EN
Installation and Operation Manual
Heated Blower Purge Regenerated Dryer
DRYPOINT
®
XFi ecoIntelligent Series
XFi models 1000
READ MANUAL FIRST BEFORE INSTALLATION AND OPERATION
Страница 1: ...EN Installation and Operation Manual Heated Blower Purge Regenerated Dryer DRYPOINT XFi ecoIntelligent Series XFi models 1000 READ MANUAL FIRST BEFORE INSTALLATION AND OPERATION ...
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Страница 3: ...4 INSTALLATION 11 4 1 Design and Use of the Dryer 11 4 2 Location and Installation 11 4 3 Optimal Istallation Diagram 13 4 4 Mounted Filters with Bypass 13 5 DRYER OPERATION 14 5 1 Start Up 14 5 1 1 Verification Prior to Start up 14 5 1 2 Desoccant Fill Procedure 15 5 1 3 Start up Procedure 16 5 1 4 General Operation 17 5 2 Purge Adjustment 18 5 3 Isolation and Shutdown Procedures 19 5 4 Controlle...
Страница 4: ... Tower Insulation 49 5 5 6 Failure to Switch 49 5 5 7 Valve Position Indicators 50 5 5 8 Filter Contamination 50 5 5 9 Drain Alarm 50 5 6 Electrical Wiring Diagram 50 6 MAINENANCE AND SERVICE 51 6 1 Maintenance and Service Information 51 6 1 1 Routine Maintenance 51 6 1 2 Maintenance and Service Intervals 52 6 1 3 Desiccant Replacement 52 6 1 4 Inlet and Exhaust Repair 52 6 2 Maintenance and Spare...
Страница 5: ...responsible for following all of the relevant laws rules and regulations and ensuring that only experienced and trained personnel install and or operate the dryer In most countries states cities and or local municipalities the installation may only be carried out by a licensed installation company Inspections must be carried out by a qualified and licensed third party firm in accordance with all a...
Страница 6: ...cal service department notified thereafter To move the packaged unit we suggest the use of a suitable crane by the lifting lugs We do not recommend moving the unit by any hand operated or manual mechanism Handle with care Heavy blows could cause irreparable damage Even when packaged keep the machine protected from severe weather The packaging materials are recyclable Each material must be properly...
Страница 7: ...mption kW 23 7 30 6 35 1 50 3 56 3 65 7 Avg Power Consumption kW 15 8 19 9 24 0 30 0 35 8 43 5 DRYPOINT XFi Model Size 2800 3300 4000 5000 6000 Flow Rate scfm 2800 3300 4000 5000 6000 Inlet Outlet Connection 150 ANSI Flange 4 6 6 6 6 Height A in 126 108 138 137 135 Width B in 104 118 136 138 140 Depth C in 103 106 107 107 113 Total Weight per Dryer Lbs 10 539 12 419 16 089 16 089 23 456 Max Power ...
Страница 8: ... and cools the heater down to a preset temperature After the temperature is reached the purge control valve opens and desiccant bed cooling takes place during phase 2 The purge air also passes the exhaust valves and is vented to open atmosphere Just before the freshly regenerated bed is brought to an on line state to become the drying bed it is slowly pressurized from atmospheric pressure up to li...
Страница 9: ...DRYPOINT XFi 1000 manual_revA EN 9 3 4 Flow Diagram Number Name Number Name 1 Inlet Valve 4 Heater 2 Exhaust Valve 5 Purge Valve 3 Blower 6 Depressurization Valve ...
Страница 10: ...n line heater and pushes it into the regeneration Vessel This heated dry air flows through the Vessel and desorbs water from the moisture laden desiccant then exits through regeneration exhaust valve EV B 2 Step 5 The heater 4 turns off while the blower 3 remains on and cools the heater After the set temperature is reached the blower 3 turns off and purge valve 5 opens and additional desiccant bed...
Страница 11: ...proper location could directly affect the proper operation of the dryer This unit is not suitable to be used in explosive atmospheres where risk of fire could exist in the presence of gaseous or solid pollutants or in outdoor applications or areas exposed to the elements Do not use water to extinguish fire on the dryer or in the surrounding area Machine level noise could be higher than 85 dBA Inst...
Страница 12: ...esiccant bed will lead to overloading of the dryer poor dew point performance and rapid deterioration of the desiccant material Any oil entering the desiccant bed may permanently reduce the capacity of the desiccant material Desiccant dust traveling downstream of the dryer may cause contamination and or accelerated wear to other components and equipment Therefore a particulate post filter should b...
Страница 13: ...r while providing the most reliable shop air supply due to the downstream receiver Under no circumstances should the peak demand air flow exceed the maximum rated air flow of the dryer We recommend the dryer be installed with a 0 01 micron CLEARPOINT coalescing pre filter at the inlet and a 1 micron CLEARPOINT particulate post filter at the outlet It is recommended to install both 5 micron and 1 m...
Страница 14: ...r be operated under pressure that exceeds the maximum pressure rating of the unit Operating the dryer at a pressure higher than the maximum rating could be dangerous for both the operator and the machine The inlet air temperature and air flow rate entering the dryer must be within the limits indicated on the data plate Installation precautions must be taken in order to limit the vibration that can...
Страница 15: ...the installation location The unit should be bolted down before filling 2 Power to the dryer must be disconnected and the unit should have no pressure Verify the Vessel pressure gauge read zero 0 psig 3 It may be necessary to remove the pressure relief valves to gain access to the desiccant fill ports DO this if necessary 4 Fill the dryer with the correct amount of desiccant according to the chart...
Страница 16: ...ound the dryer Before starting the dryer your compressor should be running your compressed air system pressurized and the dryer bypassed and not yet pressurized 1 Begin with the dryer bypassed and in isolation see Section 4 2 Section 4 4 2 Ensure that purge exhaust valves are in closed position this may have to be performed manually as the result of there being no air in the system in order to dri...
Страница 17: ...gh may accelerate the first maintenance interval of the exhaust valves exhaust silencers and post filter element Exhaust valves and silencers may have to be replaced due to dusting from shipping and the initial start up to ensure proper operation Post filter elements should also be part of a regular preventative maintenance schedule Never service the dryer or filters without first relieving pressu...
Страница 18: ...igned markings on the valve stem and valve body indicating the closed position 3 Referencing a calibrated flow meter rotate the knob counter clockwise in 1 8 turn 45 degree increments until the desired flow rate has been achieved counting each time a full rotation has been made 4 Record the standard system pressure and valve setting in this manual for future reference A blank table has been provid...
Страница 19: ... 3 Open the bypass valve 4 Close the outlet isolation valve 5 Close the inlet isolation valve Depressurization and Shut Down 1 Open the bypass valve 2 Close the outlet isolation valve 3 Close the inlet isolation valve 4 Allow the dryer to continue to run During the normal operating cycle both Vessels will blow down and depressurize 5 Disconnect the power to the dryer 6 Open the manual ball valves ...
Страница 20: ...peration of the dryer is controlled and monitored constantly by the advanced system controller This is a multi function device Displays the operating status and current process step Allows for dryer setting adjustments Provides and records system alerts and troubleshooting tips Charts the system performance such as heater blower and dewpoint optional Tracks the maintenance schedule and provides sp...
Страница 21: ...trical control panel powers the controller When pressed the controller startup sequence begins This includes a system boot process which takes about 30 seconds Once the startup sequence is complete the START window will be displayed However this screen is locked and will automatically continue to the HOME screen ...
Страница 22: ...ich the HOME screen will be displayed and the controller will automatically begin in Startup before the drying sequence commences 5 4 3 Home Screen HOME After the controller startup the HOME screen dryer operation is displayed This screen can be accessed at any time by pressing the HOME button ...
Страница 23: ...nt operational sequence Each step is detailed below along with a screen shot of the process Startup System Start up 40 seconds The controller is evaluating its system parameters to determine the correct step on which to start The system retains its sequence history so in the case of a power interruption the controller will restart on its last step ...
Страница 24: ...e the desiccant material adsorbs the humidity down to the target dew point Step 2 Vessel B Open Depressurization Valve 240 seconds The Vessel B depressurization valve is opened This depressurizes Vessel B to atmospheric pressure through the exhaust silencers As the depressurization valves are spring return angle body valves at the end of the step it will return to its normally closed position ...
Страница 25: ...4 Start Vessel B Heating Period Regeneration 140 minutes The blower and heater turn on The blower forces air across the in line heater and pushes it into the regeneration tower This heated dry air flows through the tower and desorbs water from the moisture laden desiccant then exits through the regeneration exhaust valve of Vessel B ...
Страница 26: ...e blower turns off and the purge valve opens and additional desiccant bed cooling takes place At the end of this step the adsorption material of vessel B is completely regenerated Step 6 Vessel B Regeneration Valve Closes Repressurization 4 minutes Vessel B Regeneration exhaust valve closes thus the vessel is repressurized to full working pressure Purge valve closes once repressurization is comple...
Страница 27: ... dryer will remain in the drying state on Vessel A Step 8 Vessel B Parallel Mode 10 minutes Vessel B inlet valve is opened and inlet air enters Vessel B During this time both Vessel inlet valves are open allowing for parallel flow This allows for reduced dewpoint and temperatures spikes for the air leaving the dryer ...
Страница 28: ...anual If a power interruption occurs while the dryer is in operation the inlet and regeneration valves will not move The depressurization valve will return normally open and the depressurization valves will return normally closed Upon power startup the dryer will remember its sequence step and continue where it left off 5 4 4 Controller Settings SETTINGS Within the SETTINGS function of the control...
Страница 29: ...ant to have this accurate In case of a power is removed from the controller the Date and Time are maintained in the memory Currently only English is active in the controller Units of Measure can be selected by taping on the icon to change from F Psig C Barg The units selected will be adjust for all unit of measure references Parameters This function is locked and not accessible ...
Страница 30: ... Dew point demand is a standard feature If it can be Enabled running in Energy Savings mode or Disabled running in fixed time mode Outlet Target Dew point Maximum Cycle Extension and Alarm settings can be adjusted here Communication The communication screen shows the default IP address of the PLC HMI PROFIBUS and MODBUS NOTE This is only a notes section for the IP address If the note section is up...
Страница 31: ...can track energy usage of the blower heater and purge By entering the energy rate kW we can calculate the total energy consumption With the ecoIntelligent Control described in Section 5 5 1 we can look at the energy savings of this function vs dryer running in a fixed time cycle ...
Страница 32: ...continually monitor specific dryer characteristics along with any ancillary equipment provided it is connected to the controller If there is a functional issue associated with normal operation an alarm will be triggered and be displayed as a red background flash on any controller screen ...
Страница 33: ...d temperature sensor failures will stop the dryer a moisture failure will not A dewpoint sensor failure will default the dryer into a fixed time cycle mode Limit Switch Alarm Limit Switch Alarm is an alarm from a limit switch Moisture Alarm Dew point or humidity alarm of process air cabinet enclosure or ambient conditions Maintenance Alarm Maintenance alarms are based solely on system timers Major...
Страница 34: ... sure depressurized vessel is at low threshold Residual pressure may be present 203 Loss of Pressure Alarm MAJOR Pressure fell below HIGH threshold on process drying side during regeneration check air delivery from supply compressor s 204 Pressure Not Equal MAJOR Pressure fell below HIGH threshold during Standby and or Parallel check air delivery from supply compressor s 205 Pressure Equal During ...
Страница 35: ...ater 302 Vessel Exceeding Temperature MINOR Vessel is heating too much too fast 303 Vessel Heating Too Slow MINOR Vessel is not heating fast enough 304 Enclosure High Temperature Alarm MINOR Enclosure temperature is too high ensure vortex cooler delivery is adequate 305 Dryer Inlet Temperature High MINOR Dryer Inlet Temperature High this could result in water overloading to desiccant column and cr...
Страница 36: ... Vessel B inlet valve didn t close Check vessel B inlet valve 502 Failure To Open Vessel A Inlet Valve MAJOR Vessel A inlet valve didn t close Check vessel A inlet valve 503 Failure To Open Vessel B Inlet Valve MAJOR Vessel B inlet valve didn t close Check vessel B inlet valve 504 Failure To Open Vessel A Regen Outlet Valve MAJOR Malfunction with Vessel A regen outlet valve Make sure limit switch ...
Страница 37: ... MINOR The recommended maintenance timer interval for the pre filter change is overdue 702 Service Pre Filter Soon MINOR The recommended maintenance timer interval for the pre filter change is due soon 703 Service Pre Filter Overdue MINOR The recommended maintenance timer interval for the pre filter change is overdue 704 Service Post Filter Soon MINOR The recommended maintenance timer interval for...
Страница 38: ...edged and addressed have an IO after the date and time indicating the moment in time when the alarm was reset Highlighting the alarm then tapping the help button will provide a brief information text You can also download a log of the alarm history which can be sent to a BEKO Technologies Service Technician for further review Notices that all past alarms are stored as history in the controller as ...
Страница 39: ...DRYPOINT XFi 1000 manual_revA EN 39 In ALARM SETTINGS adjust to the set point of an alarm or delay timer can be adjusted ...
Страница 40: ...YPOINT XFi 1000 manual_revA EN 40 5 4 6 Graphs and Data GRAPHS DATA The GRAPHS DATA screen allow access to real time performance data and graphs This data is captured and logged and available for download ...
Страница 41: ...on Phase shows real time temperatures of the regeneration phase The temperatures are recorded every minute and displayed in a graph The Performance shows real time pressure of the system The pressures are recorded every minute and displayed in a graph ...
Страница 42: ...00 manual_revA EN 42 The Enclosure Ambient Info shows real time temperature humidity from the controls enclosure and ambient environment The temperature and humidity are recorded every minute and displayed in a graph ...
Страница 43: ...ce and Maintenance SERVICE MAINTINANCE Service and Maintenance allows the access to information such as Maintenance and spare part order numbers Setting maintenance interval reminders Electronic copy of the product manual General system information ...
Страница 44: ..._revA EN 44 Operating Hours show time related information of the dryer including Comparison of the current time cycle for the major steps to the previous time cycle heating cooling and drying Total operating hours of the dryer ...
Страница 45: ...ual in the controller There is a table of contents to quickly access a particular section of the manual and each page can be scrolled thorough The Information shows Controller software version PLC seral number Manufacturing date In addition to the contact information of BEKO Technologies Corp ...
Страница 46: ...rs button allows the user to observe in hours Initial maintenance alarm for the listed characters The alarm reminder interval after initial alarm triggers The total time counting up since the last reset Each timer comes preset and can be adjusted if desired by pressing the individual value If it is desired to return to the factory settings press DEFAULT VALUES To reset the total time counter press...
Страница 47: ...d the compressor is OFF the controller display screen shows this information 5 4 9 Power Requirements Each DRYPOINT XF dryer operate using 460VAC 60Hz 3ph Connecting electricity to the dryer must be done by a qualified electrician after review of the electrical requirements schematic and installed to the National Electric Code The optional BEKOMAT on the pre filter at the dryer inlet is supplied a...
Страница 48: ...the controller network capability contact your local distributor For technical support contact BEKO Technologies Corp Only qualified personnel may carry out the service for the network connection of the dryer Before any service make sure that no parts of the machine are powered ...
Страница 49: ...ion of time For more information see Dew point Demand described in section 5 5 2 During regeneration the ecoIntelligent Control is monitoring the desiccant bed temperature When the set point for proper regeneration is met the heater and blower will turn off thus saving energy over a fix time cycle dryer During cooling the selection between purge cooling or ambient air cooling is made based on the ...
Страница 50: ...tches ON and OFF Hence it prevents a situation where the dryer continues to operate and use purge air from the compressed air network though there is no supply of compressed air In case the voltage 120V AC Input drops at the input the purge exhaust valves are immediately closed After the compressor signal comes back online the drying cycle is continued from the same point meaning that the last ope...
Страница 51: ...he CLEARPOINT pressure differential gauge along with electrical contacts When the pressure differential across the element is too great an electrical signal is generated to the PLC providing a minor alarm message to change the media or check for trouble 5 5 9 Drain Alarm Standard Drain Alarm is a feature that is provided for customers by utilizing the BEKOMAT drain alarm features The BEKOMAT is ab...
Страница 52: ...perly Check the differential pressure of any installed pre and post filtration Check that the Vessel switching operation takes place correctly at the set cycle times Check that the Vessel pressure gauge of the regenerating Vessel reads 0 psig while the drying Vessel reads full line pressure ANNUALLY Replace the pre and post filter elements Replace the depressurization silencers Replace the pre fil...
Страница 53: ...manufacturer supplied desiccant which is high quality high capacity desiccant designed and sized for the dryers see Desiccant Fill Procedure 5 Carefully knock on the sides of the Vessel chambers while filling so that the desiccant will pack tightly Some settling may be required in order to fit the specified fill amount into the Vessel Tank sizes may be the same for multiple models so do not be con...
Страница 54: ...red Maintenance Parts Interval DESCRIPTION Order No 1000 Annual Pre filter Element 0 01 μm 25SX 4038116 Post filter Element 1 0 μm 25FX 4038109 Depressurization Silencer Element 1 2 NPT gcghchgchgchgbvhgvhc NPT 4039962 Component Filter Elements Blower Filter Element On Request Dew point Filter Element 4038241 Pilot Air Filter Element 4038242 Service Unit for CLEARPOINT with BEKOMAT BEKOMAT 32 Serv...
Страница 55: ...ssure Gauge 4034195 2 FRL Combo Package 20 130 psig Filter Regulator Combo 4026419 Brass Cone Silencer NPT Replacement Brass Cone Silencer 4026418 1 8 NPT Silencer 4026673 2 EMS Sensor Replacement EMS Sensor On Request Pressure Sensor Replacement Pressure Sensor 4024284 2 Replacement Tube Fitting Package On Request Vessel Screen 2 1 2 Flanged Screen 4029150 2 System Fuses Transformer Fuse 3 5A 403...
Страница 56: ...lves Controller Compressor off Check power and electric Check the operation of inlet and purge exhaust valves Ensure Control pilot air is delivering at 80 psi Ensure DIN connectors are properly attached to solenoid valves See controller troubleshooting Check if compressor Sync is commanding dryer off All the inlet air is discharged through the silencers Faulty inlet valve Faulty signal Faulty Outl...
Страница 57: ... desiccant Contaminated inlet pre filter replace Contaminated outlet post filter replace Overflow ensure air inlet flow does not exceed dryer capacity Remove desiccant screens and clean screens See purge exhaust troubleshooting Back pressure Purge muffler fouled Vessel screen Restricted purge piping Bad Purge Exhaust Valve Replace with new Empty Vessels remove screens and clean Clean See purge Exh...
Страница 58: ...ator Check electrical connections Clean drain and plumbing Install service drain kit or replace entire unit Pre Filter Application Dirty element Electrical Differential pressure gauge Failure with upstream bulk water separator Contaminated filter replace element Faulty electrical signal Clean check and or replace Post Filter Dryer dusting Dirty element Electrical Differential pressure gauge Ensure...
Страница 59: ... steel Epoxy paint Filter cartridge Filtering material PVC Oil Solenoid valve Bronze Steel Techno polymer PVC Condensate Drain PVC Aluminum Steel Bronze Silencers Aluminum Stainless steel Safety Valves Brass Bronze Gaskets and O Ring Graphite Synthetic elastomer Electric cables Copper PVC Electric Parts PVC Copper Bronze Silicon We recommend complying with the safety rules and regulations for the ...
Страница 60: ...ir operated switching valves used to depressurize the offline Vessel prior to regeneration Depressurization Silencer Installed to reduce exhaust noise during Vessel depressurization for the protection all personnel and to comply with OSHA standards Silencers are non mechanical but must be maintained Purge Flow Control Valve Valve that allows the adjustment and regulation of purge air flow used for...
Страница 61: ...DRYPOINT XFi 1000 manual_revA EN 61 For technical product support please call 1 800 235 6797 and select Option 2 ...
