersoll-Rand afterfilter must be mounted behind the adsorption
dryer. Since no condensate accumulates in the afterfilter, this filter is always equipped
with a manual vent valve.

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REV 10 – 23 February 2006
Both filters are equipped with a differential pressure indicator to ensure a direct display
of the degree of contamination of the filter elements.

2. INSTALLATION
2.1 GENERAL
Ensure that the installation site is free of dust, dirt and litter. The site floor must be level
and strong enough to support the equipment. The site itself must be an heated
environment (minimum 50°F) to ensure proper operation and warranty protection.
Ensure that the Ingersoll-Rand adsorption dryer is carried only by its skid base frame.
The adsorption dryer must be positioned so that the side from which it is to be operated
is easily accessible. The piping is to be connected at a slightly downward slope. Install
isolation valves on the inlet and outlet sides of the adsorption dryer. Also, a bypass
pipe with an additional isolation valve should be mounted onto the adsorption dryer to
allow for an uninterrupted supply of compressed air in case the adsorption dryer
requires maintenance or repair. The bypass assembly is optionally provided (see
paragraph 1.2) or can be customer furnished. If vibrations occur at the installation site,
the adsorption dryer skid frame is to be placed onto vibration dampers.

2.2 MECHANICAL ASSEMBLY

• The equipment should be located in an area with adequate clearances for
service. An overhead clearance of not less than two feet above each desiccant
tower is required for loading of the desiccant.

• Remove all protective shipping crates, flange covers, etc.

• Using the mounting holes provided on the skid, anchor the dryer to a solid, level
foundation designed to support the equipment.

• Do not hydrostatically test the pressure vessels. All TZE dryer pressure vessels
and welded piping are hydrostatically tested at one and one-half times the design
pressure after fabrication and before assembly.

• Desiccant for models TZE820 and up is shipped loose and must be installed on
site. Refer now to paragraph 4.3 for instructions on installing the desiccant.

• If the equipment is installed in a high traffic area, protective barriers may be

required to prevent possible damage of equipment and to prevent contact with
hot surfaces.

• Due to vibration during shipping some tube fittings may have loosened.
Therefore, inspect all connections and tighten if required.

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REV 10 – 23 February 2006

• Ensure that the inlet and outlet connections to and from the dryer are made using
the correctly rated fittings and piping to meet the design conditions.
NOTE: System isolation and by-pass valves should be installed. If not supplied
by Ingersoll-Rand as part of the equipment package (i.e., 3V option – see
paragraph 1.2), they should be supplied and installed by others. Ensure
that this bypass facility is installed so that future servicing of the dryer
system off-line may take place.

• Full flow relief valves to protect the system from over-pressure must be
customer-provided in accordance with local regulations.

• The purge exhaust on the TZE650 and smaller dryers is equipped with an
exhaust muffler. If required, the muffler can be removed and purge exhaust can
be connected to a vent header. Follow recommendations for pipe sizing listed
below.

• The purge exhaust connection on the TZE820 and larger dryers must be
connected to a vent header. To ensure satisfactory regeneration of the desiccant
chambers, the purge exhaust piping should be sized as follows to prevent back-
pressure build up.
EXTENDED LENGTH PIPE SIZE REQUIRED
TO 10 FEET SAME SIZE AS DRYER EXHAUST
TO 25 FEET 1 SIZE LARGER THAN DRYER EXHAUST
TO 50 FEET 2 SIZES LARGER THAN DRYER EXHAUST
TO 100 FEET 3 SIZES LARGER THAN DRYER EXHAUST
Caution!
The noise at the outlet of the exhaust header may exceed 100 dBa, and
the flow velocity will be high. Exhaust must be piped to an area where
these flow velocities and noise levels can be safely tolerated.

2.3 FILTER INSTALLATION

2.3.1 PREFILTER INSTALLATION (SHIPPED LOOSE)

• Mount prefilter in such a way as to allow clearance for the element installation
and removal.

• Locate the prefilter as close to the dryer inlet connection as possible.

• The filter must be piped so that the correct flow direction indicated on the filter is
followed.

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REV 10 – 23 February 2006

• Ensure that all piping and valves are equivalent or larger in size to the dryer inlet
connection.

• Connect drain port to a condensate collector. Use an easily visible collector to

aid in operational inspection.

2.3.2 AFTERFILTER INSTALLATION (SHIPPED LOOSE)

• Mount afterfilter in such a way as to allow clearance for the element installation
and removal.

• The filter must be piped so that the correct flow direction indicated on the filter is
followed.

• Ensure that all piping and valves are equivalent or larger in size to the dryer inlet
connection.

2.3.3 FILTER SKID WITH 3 VALVE BYPASS (IF DRYER INCLUDES 3V OPTION)

• Filters skid should be located as close to dryer as possible. Use the skid bolt
holes to secure the assembly.

• Ensure that the skid is located such that the 3-valve bypass will bypass the dryer
and filters when in use.

• Check the flow direction of each filter to ensure the prefilter is connected to the
inlet pipe of the dryer and afterfilter is connected to the outlet pipe of the dryer.

• Connect the filter skid piping and dryer skid piping using materials and fabrication
procedures that are suitable for compressed air pressure piping. All flanges are
ANSI B16.5 Class 150 raised face flanges.

2.4 ELECTRICAL CONNECTION

Warning – high voltage!
Be sure that power is removed from the line feed before making
connection between the site drop and the equipment.

• Connect the dryer to a correctly sized power supply. Refer to the dryer
nameplate or the electrical drawing (see section 7) for the supply voltage and
amperage requirement to properly size the electrical service. Only one electrical
connection is required. All internal wiring was done at the factory.

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REV 10 – 23 February 2006
NOTE: A disconnect switch is not provided with the dryer and must be supplied
by the customer in accordance with the local electrical code.

• Ground the frame of the dryer in accordance with the local electrical code.

• It is recommended that the common alarm relay, located in the dryer control
panel, be connected to the control room or operator station so that an immediate
response to the dryer alarm may be given when required.

• Before energizing the electrical circuit, the electrical heater assembly should be
inspected to determine that no moisture has accumulated in the heater enclosure
or terminations. A 1000V meg-ohmmeter should be used to determine the
phase-to-ground insulation resistance for each phase. A minimum value of 500
kOhms should exist.

2.5 EMS CONTROL CONNECTION

• A probe sample line must be run from downstream of the afterfilter.

• A 10-ft length of 1/8-in stainless steel tubing and necessary compression fittings
are provided.

• Tube fittings are to be installed downstream of the afterfilter at the differential

pressure indicator (DPI) port T-fitting on the afterfilter outlet nozzle

• Remove the hexagonal plug from the DPI T-fitting.

• Insert 1/8-in tubing into compression fitting and tighten.

• Run the tubing back to the hygrometer housing. Cut to necessary length and
connect to the upper connection fitting. Tubing is semi-flexible so care must be
taken when bending to ensure the tubing does not kink.

• If the sample port is installed at a distance longer than the tubing supplied,
contact your Ingersoll-Rand distributor for assistance.

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3. EQUIPMENT OPERATION
3.1 GENERAL OPERATING PRINCIPLES
This dryer model has two parallel adsorption chambers filled with desiccant. While the
medium is being dried flowing top-down in one chamber, regeneration takes place from
the bottom up in the other chamber. The changeover from one chamber to the other is
controlled by the Energy Management System that monitors desiccant performance by
measuring the outlet air dew point. It can operate continuously and is fully automatic.
The standard dryer with EMS has a cycle time of eight hours. Half the cycle time is
dedicated to air drying work and the other half to desiccant regeneration, with one
chamber working to dry the air while the other regenerates. The dryer is configured at
the factory.
Wet air enters the working desiccant chamber (it can be either the left or right) at the
inlet switching valves (top) and is dried as it flows downward through the desiccant bed.
Dry air exits the dryer through the outlet check valve.
The regeneration of the off-line tower begins with a heating cycle. After having
depressurized the off-line tower, the purge orifice allows a portion of the dry outlet air to
flow across the regeneration heater. The heated regeneration air then passes upward
through the desiccant bed where it picks up previously adsorbed moisture from the
desiccant and is then evacuated to atmosphere through the purge exhaust valve.
At the completion of the regeneration heating cycle, the cooling cycle begins. The
regeneration heater is de-energized. The purge orifice allows a portion of the dry outlet
air to flow through the off-line tower. It is then evacuated to atmosphere through the
purge exhaust valve. When the cooling cycle is completed, the purge exhaust valve is
closed and the off-line tower is repressurized. Once at line pressure, the dryer is ready
to switch drying from one tower to the other. Dryer models TZE3000 and 3500 have
purge control valves which close once at line pressure and prior to switching from one
tower to the other.
The purge air is controlled by a purge adjusting valve and purge orifice located in the
purge line. Purge pressure is indicated on the purge pressure gauge.
Ingersoll-Rand high-efficiency prefilters and reverse-flow afterfilters are designed to
remove solids, oil and water condensate from compressed air and other neutral,
compressed gases. These filters provide high flows and low differential pressures.

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The prefilter is designed to flow from the inside to the outside. The afterfilter is designed
to flow from the outside to the inside. Solids are filtered out by impact or by the effect of
inertia, whereas oil particles and drops of moisture are filtered out by the effect of
coalescence. The contaminants collect at the bottom of the filter vessel and are drained
automatically or manually.

3.1.1 DRYER PROGRAM STEPS

This automatic dryer is equipped with a PLC which retains last-position data in the event
of a power failure or fast shutdown. The dryer will restart at the last position or can be
manually cycled on the operator interface to reset at step 1.

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OPEN LEFT CHAMBER OPEN RIGHT CHAMBER

STEP 1 INLET VALVE STEP 8 INLET VALVE
EV-1R & EV-11L (VALVE TO MOVE)
EV-1L & EV-11R (VALVE TO MOVE) 10-SEC TIMER/VALVE TO OPEN
10-SEC TIMER/VALVE TO OPEN

10 SEC PASS, LEFT 10 SEC PASS, RIGHT

CHAMBER ABOVE 60 psig CHAMBER ABOVE 60 psig

CLOSE RIGHT CLOSE LEFT CHAMBER

STEP 2 CHAMBER INLET VALVE STEP 9 INLET VALVE
EV-1L & EV-11R WAIT 5 SEC EV-1R & EV-11L WAIT 5 SEC FOR
FOR VALVE TO CLOSE VALVE TO CLOSE

5 SEC PASS 5 SEC PASS

DEPRESSURIZE DEPRESSURIZE
STEP 3 RIGHT CHAMBER STEP 10 LEFT CHAMBER
EV-2L & EV-3L (IF L/C <10 psig)
EV-2R & EV-3R (IF R/C <10 psig) ENERGIZE EV-1R & EV-11L
ENERGIZE EV-1L & EV-11R

10 SEC PASS AFTER RIGHT 10 SEC PASS AFTER LEFT

CHAMBER BELOW 30 psig CHAMBER BELOW 30 psig

RIGHT CHAMBER LEFT CHAMBER

STEP 4 HEATING PERIOD STEP 11 HEATING PERIOD
START R/C HEATING MODE START L/C HEATING MODE
FOR 140 MINUTES MAXIMUM; FOR 140 MINUTES MAXIMUM
ENERGIZE EV-1L AND EV11R ENERGIZE EV-1R & EV11L

HEATING TIMER FINISH OR PURGE HEATING TIMER FINISH OR PURGE

OUTLET TEMP ABOVE 200-DEG F OUTLET TEMP ABOVE 200-DEG F

RIGHT CHAMBER LEFT CHAMBER

STEP 5 COOLING PERIOD STEP 12 COOLING PERIOD
START R/C COOLING MODE FOR START L/C COOLING MODE FOR
100 MINUTES MAXIMUM / 100 MINUTES MAXIMUM /
60 MINUTES MINIMUM; 60 MINUTES MINIMUM
ENERGIZE EV-1L & EV-11R ENERGIZE EV-1R & EV-11L
IF COOLING TIMER DONE (100 MINUTES) OR PURGE IF COOLING TIMER DONE (100 MINUTES) OR PURGE
OUTLET TEMP BELOW 120-DEG F & 60 MINUTES PASSED OUTLET TEMP BELOW 120-DEG F & 60 MINUTES PASSED

REPRESSURIZE REPRESSURIZE
STEP 6 RIGHT CHAMBER STEP 13 LEFT CHAMBER
ENERGIZE EV-1L & EV-11R ENERIZE EV-1R & EV-11L

120 SEC PASS & BOTH 120 SEC PASS & BOTH
CHAMBERS ARE ABOVE 60 psig CHAMBERS ARE ABOVE 60 psig

RIGHT CHAMBER LEFT CHAMBER

STEP 7 STANDBY STEP 14 STANDBY
ENERGIZE EV-1L & EV-11R ENERGIZE EV-1R & EV11L

DRYER HALF-CYCLE COMPLETED (240 DRYER HALF-CYCLE COMPLETED (240

Su
MINUTES) OR BAD DEWPOINT OR EMS OFF MINUTES) OR BAD DEWPOINT OR EMS OFF SD
& BOTH CHAMBERS ARE ABOVE 60 psig & BOTH CHAMBERS ARE ABOVE 60 psig E

GO TO STEP 8 GO TO STEP 1

FIGURE 1 – DRYER PROGRAMMED STEPS

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3.2 OPERATOR CONTROLS / LOW-VOLTAGE CONTROL PANEL

The operator status display and control interface (i.e., monitor) is detailed in Figure 2. It
is provided to allow the operator to manually cycle through the programmed steps, and
to indicate system status. The system operating setpoints cannot be changed at this
panel.

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TEXT
DISPLAY

F1 – DRYER STATUS
F2 – MANUAL STEP AHEAD (MANUAL MODE ONLY)
F3 – DRYER ALARM STATUS
F4 – ALARM RESET
SHIFT – In order to choose one of the next four options, the SHIFT button
must be pressed first. An “s” in the lower right corner indicates the
upper row is now active.

F5 – DRYER OPERATING MODE MENU

F6 – HEATER SHEATH TEMPERATURE AND SETPOINT
F7 – HEATER OUTLET TEMPERATURE AND SETPOINTS
F8 – REGENERATION OUTLET TEMPERATURE AND SETPOINTS
Arrows allow user to scroll up or down within the display. A flashing
arrow on the right side of the screen indicates that more information is
available in the direction of the arrow and can be accessed by using
the scroll arrows.
ESC – ACCESSES THE MENU MODE (ACCESS IS NOT REQUIRED).
ENTER – NO FUNCTIONALITY FOR THIS BUTTON.

FIGURE 2 – OPERATOR MONITOR

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3.2.1 DRYER STATUS

The F1 key is pressed to display the present status of the dryer. This allows you to see
which step of the program cycle is currently engaged. A message can appear below
the dryer status at any time when in manual mode. A blinking arrow on the right side of
the display will indicate this. To access the messages, press the green arrow on the
right side of the interface.

MESSAGE IDENTIFICATION MESSAGE DESCRIPTION

Opening the left chamber (L/C) inlet valve.
SELECT LEFT CHAMBER DRYING
Closing the right chamber (R/C) inlet valve.
LEFT CHAMBER DRYING
Depressurizing the right chamber.
R/C IN DEPRESS MODE
LEFT CHAMBER DRYING
Heating the right chamber for regeneration.
R/C IN HEATING MODE
LEFT CHAMBER DRYING
Cooling the right chamber.
R/C IN COOLING MODE
LEFT CHAMBER DRYING
Pressurizing the right chamber.
R/C IN REPRESS MODE
LEFT CHAMBER DRYING Right chamber in standby until the end of the
R/C IN STANDBY MODE half cycle.
The dryer is in EMS mode on the left
LEFT CHAMBER IN EMS MODE chamber. This will extend the half cycle for a
R/C IN STANDBY MODE maximum of 12 hours or until the outlet
dewpoint goes higher than -40°F.
SELECT RIGHT CHAMBER Opening the right chamber inlet valve.
DRYING Closing the left chamber inlet valve.
RIGHT CHAMBER DRYING
Depressurizing the left chamber.
L/C IN DEPRESS MODE
RIGHT CHAMBER DRYING
Heating the left chamber for regeneration.
L/C IN HEATING MODE
RIGHT CHAMBER DRYING
Cooling the left chamber.
L/C IN COOLING MODE
RIGHT CHAMBER DRYING
Pressurizing the left chamber.
L/C IN REPRESS MODE
RIGHT CHAMBER DRYING Left chamber in standby until the end of the
L/C IN STANDBY MODE half cycle.
The dryer is in EMS mode on the right
RIGHT CHAMBER IN EMS MODE chamber. This will extend the half cycle for a
L/C IN STANDBY MODE maximum of 12 hours or until the outlet
dewpoint goes higher than -40°F.

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3.2.2 ALARM INFORMATION

The F3 button is pressed to display the status of the dryer alarms. If there is no alarm,
a NO ALARM message will appear. If more than one alarm is active, a flashing arrow
will appear on the right side of the display. To access the messages, press the green
arrow on the right side of the panel. In order to reset non-active alarms, press the F4
key. When all the alarm conditions have been cleared, the NO ALARM message will
appear.

MESSAGE IDENTIFICATION MESSAGE DESCRIPTION

Heater outlet temperature is above the
HEATER OUTLET OVER TEMPERATURE
setpoint.
Indicates the thermocouple module
THERMOCOUPLE MODULE IN ERROR
has lost it’s 24Vdc supply.
Indicates a thermocouple connected to
THERMOCOUPLE OUT OF RANGE
the module is defective or open.
The heater has failed to reach the
HEATER FAILURE ALARM
setpoint temperature within 15
FAIL REACH SETPOINT
minutes.
OVERSHEATH ALARM The heater sheath temperature is
SHEATH TEMPERATURE TOO HIGH above the setting.
The left chamber did not reach the low
DEPRESS FAILURE ON LEFT CHAMBER setting of the pressure switch within
time limit.
The right chamber did not reach the
DEPRESS FAILURE ON RIGHT CHAMBER low setting of the pressure switch
within time limit.
The left chamber did not reach the
REPRESS FAILURE ON LEFT CHAMBER high setting of the pressure switch
within time limit.
The right chamber did not reach the
REPRESS FAILURE ON RIGHT CHAMBER high setting of the pressure switch
within time limit.
Indicates the outlet dewpoint is above
HIGH HUMIDITY ALARM
alarm setpoint.
NO ALARM Indicates no alarm is active.

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3.2.3 DRYER OPERATION MODES

The F5 button is pressed to display the dryer mode of operation. The actual mode will
be displayed whether it is in automatic or manual mode. To change the actual mode of
the dryer, press F2 when in the dryer mode screen. The actual mode will change from
one to the other each time the F2 button is pressed. If the dryer mode screen is left
unattended for thirty seconds, it will automatically switch to the dryer status screen. In
manual mode, the READY TO STEP AHEAD PRESS F2 TO CONTINUE message
will be shown when the dryer is ready to perform the next step. In order to go to the
next step in manual mode you must not be in the dryer operation mode screen. Failure
to do so will simply change the operating mode of the dryer.

MESSAGE IDENTIFICATION MESSAGE DESCRIPTION

The dryer is in automatic mode. The dryer
DRYER IN AUTO MODE will perform its cycle without any external
intervention except in case of alarm.
The dryer is in manual mode. The dryer will
need external intervention in order to do to
DRYER IN MANUAL MODE
the following step. If no external intervention
is provided the dryer will stay in that step.
The dryer is ready to go to the next step
READY TO STEP AHEAD when in manual mode. The user must wait
PRESS F2 TO CONTINUE for this signal in order to press F2 for making
the dryer step ahead in its cycle.

3.2.4 HEATER SHEATH INFORMATION

The F6 button accesses heater sheath information. On this screen the actual sheath
temperature in degrees Fahrenheit is displayed and so is the temperature setpoint for
the sheath over-temperature alarm. The setpoint cannot be changed from the panel.

MESSAGE IDENTIFICATION MESSAGE DESCRIPTION

Displays temperature of the heater sheath
(XXXX) and also at which temperature the
HEATER SHEATH XXXX F
dryer will turn in alarm (YYYY).
ALARM SETPOINT YYYY F
Both temperatures are in degrees
Fahrenheit.

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3.2.5 HEATER OUTLET INFORMATION

The F7 button accesses the heater outlet information. On this screen the actual
temperature in degrees Fahrenheit is displayed and so is the temperature setpoint for
the heater outlet over-temperature and heating failure alarm. The setpoint cannot be
changed at the panel.

MESSAGE IDENTIFICATION MESSAGE DESCRIPTION

Displays the heater outlet temperature
HEATER OUTLET XXXX F (XXXX) and the regulation temperature
HEAT CONTROL YYYY F setting (YYYY) of the heater.
Both temperatures are in degrees F.
Displays the actual heater outlet temperature
HEATER OUTLET XXXX F (XXXX) and the heating failure alarm
HEAT FAIL AT ZZZZ F temperature setting (ZZZZ).
Both temperatures are in degrees F.
Displays the actual heater outlet temperature
HEATER OUTLET XXXX F (XXXX) and the high outlet temperature
HEAT OVERTEMP VVVV F alarm setting (VVVV).
Both temperatures are in degrees F.

3.2.6 REGENERATION OUTLET INFORMATION

The F8 button accesses regeneration outlet information. On this screen the actual
temperature in degrees Fahrenheit is displayed and so are the control setpoints for end
of heating and end of cooling. The setpoints cannot be changed at the panel.

MESSAGE IDENTIFICATION MESSAGE DESCRIPTION

Displays the actual regeneration outlet
REGEN OUTLET XXXX F temperature (XXXX) and the end of heating
HEAT SETPOINT YYYY F mode temperature setting (YYYY).
Both temperatures are in degrees F.
Displays the actual regeneration outlet
REGEN OUTLET XXXX F temperature (XXXX) and the end of cooling
COOL SETPOINT ZZZZ F mode temperature setting (ZZZZ).
Both temperatures are in degrees F.

3.2.7 DRYER OFF, DRYER ON, EMS ON – 3-POSITION SWITCH

This 3-position switch provides for manual selection of dryer basic functions. Ensure
that the switch is set at DRYER OFF before beginning the initial startup procedure.

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3.2.8 STATUS LAMPS

A green light announces that there is POWER at the control panel when lit. A red light
announces that there is an ALARM condition when lit. Refer to the operator monitor to
determine the cause.

3.2.9 PRESSURE GAGES

Three gages are mounted in a row above the low-voltage control panel. The two
outside read the pressure within each chamber (left side for left chamber, right for right)
and the middle gage shows the purge pressure.

3.3 INITIAL START-UP

Attention!
All pipes and wire connections must be tightened!
Furthermore, before start-up:

• The pipes must be checked for the presence of scale, abraded

material from the threading, or other similar impurities.
• All isolation valves on the prefilter, afterfilter and on the bypass line (if
installed) should be closed.
• The ambient temperature must not be less than 33°F.
NOTE: Breakdown resulting from faulty installation does not fall under the
Ingersoll-Rand warranty obligation.

3.3.1 PRESSURIZING DRYER

Prior to pressurizing the dryer system, verify the following:

• DRYER OFF/DRYER ON/EMS ON switch is in the DRYER OFF position

• System outlet block valve is closed

• Prefilter, afterfilter and pilot air filter vent valves are closed

• Desiccant chamber vent valve is closed

• Pilot air isolation valve is open

• Hygrometer adjustment/isolation valves are closed.

Slightly open the inlet isolation valve to slowly admit compressed air to the system.
When full system operating pressure has been reached, all connections should be soap

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bubble tested for leaks. Any leaks should be repaired and retested prior to placing the
equipment in service. If some gas other than the process air will be used for leak
testing, consult Ingersoll-Rand for its compatibility with system components before
proceeding.
Fully open the inlet isolation valve.
When the system is filled with process air and leak tight, slowly open the system outlet
valve to pressurize the downstream piping. During this procedure, ensure that the dryer
system pressure does not fall beyond 95% of its reading prior to opening the system
outlet valve. This will protect the equipment internal components (i.e., filter elements,
desiccant) from gas velocities above design conditions.
When pressurizing is complete, then fully open the system outlet valve to place the
equipment in service.
Verify that the system inlet pressure and temperature are at the design operating levels
(see paragraph 1.4)
Ensure that the pilot pressure regulator is set between 80 and 100 psig.

3.3.2 ENERGIZING DRYER CONTROLS

Turn 3-position switch to the DRYER ON position.

The operator monitor controls the dryer cycle. This should be used as a reference
guide to ensure dryer is cycling. A manual mode is included in the dryer program to
allow for fast cycling to verify to operation of the dryer.
Review the operational program of the dryer (paragraph 3.1.1) and the wiring schematic
(see section 7) before operating the dryer.
NOTE: The hygrometer will signal an open circuit (the ALARM light will
illuminate) until probe cable is connected to hygrometer probe. This
connection is described in paragraph 3.3.4 – leave it as is for now.
While dryer is in purge mode for either chamber, the regeneration pressure setting
should be checked. Refer to paragraph 3.3.3 for the correct blower flow setting.
Warning!
Failure to correctly set the purge pressure can lead to improper
regeneration of the desiccant bed, resulting in a dewpoint failure
when the chamber is returned to service.

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3.3.3 PRESSURE SWITCH ADJUSTMENT

On the TZE dryer there are four pressure switches: PSH-1, PSL-1, PSH-2 and PSL-2.
The PSH pressure switches are set at 30 psig below the operating pressure of the
dryer, and use the normally open contact. When the adjustment is done, the contact
between C and NC should close when increasing to the desired pressure.
The PSL switches are set at 10 psig regardless of the operating pressure and use the
normally closed contact. When the adjustment is done, the contact between C and NC
should close when decreasing to the desired pressure.
To increase the pressure, screw the knob toward the pressure switch diaphragm (see
figure 3). To decrease the pressure, turn away from the pressure switch diaphragm.

ADJUSTMENT
KNOB
FIGURE 3 – PRESSURE SWITCH ADJUSTMENT
3.3.4 EMS START UP

Refer to the general assembly drawing provided in section 7, and to figure 4.

The EMS hygrometer probe has been shipped inside of its own sealed package to
ensure that the probe does not become saturated with ambient air during storage and
transport. Do not remove probe from the package until dryer system has been started
and probe is to be inserted into the sample cell.

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• Check that the sample line is connected from the dryer outlet to the inlet valve on
the humidity probe sample cell.

• Check that the humidity probe is installed into the sample cell.

• Connect the cable to the humidity probe.

• Fully open the inlet valve to the sample cell.

• Partially open the discharge valve of the sample cell to vent off a small amount of
sample air. Do not fully open discharge valve.

• Perform a soap bubble test to check for leaks on all parts of the sample line
connections and the humidity sample cell.

• The digital display will now read the dewpoint of the dryer system. It will take a
short period of time for a humidity probe to be purged of humidity.

FIGURE 4 – HYGROMETER PROBE ASSEMBLY

NOTE: The dryer should be operated in the DRYER ON position at the time of
initial start-up and at all times when the hygrometer or humidity probe are
removed for service.

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3.4 SHORT-TERM SHUTDOWN

Follow this sequence when switching off the adsorption dryer:

• First close all the shutoff valves up- and downstream of dryer

• Then immediately switch DRYER OFF.

Danger!
Dryer will remain pressurized.

3.5 SHUTDOWN IN CASE OF A FAULT OR FOR MAINTENANCE

Follow this sequence when switching off the adsorption dryer:

• First switch off the dryer. Make certain dryer is not in heating or cooling mode.
The dryer electrical panel will still have power. The dryer disconnect must be
turned off before opening electrical panel.

• Close all the isolation valves upstream and downstream of the adsorption dryer.

• Depressurize the dryer by using the hand valve mounted at the bottom of the
desiccant chamber.

• Depressurize the filters by opening vent valves at the bottom of each filter vessel.

Danger!
Before any kind of maintenance or repair work is done, the dryer
must be depressurized and disconnected from the power source.

3.6 RESTARTING
• Close the hand valve mounted at the bottom of the afterfilter and at the bottom of
each desiccant chamber

• Slowly open the inlet isolation valve and pressurize the dryer up to the regular
operating pressure by keeping the shutoff valve mounted behind the afterfilter
closed.

• Switch DRYER ON.

NOTE: If the dryer is restarted after a long standstill, proceed as for an initial
start-up (see paragraph 3.3).

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4. MAINTENANCE
4.1 CHECKLIST
These checks are to be carried out by the operator during the routine operations cycle.

4.1.1 DAILY CHECK

• Operate prefilter drain ball valve as required to prevent excess accumulation.

This may require frequent exercise depending on line moisture content. If the
drain is automatic, check for functionality and blow down daily to remove
accumulated fluids.

• Check filter differential pressures. A filter differential pressure of 5 to 8 psi (or

pointing in the red field) indicates a dirty filter element and it should be replaced.
Filter elements should last between 6 to 12 months under normal use.

• Check correct purge pressure.

• Ensure dryer is cycling without alarms.

4.1.2 WEEKLY CHECK

• Check all mufflers for backpressure. Replace if clogged or dirty.

• Verify heater operation.

4.1.3 QUARTERLY CHECK (EVERY THREE MONTHS)

• Check operating conditions, purge rate, line pressure, inlet flow.

• Check dryer operating cycle for proper operation of valve operators, solenoid
valves, dump valves, heaters, pressure switches and temperature controller.

• Check the outlet dewpoint.

• Blow down relief valves.

• Check heater outlet temperature is between 400°F and 425°F.

• Verify pressure switch operation.

• Inspect pilot air filter element. If element seems clogged, dirty or damaged,
replace it.

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4.1.4 ANNUAL CHECK

• Disassemble, clean and inspect the inlet switching, purge exhaust and
depressurization valves/actuators. Replace all worn or damaged parts.

• Disassemble, clean and inspect the outlet and purge check valves. Replace all
worn or damaged parts.

• Inspect the desiccant through the chamber fill port. Replace desiccant if
degraded or if oil is present (see paragraph 4.3).

• Replace prefilter, afterfilter and pilot air filter elements at least once a year.

• Replace the dewpoint sensor humidity probe.

NOTE: Should the need for spare parts or service arise during work on the
adsorption dryer, the dryer model and its serial number must be
conveyed to Ingersoll-Rand. This information is given on the nameplate
mounted on the control cabinet. Telephone Ingersoll-Rand to arrange for
maintenance support (1-800-526-3615).

4.2 CHANGING THE FILTER ELEMENT

• The filter element within the filter housing must be replaced annually

• Depressurize the dryer and switch DRYER OFF

Danger!
Change filter elements only when the housing is fully depressurized

• Separate the lower part of the housing from the upper part

• Loosen and remove the element by hand

• Install the new filter and the O-ring/gasket, making sure that the filter seats
perfectly

• Refit the filter housing.

NOTE: Filter elements cannot be cleaned or reused.

Attention!
Filters may contain pollutants as appropriate to their function.
Dispose of used filters in accordance with your local, state and federal

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regulations.

4.3 REPLACEMENT OF THE DESICCANT

Desiccant life is determined by the care with which it is handled, the quality of filtered
inlet air provided and by its time in use. Be careful to not abrade (i.e., wear down) the
desiccant when installing it. Proper filtering of inlet air, and constant pressure and
temperature, will also extend its life. In order to ensure trouble-free operation, we
recommend replacing the desiccant every 10,000 operating hours, or every 3 years.
The following considerations determine the life expectancy of desiccant:

• Care in installation

• Quality of input gas (e.g., air)

• Constancy of flow and temperature

• Whether full-service cycling or low-demand usage

• Time in service.
The following clues will suggest that you examine the desiccant and consider its
replacement:

• Discoloring of desiccant (e.g., oil residue, other contaminants): a brown or yellow

tinge indicates that the adsorbancy capacity of the desiccant has been
diminished

• Frequent afterfilter replacement due to desiccant dust accumulation

• Performance dew point rises.

Refer to paragraph 1.4 to determine the desiccant quantity required for your model of
dryer.

• Close dryer inlet/outlet isolation valves

• Depressurize and switch DRYER OFF

Danger!

• Wear protective equipment and clothing when handling

desiccant.

• Remove the drain plug and empty the old desiccant into a container

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4.3 REPLACEMENT OF THE DESICCANT (CONTINUED)

Danger!

• Desiccant may contain pollutants.

• Desiccant is to be disposed of in accordance with local, state
and federal regulations.

• Screw the plug back in and fill with new desiccant from above (refer to paragraph
1.4 regarding quantities for each chamber)

• Start up the adsorption dryer in accordance with paragraph 3.3 for initial start-up.

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5. PARTS LISTINGS
5.1 PARTS LIST FOR TZE400 TO TZE650
Description TZE400 TZE500 TZE650
Part # Qty Part # Qty Part # Qty
Consumables
Prefilter ( Element Only ) Refer to filter
nameplate or
Afterfilter ( Element Only ) consult factory
Muffler 38328167 2 38328167 2 38328167 2
Moisture Indicator 38016713 1 38016713 1 38016713 1
Activated Alumina – Pounds 38335253 544 38335253 700 38335253 866
Probe -100 to +20C 38035510 1 38033510 1 38033510 1
LDP Option
Activated Alumina – Pounds 38335253 364 38335253 470 38335253 580
Molecular Sieve 4A – Pounds 38340030 180 38340030 230 38340030 286
Inlet Valve
Inlet Valve Kit/ 38331666 2 38331666 2 38331666 2
Inlet Valve 38331658 2 38331658 2 38331658 2
Solenoid Block 38331120 1 38331120 1 38331120 1
Gasket Consult factory
Outlet Valve
Valve Kit Consult factory
Check Valve 38015855 2 38015855 2 38015855 2
Gasket 38049490 4 38049490 4 38049490 4
Purge
Purge Valve Kit 38331708 2 38331708 2 38331708 2
Purge Valve 38007076 1 38007076 1 38007076 1
Purge Exhaust Valve 38331716 2 38331716 2 38331716 2
3V Bypass Option
Ball Valve 38049540 3 38049540 3 38049540 3
EMS
Digital Panel Meter 38431730 1 38431730 1 38431730 1
Replacement Parts
Pressure Gauge 38006714 3 38006714 3 38006714 3
PLC 38028759 1 38028759 1 38028759 1
Power Supply 38328357 1 38328357 1 38328357 1
Text Display 38018065 1 38018065 1 38018065 1
Thermocouple 38031001 1 38031001 1 38031001 1
Relief Valve 38007084 2 38007084 2 38007084 2
Temperature Indicator 38006698 2 38006698 2 38006698 2
Heater 38028668 1 38028668 1 38028676 1
Gasket Consult factory
Pressure Regulator 38015145 1 38015145 1 38015145 1
Pressure Switch 38006565 5 38006565 5 38006565 5
Light Bulb 38335212 2 38335212 2 38335212 2

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TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

Description TZE400 TZE500 TZE650

Transformer Primary Fuse 38015244 2 38015244 2 38015244 2
Transformer Secondary Fuse 38006870 1 38006870 1 38006870 1
Heater Fuses 38006896 3 38006896 3 38006896 3
Control Fuses 38015236 1 38015236 1 38015236 1
Control Relay Consult factory
Heater contactor 38049367 1 38049367 1 38049367 1

5.2 PARTS LIST FOR TZE820 TO TZE1225

Description TZE820 TZE1000 TZE1225
Part # Qty Part # Qty Part # Qty
Consumables
Prefilter ( Element Only ) Refer to filter
nameplate or
Afterfilter ( Element Only ) consult factory
Pilot Air Filter Element 38049474 1 38049474 2 38049474 2
Depressurization Muffler 38328167 2 38328167 2 38328167 2
Activated Alumina – Pounds 38335253 1320 38335253 1650 38335253 1980
Probe -100 to +20C 38033510 1 38033510 1 38033510 1
LDP Option
Activated Alumina – Pounds 38335253 882 38335253 1106 38335253 1326
Molecular Sieve 4A – Pounds 38340030 436 38340030 542 38340030 654
Inlet Valve
Inlet Valve Kit/ 38438875 2 38438875 2 38438875 2
Inlet Valve 38438842 2 38438842 2 38438842 2
Solenoid Block 38015889 1 38015889 1 38015889 1
Gasket Consult factory
Outlet Valve
Valve Kit 38436879 1 38436879 1 38436879
Check Valve 38015715 2 38015715 2 38015715 2
Gasket 38027769 4 38027769 4 38027769 4
Purge
Purge Valve 38007068 2 38007068 2 38007068 2
Purge Valve Gasket 38049490 4 38049490 4 38049490 4
Exhaust Valve 38331690 2 38331690 2 38331690 2
Exhaust Valve Kit 38331708 2 38331708 2 38331708 2
3V Bypass Option
Manual Butterfly Valve Kit 38049599 3 38049599 3 38049599 3
Gasket, 3-inch 38027769 6 38027769 6 38027769 4
Bypass Valve 38049581 3 38049581 3 38049581 3
EMS
Digital Panel Meter 38431730 1 38431730 1 38431730 1
Replacement Parts
Pressure Gauge 38006714 3 38006714 3 38006714 3
PLC 38028759 1 38028759 1 38028759 1
Power Supply 38328357 1 38328357 1 38328357 1

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 USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

Description TZE820 TZE1000 TZE1225

Text Display 38018065 1 38018065 1 38018065 1
Thermocouple 38031001 1 38031001 1 38031001 1
Relief Valve 38007084 2 38007084 2 38026852 2
Temperature Indicator 38006706 2 38006706 2 38006706 2
Heater 38006953 1 38006938 1 38015475 1
Gasket Consult factory
Pressure Regulator 38015145 1 38015145 1 38015145
Pressure Switch 38006565 1 38006565 5 38006565 5
Light Bulb 38335212 2 38335212 2 38335212 2
Transformer Primary Fuse 38015244 2 38015244 2 38015244 2
Transformer Secondary Fuse 38006870 1 38006870 1 38006870 1
Heater Fuses 38006821 3 38015293 3 38015335 3
Control Fuses 38015236 1 38015236 1 38015236 1
Control Relay Consult factory
Heater Contactor 38049367 1 38049367 1 38049367 1

5.3 PARTS LIST FOR TZE1500 TO TZE2100

Description TZE1500 TZE1800 TZE2100
Part # Qty Part # Qty Part # Qty
Consumables
Prefilter ( Element Only ) Refer to filter
nameplate or
Afterfilter ( Element Only ) consult factory
Pilot Air Filter Element 38049474 1 38049474 2 38049474 2
Depressurization Muffler 38328167 2 38328167 2 38328175 2
Activated Alumina – Pounds 38335253 2110 38335253 2640 38335253 2970
Probe -100 to +20C 38033510 1 38033510 1 38033510 1
LDP Option
Activated Alumina – Pounds 38335253 1414 38335253 1768 38335253 1990
Molecular Sieve 4A – Pounds 38340030 696 38340030 872 38340030 980
Inlet Valve
Inlet Valve Kit/ 38438875 2 38438883 2 38438883 2
Inlet Valve 38438842 2 38438859 2 38438859 2
Solenoid Block 38015871 1 38015871 1 38015871 1
Gasket Consult factory
Outlet Valve
Valve Kit 38436879 1 38437299 1 38437299
Check Valve 38015715 2 38015764 2 38015764 2
Gasket 38027769 4 38329637 4 38329637 4
Purge
Purge Valve 38007019 2 38007019 2 38007019 2
Purge Valve Gasket 38027769 4 38027769 4 38027769 4
Exhaust Valve 38438842 2 38438842 2 38438842 2
Exhaust Valve Kit 38438875 2 38438875 2 38438875 2
3V Bypass Option

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 USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

Description TZE1500 TZE1800 TZE2100

Manual Butterfly Valve Kit 38049599 3 38049607 3 38049607 3
Gasket, 3-inch 38027769 6 38329637 6 38329637 4
Bypass Valve 38049581 3 Consult factory 3 Consult factory 3
EMS
Digital Panel Meter 38431730 1 38431730 1 38431730 1
Replacement Parts
Pressure Gauge 38006714 3 38006714 3 38006714 3
PLC 38028759 1 38028759 1 38028759 1
Power Supply 38328357 1 38328357 1 38328357 1
Text Display 38018065 1 38018065 1 38018065 1
Thermocouple 38031001 1 38031001 1 38031001 1
Relief Valve 38026852 2 38026852 2 38026852 2
Temperature Indicator 38006706 2 38006706 2 38006706 2
Heater 38028684 1 38006912 1 38028692 1
Gasket Consult factory
Pressure Regulator 38015145 1 38015145 1 38015145
Pressure Switch 38006565 1 38006565 5 38006565 5
Light Bulb 38335212 2 38335212 2 38335212 2
Transformer Primary Fuse 38015244 2 38015244 2 38015244 2
Transformer Secondary Fuse 38006870 1 38006870 1 38006870 1
Heater Fuses 38015285 3 38006854 3 38006854 3
Control Fuses 38015236 1 38015236 1 38015236 1
Control Relay Consult factory
Heater Contactor 38049383 1 38049409 1 38049409 1

5.4 PARTS LIST FOR TZE2500 TO TZE3500

Description TZE2500 TZE3000 TZE3500
Part # Qty Part # Qty Part # Qty
Consumables
Prefilter ( Element Only ) Refer to filter
nameplate or
Afterfilter ( Element Only ) consult factory
Pilot Air Filter Element 38049474 1 38049474 2 38049474 2
Depressurization Muffler 38328175 2 38328175 2 38328175 2
Activated Alumina – Pounds 38335253 3444 38335253 4620 38335253 5610
Probe -100 to +20C 38033510 1 38033510 1 38033510 1
LDP Option
Activated Alumina – Pounds 38335253 2308 38335253 3096 38335253 3758
Molecular Sieve 4A – Pounds 38340030 1136 38340030 1524 38340030 1852
Inlet Valve
Inlet Valve Kit/ 38438883 2 38438891 2 38438891 2
Inlet Valve 38438859 2 38438867 2 38438867 2
Solenoid Block 38015871 1 38332391 1 38332391 1
Gasket Consult factory
Outlet Valve

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 USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006
Valve Kit 38437299 1 38437307 1 38437307
Check Valve 38015764 2 38015822 2 38015822 2
Gasket 38329637 4 38329645 4 38329645 4

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 USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

5.4 PARTS LIST FOR TZE2500 TO TZE3500 (CONTINUED)

Description TZE2500 TZE3000 TZE3500
Purge
Purge Valve 38007019 2 38007035 2 38007035 2
Purge Valve Gasket 38027769 4 38329637 4 38329637 4
Exhaust Valve 38438842 2 38438859 2 38438859 2
Exhaust Valve Kit 38438875 2 38438883 2 38438883 2
3V Bypass Option
Manual Butterfly Valve Kit 38049607 3 Consult factory 3 Consult factory 3
Gasket, 3-inch 38329637 6 Consult factory 6 Consult factory 4
Bypass Valve Consult factory Consult factory Consult factory
EMS
Digital Panel Meter 38431730 1 38431730 1 38431730 1
Replacement Parts
Pressure Gauge 38006714 3 38006714 3 38006714 3
PLC 38028759 1 38028759 1 38028759 1
Power Supply 38328357 1 38328357 1 38328357 1
Text Display 38018065 1 38018065 1 38018065 1
Thermocouple 38031001 1 38031001 1 38031001 1
Relief Valve 38026852 2 38026852 2 38026852 2
Temperature Indicator 38006706 2 38006706 2 38006706 2
Heater 38015467 1 38015418 1 38028700 1
Gasket Consult factory Consult factory Consult factory
Pressure Regulator 38015145 1 38015145 1 38015145
Pressure Switch 38006565 1 38006565 5 38006565 5
Light Bulb 38335212 2 38335212 2 38335212 2
Transformer Primary Fuse 38015244 2 38015244 2 38015244 2
Transformer Secondary Fuse 38006870 1 38006870 1 38006870 1
Heater Fuses 38006862 3 38006847 3 38006847 3
Control Fuses 38015236 1 38015236 1 38015236 1
Control Relay Consult factory Consult factory Consult factory
Heater Contactor 38338786 1 38049391 1 38049391 1

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TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

37
 USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

6. FAULTS AND TROUBLESHOOTING

6.1 DEWPOINT HAS DETERIORATED

POSSIBLE CAUSE REMEDY

Check compressor after cooler and cooling
Incoming air temperature above design system.
condition. Adjust as necessary to reduce the inlet
temperature to dryer specification.
Problem external to dryer. Verify inlet flow
Incoming air flow too high rate and reduce as necessary to dryer
specification.
Check compressed air system. Correct if
Inlet pressure below design pressure.
necessary

Check prefilter elements and seals for

damage. Replace if necessary.
Liquid water entering dryer Check operation of drain trap. Ensure
proper drainage. Repair or replace drain if
necessary.

Replace desiccant. Inspect prefilter if

Desiccant degraded or coated with oil.
desiccant is coated with oil.

Insufficient regeneration due to:

1. Heater failure 1. Inspect and replace as necessary.
2. Heater contactor failure 2. Inspect and replace as necessary.
3. Incorrect purge flow 3. Check purge flow setting.
4. Temperature setting incorrect 4. Check setpoints of heater and purge
exhaust.
Leaks at piping/tubing connections
Soap bubble test dryer and repair all leaks
downstream of the dryer.

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 USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

6.2 HIGH HUMIDITY ALARM OR SENSOR FAILURE

POSSIBLE CAUSE REMEDY

Hygrometer probe out of calibration Replace hygrometer probe.

Open circuit on probe electrical

Inspect and repair.
connection.
Incorrect flow across sensor Refer to EMS start-up (paragraph 3.3.4).
Check sensor tubing and probe filter for
Excessive moisture on sensor. buildup of moisture. Allow tubing to dry
and replace filter element.

6.3 PRESSURE DROP TOO HIGH

POSSIBLE CAUSE REMEDY
Broken or fouled desiccant Inspect desiccant and replace if required.

Inlet flow exceeding design flow rate Reduce inlet flow as necessary
Depressurize filters and inspect elements.
Pre or after filter element dirty or clogged
Replace if dirty or clogged.

6.4 SWITCHING FAILURE ALARM

If a switching failure alarm occurs, refer to paragraph 3.2.1 in order to determine where
in the dryer cycle the alarm occurred. Also refer to the program step functions
(paragraph 3.1.1) to assist in finding which component led to the switching failure.

POSSIBLE CAUSE REMEDY

Close pilot air isolation valve, depressurize
pilot air filter and inspect element. If
clogged or dirty, replace.
Check that pilot air isolation valve is fully
Pilot air insufficient open.
Check that pilot air regulator is set at 100
psig.
Inspect pilot air tubing for kinks or breaks.
Repair if necessary.
Inlet air pressure below setpoint of Correct the low pressure problem to the
pressure switches dryer.

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 USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

6.4 SWITCHING FAILURE ALARM (CONTINUED)

POSSIBLE CAUSE REMEDY

Check operation of solenoid. Replace if
not functioning.
Solenoid valve not energizing Check wiring from panel to the solenoid for
an open or short circuit. Repair if
necessary.
Shut down and depressurize dryer. Inspect
valve seats and seals for damage or wear.
Repair or replace if necessary.
Inlet or purge exhaust valves leaking
While valve is disassembled, check the
actuator stops to ensure that valve is fully
closing ( butterfly valves only).
Check valve internals are worn or Shut down and depressurize dryer. Repair
damaged or replace valves.
Inspect purge and depressurization
mufflers and replace if necessary.
Off-line desiccant chamber inlet valve or
outlet check valve leaking. Inspect as
described above
Regenerating chamber depress/exhaust
Switching failure on depressurization. valve failed to open. Check associated
solenoid valve operation as described
above.
Online chamber outlet check valve leaking.
Inspect and repair as described above.
Excessive purge flow. Check the purge
pressure setting.
Exhaust or depressurization valves not
closing or are leaking. Check solenoid
operation as listed above. Check valve
failure as listed above.
Switching failure on repressurization. Insufficient purge flow. Check purge
pressure settings. Check automatic purge
isolation valve for correct operation.
Check the setpoint of the pressure
switches. Readjust if necessary.
Check the operation of the pressure
Pressure switch malfunction. switches. Replace if needed.

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 USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

41
 USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

7. DRAWINGS

42
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TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006

43
INGERSOLL-RAND COMPANY, 800-A BEATY STREET, DAVIDSON, NORTH CAROLINA, 28036 – USA
TEL: (704) 896-4000 / FAX: (704) 896-4648
WWW.AIR.IRCO.COM