S02 - Attachment 19 - KBS manual 15-375 rev F 04-18.pdf

SERVICE DEPARTMENT : (724) 745-3038

INSTRUCTION MANUAL

MODELS

INLET

RATED

FLOW

OUTLET

RATED

FLOW

REFER

AS

MODELS

KBS 15

KBS 25

KBS 35

KBS 50

KBS 75

18 SCFM

30 SCFM

42 SCFM

60 SCFM

90 SCFM

15 SCFM

25 SCFM

35 SCFM

50 SCFM

75 SCFM

KBS 95

KBS 135

KBS 205

KBS 305

KBS 375

114 SCFM

162 SCFM

246 SCFM

366 SCFM

450 SCFM

95 SCFM

135 SCFM

205 SCFM

305 SCFM

375 SCFM

KBS SERIES

BREATHING AIR

PURIFIERS

3215430 Rev. F 04/18

Contents

1.0 General Safety Information

2.0 Receiving, Moving, Unpacking

3.0 Description

4.0 Installation

5.0 Controllers – General

6.0 Controller – Level 1

7.0 Controller – Level 2

8.0 Operation

9.0 Maintenance

10.0 Troubleshooting

11.0 Notes

12.0 Replacement Parts

Models 15 through 135 ................................................................................. 46, 47 Models 205 through 375 ............................................................................... 48, 49

13.0 Maintenance Kits

Models 15 through 75 ................................................................................... 50, 51 Models 95 through 375 ................................................................................. 52, 53

14.0 Drawings

P&ID Drawing Electrical Schematic

For Mounted Multi-Function Monitor in Hazardous Location

WARRANTY

— 1 —

2.0 Receiving, Moving, Unpacking

2.1 Receiving

• This shipment has been thoroughly checked, packed and inspected before leaving our plant.

• It was received in good condition by the carrier and was so ac-knowledged.

• Check for visible loss or damage. If this shipment shows evidence of loss or damage at time of delivery to you, insist that the carrier’s agent make a notation of this loss or damage on the delivery receipt.

2.2 Moving

CAUTION: Use lifting lugs or forklift. Do not lift equipment by piping.

2.3 Unpacking

• Check for concealed loss or damage. When a shipment has been delivered to you in apparent good order, but concealed damage is found upon unpacking, notify the carrier immediately and insist that his agent inspects the shipment.

• Fifteen days from receipt of shipment is the maximum time limit for requesting such inspection.

• Concealed damage claims are not our responsibility as our terms are F.O.B. point of shipment.

1.0 General Safety Information

1.1 Pressurized Devices

• This equipment is a pressure-containing device.

• Do not exceed maximum operating pressure as shown on the equipment serial number tag.

• Verify that equipment is fully depressurized before performing service or maintenance functions.

1.2 Electrical

• This equipment requires electricity to operate.

• Install equipment in compliance with national and local electrical codes.

• Standard equipment is supplied with NEMA 4,4X electrical enclo-sures and is not intended for installation in hazardous environ-ments.

• Disconnect power supply to equipment when performing any electrical service work.

1.3 Breathing Air

• When applied at rated capacity and operating conditions speci-fied within this manual, Breathing Air Purifiers supply air that meet the following standards:

- Occupational Safety and Health Association (OSHA) CFR 1910.134, Respiratory Protection.

- Canadian Standards Association (CSA) Z180.1-00, Compressed Breathing Air and Systems.

- Compressed Gas Association (CGA) Pamphlet G-7, Compressed Air for Human Respiration

- CGA Pamphlet G-7.1, Commodity Specification for Air.

- National Fire Protection Association (NFPA) Standard 1500, Fire

Department Occupational Safety and Health Program.

- American National Standards Institute (ANSI) Z88.2-1080, Practices for Respiratory Protection.

• In order to meet the above listed standards, the contaminant con-centrations at the purifier outlet must not exceed the limits listed in Table 1.3.1. The concentration levels of other contaminants not listed in Table 1.3.1 are not affected by the Breathing Air Purifier.

1.4 Noise

CAUTION: Do not operate purifier without mufflers installed.

1.5 High Velocity Air

CAUTION: Do not stand near mufflers during tower depres-surization.

Contaminant Maximum Allowable Concentration Purifier Outlet Concentration at Rated Conditions

OSHA CFR 1910.134 [1] CSA Z180.1-00

Carbon Monoxide (CO) ppm/v 10 5 95% Conversion (i.e. 200 ppm @ inlet

= 10 ppm @ outlet) Carbon Dioxide (CO2) ppm/v 1000 500 [2]

Oil (Condensed Hydrocarbons ) mg/m3

5 1 0

Oil Vapor (Gaseous Hydrocarbons) ppm, mL/m3

N/A N/A < .02 [3]

Odor “lack of noticeable odor” “no pronounced odor” None [4]

Table 1.3.1 [1] The OSHA Standard references CGA (Compressed Gas Association) pamphlet G-7.1, Grade D and is generally consistent with those published by ANSI and NFPA.

[2] CO is converted to CO2 by the purifier and added to the concentration of CO2 already present (normal atmospheric air contains 314 ppm v/v of CO2. Although some CO2 is absorbed in the desiccant beds, high concentrations of CO in the system and/or high concentrations of CO2 at the compressor intake could result in exceeding allowable CO2 limits.

[3] Will remove only those gaseous hydrocarbons normally absorbable by activated carbon. Outlet concentration is expressed as methane equivalent. Activated carbon will not remove methane.

[4] Will remove only those odors normally absorbable by activated carbon.

— 2 —

3.0 Description

3.1 Prefilters

• Adequate filtration is required upstream of the desiccant dryer and catalytic converter cartridge in order to protect them from contamination. The following filtration, equipped with automatic drains, is installed on all breathing air purifiers.

• Compressed air is first prefiltered through an air line filter where solid particles and high gross liquid concentrations (dust, dirt, water/oil emulsions) are removed.

• The preconditioned air then enters a 99.999% efficient coalescing type oil removal filter which eliminates virtually all submicronic particles, in particular oil mist (aerosols), which protects the desic-cant dryer and catalytic converter cartridge from oil contamination.

• Liquids removed in these filters are collected and automatically discharged from the system by automatic drains. The air then passes through a desiccant air dryer where water vapor is removed.

3.2 Desiccant Air Dryer

• The dual tower regenerative desiccant air dryer is an economical and reliable way to dry compressed air to dew points below the freezing point of water (dew points as low as -150°F (101°C) [1 ppb @100 psig, 7.0 kgf/cm2] are possible) or reduce the moisture content of compressed air when used in critical process applica-tions.

• The dryer continuously dries compressed air by using two identi-cal towers, each containing a desiccant bed. While one tower is on-stream drying, the other tower is off-stream being regenerated (reactivated, i.e., dried out). The towers are alternated on- and off-stream so that dry desiccant is always in contact with the wet compressed air. In this way a continuous supply of dry air down-stream of the dryer is possible.

• The dryer lowers the dew point of compressed air by adsorbing the water vapor present in the compressed air onto the surface of the desiccant. Desiccant is a highly porous solid containing extensive surface area.

• Adsorption occurs until the partial pressure of the water vapor in the air and that on the surface of the desiccant come into equilibrium.

As adsorption occurs, heat is released (referred to as the heat of adsorption) and is stored in the bed for use during regeneration.

• Desiccant is regenerated by driving off (desorbing) the water col-lected on its surface. A pressure-swing (also called a heatless or heater-less because no outside heat is added) dryer regenerates by expanding a portion (approximately 14 - 15% at 100 psig, 7 kgf/cm2) of the dried air to atmospheric pressure. This “swing in pressure” causes the expanded air to become very dry (have a very low vapor pressure). This very dry air (called purge air) plus the stored heat of adsorption allows the moisture to desorb from the desiccant. The purge air then carries the desorbed water out of the dryer.

• The removal of water vapor to very low levels is essential in protect-ing the next purification stage, the removal of carbon monoxide.

• Refer to Section 3.7 for graphical representation of Desiccant Air Dryer Operation.

3.3 Catalytic Converter (CC) Cartridge

• The CC cartridge removes carbon monoxide by converting it to carbon dioxide. CC cartridges are sized to allow for the efficient removal of high concentrations of carbon monoxide.

3.4 Afterfilters

• To ensure downstream air purity the following filtration is installed on all breathing air purifiers.

• Following passage through the CC cartridge, the purified air enters the particulate removal afterfilter which removes 1-micron rust, scale, and other particulates and liquid contaminants from the air stream.

• Finally, the air passes through an oil vapor adsorption filter which removes oil vapor to eliminate objectionable tastes and odors and to protect down-stream components from solid particles 0.01 micron and larger.

3.5 Automatic Purge Saving System

• Featured with the Level 2 Controller, the Automatic Purge Saving

System is designed to save energy (purge air) when pressure-swing dryers are operated at reduced loads.

• The patented Purge Saving System operates by monitoring the changes in temperature within the desiccant beds. These changes in temperature are the result of heat (thermal energy) that is re-leased when a bed is on-line drying (heat of adsorption), and the heat that is used when a bed is off-line being regenerated (heat of desorption). The magnitude of these changes in temperature is an indirect measure of the water vapor content in the air being dried.

This information is used to determine the time a tower stays on line during the drying cycle.

• Refer to Section 3.8 for graphical representation of Automatic Purge Saving System.

3.6 Breathing Air Analyzer(s) (Optional)

• Breathing air analyzers measure and display the levels of specified gas concentration and/or dewpoint and provide audible and visual alarms if that measurement exceeds predetermined set points.

• The breathing air purifier can be supplied with any of four possible combinations of air analyzing equipment:

1. Carbon Monoxide (CO) Monitor.

2. CO & Oxygen (O2) Combination Monitor.

3. CO & Dewpoint Combination Monitor.

4. CO, & O2, and Dewpoint Combination Monitor.

• Refer to analyzer instruction manuals (provided separately) for further details.

— 3 —

3.7 Description of Desiccant Air Dryer Operation

(Refer to Fig. 3-1a.) Compressed air flows through inlet shuttle valve (3) to tower (4A) where the air is dried. After the air is dried it flows through outlet shuttle valve (5) and then to the dryer outlet. A portion of the dry air, the purge stream, branches off from the main air stream prior to the outlet. The purge stream flow rate is controlled by the adjustable purge rate valve (6) and the two purge orifices (7).

The purge flow, which has been throttled to near atmospheric pressure, is directed to tower (4B). As the purge flow passes over the desiccant in tower (4B), it removes the water vapor, which was deposited there while the tower was on-line drying. The purge air then passes through purge and repressurization valve (9B) (normally closed) and purge muffler (10B) to the atmosphere.

After regeneration, purge and repressurization valve (9B) (normally closed) closes allowing tower (4B) to repressurize slowly. Adequate repressurization time is allowed so that tower (4B) is fully repressurized before tower switchover. After a controlled time period, purge and repressurization valve (9A) (normally closed) then opens. This causes the inlet and outlet shuttle valves to shift, directing the air flow through tower (4B).

(Refer to Fig. 3-1b.) Tower (4B) is now drying the main air stream while tower (4A) is being regenerated by the purge air stream. The operation of the purge and repressurization (normally closed) valves is sequenced by the control system located in the electrical enclosure.

8. Safety Valve

9. Purge and Repres-surization Valves

10. Purge Mufflers

11. Moisture Indicator A Left Tower Suffix B Right Tower Suffix

TOWER 4B REGENERATING

4B

TOWER

P urge Stream Process Stream

1. Tower Pressure Gauges

2. Purge Pressure Gauge

3. Inlet Shuttle Valve

4. Desiccant Drying Towers

5. Outlet Shuttle Valve

6. Adjustable Purge Rate Valve

7. Purge Orifices

9A

FIGURE 3- 1a

TOWER 4A DRYING

INLET

TOWER

4A

7 6 2

OUTLET

9B

10B

9A

TOWER 4B DRYING

TOWER

4A

INLET

FIGURE 3- 1b

TOWER 4A REGENERATING

7 6

2 7

9B

4B

TOWER

10A

10B10A

OUTLET

— 4 —

3.8 Automatic Purge Saving System

Assume tower A is on-line drying while tower B has just gone off-line to be regenerated. At the beginning of tower B’s regeneration cycle a thermistor temperature measurement is made at position B1. After the tower has been regenerated, another measurement is made at B1. The drop in temperature sensed during regeneration is an indirect measure of the water vapor content of the inlet air. The Automatic Purge Saving System’s microprocessor then uses this information to calculate an allowable temperature rise in the bed during the drying cycle.

When tower B goes back on-line, a temperature probe at position B2 measures the initial bed temperature at this point and then monitors the bed until the calculated temperature rise occurs. The temperature rise occurs as heat of adsorption is released during the drying process. The time for the temperature rise to occur depends on flow rate. At 100% flow the temperature rise takes 5 minutes, at 50% flow it takes 10 minutes.

NOTE: If after 30 minutes, the bed temperature has not risen to the calculated value, the dryer will automatically switch towers.

When the calculated temperature rise is reached, the towers switch with tower A now drying and tower B being regenerated. Tower B regenerates for 3.9 minutes, re-pressurizes, and remains idle until it is called upon for the next drying cycle.

1. Tower Pressure Gauges

2. Purge Pressure Gauge

3. Inlet Shuttle or Switching Valves

4. Desiccant Drying Towers

5. Shuttle or Check Valve(s)

6. Adjustable Purge Rate Valve

7. Purge Orifice(s)

Purge Stream Process Stream

8. Safety Valve(s)

9. Purge and Repres-surization Valves

10. Purge Mufflers

11. Moisture Indicator A & C Left Tower Suffix(es) B & D Right Tower Suffix(es)

4A 4B

TOWER 4A DRYING

TOWER 4B REGENERATING

10A

9A

FIGURE 3-4

10B

INLET

9B

TOWER

TOWER

A1

A2

B1

B2

OUTLET

11 5

— 5 —

4.0 Installation

4.1 Location in the compressed air system

NOTE: The air compressor should be adequately sized to handle air system demands as well as purge loss. Failure to take this into account could result in overloading air compressors and/or insufficient air supply downstream. It is desirable to install the Breathing Air Purifier where the compressed air is at the lowest possible temperature (downstream of aftercoolers) and the highest possible pressure (upstream of pressure reducing valves) without exceeding the maximum operating pressure of the equipment. (Refer to Figure 4-1)

4.2 Physical Location

The purifier must be installed with suitable overhead protection as well as clearance to change desiccant. Sufficient clearance around the periphery of the purifier should be provided to allow maintenance personnel access to all areas for routine inspections and adjustments.

4.3 Minimum & Maximum Operating Conditions

The compressed air supply to the purifier inlet should be checked peri-odically to ensure that purifier design specifications are not exceeded.

Normally the compressor installation includes intercoolers, aftercoolers, separators, receivers, or similar equipment, which adequately pretreat the compressed air supply in order to avoid excessively high air tem-peratures and liquid slugging of downstream equipment.

4.1.1 Aftercooler/Separator

Compressed air entering the Purifier must be cooled to a temperature of 140°F (60°C) or lower. Use of an aftercooler and condensate separator may be necessary to reduce inlet air temperature to an acceptable level.

NOTE: Installation of a refrigerated dryer ahead of a Breathing Air Purifier does not increase purifier capacity or reduce purge flow requirements.

4.1.2 Breathing Air Purifier

NOTE: By-pass lines are recommended so that maintenance work can be performed without shutting off the air supply.

4.1.3 Receiver(s)

Air receivers dampen pulsations from the compressor discharge line and can eliminate some of the condensed moisture that is carried over from the aftercooler and separator. They also provide a reservoir of stored air for response to system demands in excess of compressor capacity.

Size and location of receivers in the compressed air system need to be considered carefully. Flows must not exceed the adjusted maximum inlet capacity of the desiccant air dryer.

4.4 Maximum Operating Pressure (MOP)

• 150 psig (10.5 kgf/cm2) is standard.

Refer to Dryer Serial Number Tag.

WARNING – Do not operate the purifier at pressures above the maxi-mum operating pressure shown on the serial number tag.

NOTE: Consult factory for applications requiring higher maximum operating pressures.

4.5 Minimum Operating Pressures

• 60 psig (4.2 kgf/cm2) is the minimum operating pressure.

Refer to Dryer Serial Number Tag.

WARNING – Do not operate the purifier at pressures below the mini-mum operating pressure shown on the serial number tag.

4.6 Maximum Compressed Air Temperature

at Purifier Inlet

• 140°F (60°C) for all models.

Compressor Aftercooler Separator Receiver Prefilters Afterfilters ReceiverDesiccant Dryer

Figure 4-1

Breathing Air Purifier

Catalytic Converter

Figure 4-1

— 6 —

Figure 4-2 (continued on next page)

FRONT VIEW REAR VIEWSIDE VIEW

TOP VIEW

7/8 x 1-1/4 SLOT [22] X [32]

(TYP 4 PLCS)

CATALYST

CARTRIDGE

GENERAL COALESCING FILTER

HIGH EFFICIENCY OIL REMOVAL FILTER

OIL VAPOR REMOVAL FILTER

DRY DESICCANT AFTERFILTER

D

E

C

(TYP)

M

(MAX)

A

L

(MAX)

J

(TYP)

B

PURGE PRESSURE

GAUGE & REGULATOR

PURGE EXHAUST

MUFFLER

PURGE EXHAUST

VALVE

INLET SHUTTLE

VALVE ASSEMBLY

PURGE ADJUSTING

VALVE

ASME CODE TAG

OUTLET SHUTTLE

VALVE ASSEMBLY

ASME PRESSURE

RELIEF VALVE

PILOT AIR FILTERLEFT CHAMBER

PRESSURE GAUGE

MOISTURE INDICATOR

INLET/OUTLET

ISOLATION VALVES

DESICCANT

FILL PORT

LIFTING LUG

CONTROL

ENCLOSURE

INLET

PRESSURE GAUGE

OUTLET

PRESSURE GAUGE

RIGHT CHAMBER

PRESSURE GAUGE

DESICCANT

DRAIN PORT

DESICCANT

CHAMBERS

CENTERLINE OF AIR

INLET/OUTLET

CONNECTIONS

H

F

AIR INLET

G

AIR OUTLET

N

(MAX)

R

(AIR INLET/OUTLET

CONNECTION SIZE)

P

— 7 —

DIMENSIONS IN INCHES

MODEL 15 25 35 50 75 95 135 205 305 375

A 27.9/16 27.9/16 27.9/16 27.9/16 27.9/16 38.3/8 38.3/8 41.3/8 49.3/8 49.3/8

B 13.13/16 13.13/16 13.13/16 13.13/16 13.13/16 19.3/16 19.3/16 20.11/16 24.11/16 24.11/16

C 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4

D 29.1/2 29.1/2 29.1/2 29.1/2 29.1/2 35.1/2 35.1/2 35.1/2 35.1/2 35.1/2

E 14.3/4 14.3/4 14.3/4 14.3/4 14.3/4 17.3/4 17.3/4 17.3/4 17.3/4 17.3/4

F 7.3/4 7.3/4 7.3/4 7.3/4 7.3/8 10.5/8 10.5/8 10 13.9/16 13.5/8

G 15.3/4 15.3/4 15.3/4 15.3/4 15.7/8 19.5/8 19.5/8 20.1/8 24.13/16 24.13/16

H 31.1/4 31.1/4 31.1/2 45.3/4 45.3/4 37 37 52.5/8 42.3/8 46.3/8

J 1.3/4 1.3/4 1.3/4 1.3/4 1.3/4 1.3/4 1.3/4 2.3/4 2.3/4 2.3/4

L 42 42 42 42 42 49 49 58 64 64

M 38 38 38 38 38 45 45 47 52 52

N 49 49 49 64 81 56 56 75 66 74

P 20.5/8 20.5/8 23.1/4 23.1/4 23.1/4 24.3/8 24.3/8 31.1/8 31.7/16 31.7/16

R 1/2 NPT 1/2 NPT 1 NPT 1 NPT 1 NPT 1 NPT 1 NPT 2 NPT 2 NPT 2 NPT

WT/LBS 440 450 455 560 700 820 820 1185 1405 1560

DIMENSIONS IN MILLIMETERS

MODEL 15 25 35 50 75 95 135 205 305 375

A 700 700 700 700 700 975 975 1051 1254 1254

B 350 350 350 350 350 487 487 525 627 627

C 32 32 32 32 32 32 32 32 32 32

D 749 749 749 749 749 902 902 902 902 902

E 375 375 375 375 375 451 451 451 451 451

F 197 197 197 197 187 270 270 254 344 346

G 400 400 400 400 403 498 498 511 630 630

H 793 793 799 1161 1161 940 940 1337 1076 1178

J 44 44 44 44 44 44 44 70 70 70

L 1071 1071 1071 1071 1071 1247 1247 1481 1622 1622

M 962 962 962 962 962 1137 1137 1183 1327 1327

N 1234 1234 1234 1615 2047 1433 1433 1900 1668 1871

P 524 524 591 591 591 620 620 790 799 799

R 1/2 NPT 1/2 NPT 1 NPT 1 NPT 1 NPT 1 NPT 1 NPT 2 NPT 2 NPT 2 NPT

WT/KGS 200 205 207 255 319 373 373 538 639 710

Figure 4-2 (continued from previous page)

— 8 —

4.7 Ambient Temperatures

4.7.1 Minimum Ambient Temperature

• Standard units: 35°F (2°C)

4.7.2 Maximum Ambient Temperature

• 120°F (49°C)

NOTE: If the Breathing Air Purifier is installed in ambients below 35°F (2°C), low ambient protection requiring heat tracing and insulation of the prefilter bowls, auto drains and/or sumps, and lower piping with inlet switching and purge/repressurization valves is necessary to prevent condensate from freezing. If installing heat tracing, observe electrical class code requirements for type of duty specified. Purge mufflers and their relief mechanisms must be kept clear from snow and ice buildup that could prevent proper discharge of compressed air.

4.8 Mounting

Install the Breathing Air Purifier on a level pad. Holes are provided in the purifier base members for floor anchors.

NOTE: Floor anchors must be used if area is subject to vibration.

4.9 Piping

Inlet and Outlet connections Observe locations of inlet and outlet connections as shown in Figure 4-2 and connect inlet and outlet piping as indicated.

NOTE: All piping must be supported so as not to bear on the purifiers or filters.

4.10 Isolation Valves

Breathing air purifiers are pre-installed with inlet and outlet isolation ball valves. Care must be used to ensure that equipment is pressur-ized slowly. Rapid pressurization could cause excessive pressure drop across filter elements.

4.11 Electrical Connections

All KBS dryers, regardless of which controller they are supplied with, will require no more than 35 watts from a single-phase power source for operation.

Refer to the appropriate controller sections for detailed information on connections, ratings, and operation of the Level 1 or Level 2 Controller.

NOTE: Refer to the purifier serial number tag for allowable voltages, frequency and power rating.

4.12 Provisions for Purge Exhaust

• Purge exhaust must be routed through the factory supplied mufflers or piped to a remote location.

• Purge mufflers - If shipped separately, install purge exhaust muf-flers in the locations shown in Figure 4-2.

• If purge exhaust is piped to a muffler located in a remote location, choose a combination of diameters, lengths, and turns that limits the additional pressure drop to 1 psid or less.

WARNING – Do not operate purifier without installed mufflers. Ex-hausting compressed air directly to atmosphere will result in noise levels above OSHA permissible levels and rapidly expanding gas could potentially cause harm to persons or property.

4.13 Initial Desiccant Charge

The purifier is shipped complete with desiccant and is ready to operate after piping and electrical connections are made and controller settings are established.

4.14 Icon Identification

P Left Tower Pressure Gauge

Right Tower Pressure Gauge

Air Outlet

Air Inlet

Purge Pressure Gauge

Electrical Inlet

— 9 —

5.0 Controllers – General

5.1 Overview

The solid-state dryer controller is located in a polycarbonate, NEMA Class 4/4X, IP66 rated electrical enclosure mounted to a center panel located between the two desiccant towers. Controls are available in two functional levels. Both the Level 1 and Level 2 controls offer fixed-time cycles that provide dew points corresponding to ISO compressed air quality class 2. A key difference between the Level 1 and Level 2 con-trols is the way in which they address energy savings. When inlet flow is less than the adjusted rated capacity of the dryer, average purge air requirements are reduced. This reduction can translate to energy sav-ings at the air compressor.

Level 2 Controllers feature the Automatic Purge Saving System (APSS) as described in Sections 3.5 and 3.8. When Level 2 Controllers are oper-ated in demand rather than fixed cycle modes, the APSS automatically adjusts to dryer loading and extends drying time when possible. Average purge use is thus automatically reduced.

A feature-by-feature comparison of each controller can be found in Table 5-1.

Table 5-1 Feature Comparison – Level 1 and 2 Controllers

(continued on next page)

Breathing Air Purifier Controllers Level 1 Fixed Cycle Only

Level 2 Fixed Cycle and APSSCategory Feature

General

AC Input Voltage: 85-264 VAC, 47-63 Hz (See Note 1) • •

DC Input Voltage: 11.5-28 VDC (See Note 1) • •

Auxiliary power terminals (See Note 2) • •

Solenoid valve coil voltage 12 VDC 12 VDC

NEMA 4/4X, IP 66 electrical enclosure rating • •

Soft on/off switch with two power recovery modes (See Note 3) • •

Tower status LEDs (green=drying, amber=regenerating) • •

Process valve status LEDs (on=valve open, off=valve closed) • •

Operating mode LEDs (see next category for number of modes) •

Alarm LED (red) • •

Voltage-free alarm contacts, 5A rating • •

Alarm reset switch (mounted on front panel) • •

Service reminder LEDs (See Note 4) • •

Vacuum fluorescent text display •

Operating Modes (See NOTE 5)

ISO Class 1 (-100°F/-73°C PDP) - fixed cycle (4 minute) • •

ISO Class 2 (-40°F/-40°C PDP) - fixed cycle (10 minute) • •

ISO Class 2 (-40°F/-40°C PDP) - demand cycle •

Digital I/O

Controlled shutdown and restart (upon user supplied contact closure) • •

Tower pressure switches (2) • •

High Inlet Temperature Switch •

Low Inlet Pressure Switch •

High Humidity or Dew Point Alarm Optional

Electric drain alarm (1 or 2 filters) Optional

Electric drain test (1 or 2 filters) Optional

Analog I/O (12 bit accuracy)

Thermistors (4) •

Analog input #1 (0-5 VDC) Dew point transmitter Optional

Analog input #2 (0-5 VDC) Pressure transducer •

Analog input #3 (0-5 VDC) Temperature sensor •

Communication RS232 communication port • •

— 10 —

Table 5-1 (continued from previous page)

NOTES:

1. The Level 1 and Level 2 Controllers will accept either AC (Alternating Current) or DC (Direct Current) input power.

2. (Level 1 & Level 2 Controllers) The auxiliary power terminals are in parallel with the input power terminals (i.e., there are two common terminals for each input power connection point, L, N, and PE. The auxiliary power terminals provide a connection point for another device that operates on the same voltage as the Breathing Air Purifier Controller.

3. (Level 1 & Level 2 Controllers) The controller has two power recovery modes. For Level 1 the selection is made using a jumper on the circuit board. For Level 2 the selection is made using the switches on the front panel. In one mode, the controller remembers its state (on or off) prior to a power interruption and returns to that state when power is restored. In the other mode, the controller always returns to the off state when power is restored after an interruption.

4. (Level 1 & Level 2 Controllers) The service reminder LEDs indicate that it is time to perform preventive maintenance on the (a) filters and drains, (b) valves, or (c) desiccant. The user selects between Normal and Severe service intervals. For Level 1 the selection is made using a jumper on the circuit board. For Level 2 the selection is made using the switches on the front panel.

5. (Level 2 Controllers) The operating mode (fixed or demand cycle) is selected via switches on the front panel.

6. PDP - Pressure Dew Point MOP - Maximum Operating Pressure

— 11 —

6.0 Controller – Level 1

This section provides connection, adjustment and operational informa-tion for the Level 1 – Fixed Cycle Controller. Similar information for the Level 2 Controller featuring the APSS, Automatic Purge Saving System, can be found in Section 7.

6.1 Reference Figures – Level 1 Controller

• Figure 6-1, Front Panel Overlay – Level 1 Controller

• Figure 6-2, Electrical Schematic – Level 1 Controller

• Figure 6-3, Point-to-Point Diagram – Level 1 Controller

• Figure 6-4, Panel Layouts – Level 1 Controller

• Figure 6-5, Enclosure Penetrations – Level 1 Controller

6.2 Connections – Level 1 Controller

See Figure 6-5, Enclosure Penetrations for the location, size and func-tion of the various cable and cord connectors that are provided on the bottom of the Level 1 enclosure.

6.2.1 Connections - Input Power

6.2.1.1 VAC Input Power Connections

Single-phase, alternating current (AC) input power connections ranging from 85-264 VAC and 47 to 63 Hz. can be made at terminals TB5-20, -22, and –24. See reference figures for proper polarity. These terminals are connected to accessory output terminals TB5-21, -23, and –25 respectively. Accessory output terminals can be used to direct power at the same voltage and frequency to external devices.

CAUTION: Accessory output terminals are NOT controlled by the power on/off switch and are always energized when power is provided to terminals TB –20, -22, and -24.

6.2.1.2 VDC Power Connections

• The control and display boards operate on low-voltage direct current. The controller is provided pre-wired with an AC to 12 VDC power supply board. For users with AC power as described in Section 6.2.1.1, their AC input is directed to the power supply board where it is conditioned and returned to the control board as 12 VDC at terminals TB4-18 and –19.

• For users with direct current (DC) input power ranging from 11.5 to 28 VDC, use of the AC to DC power supply board is not needed and their connections can be made at terminals TB4-18 and –19 by first removing the black and red leads coming from the power supply board. See reference figures for proper polarity.

6.2.2 Connections – Common Alarm Contacts

Connections to voltage-free common alarm contacts with a minimum 5-amp rating can be made at terminals TB2-7 through –9.

• Terminal TB2-9 is the common contact connection.

• Terminal TB2-7 is the N.O. (normally open) contact connection.

• Terminal TB2-8 is the N.C. (normally closed) contact connection.

• The alarm relay coil is energized when power is supplied to the controller input terminals and there are no alarms.

• The coil is de-energized when power is removed or when an alarm condition exists.

• The common alarm is designed to activate on: a) either a dryer fault condition or a service reminder, or b) a dryer fault condition only. This is user selectable.

• For the common alarm to activate on either a dryer fault condition or a service reminder, the jumper at J2 is removed. This is the default configuration.

• To have the common alarm activate on a dryer fault condition only, the jumper at J2 is installed.

• Additional information on the common alarm relay logic appears in Table 6-1.

Power To

Controller

Controller On or Off?

Alarm or Service

Reminder

Alarm Relay Coil

Alarm N.O.

Contact

(TB2-7)

Alarm N.C.

Contact

(TB2-8)

No N/A N/A De-Energized Open Closed

Yes Off N/A Energized Closed Open

Yes On No Energized Closed Open

Yes On Yes De-Energized Open Closed

Table 6-1 Common Alarm Relay Logic –Level 1 Controller

6.2.3 Connections – Remote Start / Stop

Terminals TB1-1 and –2 are used to provide a 5 VDC output to a remote switch or volt free contacts that when closed will stop the dryer at the end of the current half cycle. The dryer will resume running at the beginning of the new half cycle when the remote switch or contacts are reopened.

When dryer operation is in the remote stop state, all four tower drying (green) and regenerating (amber) LEDs flash simultaneously.

NOTE: Remote start / stop is disabled when the dryer is in the Manual cycle operation mode. When the dryer is in the remote stop state, the only front panel and remote selector switches (see Section 6.2.4) that remain enabled are the power on/off switches.

CAUTION: It is the responsibility of the end-user that, when using this feature, the supply of properly treated breathing air will not be compromised in any way.

6.2.4 Connections – Remote Switches

The controller door is equipped with two momentary-contact, push button switches. Pressing the appropriate icon printed on the display overlay actuates these switches. The display board containing the switches, display LEDs and the J2 terminal strip is mounted on the inside of the enclosure door. The terminal strip provides connection points for remotely mounted, NO (normally open), momentary-contact push buttons that provide the same function as the board mounted switches. The terminal – switch combinations are:

• Terminals J2-1 and –2 (unused)

• Terminals J2-3 and –4 (unused)

• Terminals J2-5 and –6 (remote power on / off switch)

NOTE: Care must be exercised in using this remote switch to stop a dryer. Closing this switch will affect the same response as a loss of power. Both purge-repressurization valves will close. A tower that is actively purging when the power on/off button is actuated will be subjected to a rapid repressurization that can lead to fluidiza-tion and subsequent abrasion of the desiccant bed. Ideally, dryers should only be powered off during those portions of the drying cycle when both desiccant towers are at full operating pressure.

Use of the remote start/stop connections as described in Section

6.2.3 would be preferable in most cases.

CAUTION: It is the responsibility of the end-user that, when using this feature, the supply of properly treated breathing air will not be compromised in any way.

• Terminals J2-7 and –8 (remote alarm reset and manual cycle increment switch)

6.2.5 Connections – RS232

Refer to Figure 6-4, Panel Layouts – Level 1 Controller. RS232 connec-tions can be made at the 3-pin connector labeled J5 and located at the upper left-hand corner of the control board. A cable for this connection can be purchased through your distributor.

— 12 —

6.3 Control Board Jumpers – Level 1

Refer to Figure 6-3, Point to Point Connection Diagram – Level 1 Controller. In the upper left hand corner of the control board there are four two-pin jumpers labeled J1 through J4. The jumper is a removable bridge that is used to make or break continuity between the two pins that form a pair. When installed in the ON position, the jumper is placed on both pins of the pair and continuity between the pins is established.

When installed in the OFF position, the jumper is removed or stored on a single pin and continuity is broken. Jumper functions are as follows:

6.3.1 Jumper J1 – Cycle Times

Jumper J1 is used to select the drying cycle time. Installed in the OFF position when the drying cycle time is 10 minutes (-40°F/-40°C PDP).

Installed in the ON position when the drying cycle time is 4 minutes

(-100°F/-73°C PDP).

6.3.2 Jumper J2 – Common Alarm.

Jumper J2 is installed in the OFF position to enable both dryer fault alarms and service alarms to activate the common alarm. This is the default configuration. Install jumper J2 in the ON position if the common alarm is to be activated by a dryer fault alarm only.

6.3.3 Jumper J3 – Service Reminder Interval

Jumper J3 is used to select the service reminder interval. Installed in the OFF position when the Normal service reminder interval is desired.

Installed in the ON position when the Severe service reminder interval is desired. Service items, check points and time intervals appear in Table 6-2.

6.3.3.1 Filter Service

When the service interval for filters has expired the following LEDs will blink:

• Service LED (amber)

• Two filter LEDs (amber)

6.3.3.2 Desiccant Service

When the service interval for desiccant has expired, the following LEDs will blink:

• Service LED (amber)

• Both tower regenerating LEDs (amber). The service function overrides the normal display of the tower regenerating LEDs.

6.3.3.3 Valve Service

When the service interval for valves has expired, the following LEDs will blink:

• Service LED (amber)

• Valve LEDs (green) The service function overrides the normal display of the valve LEDs.

6.3.3.4 Catalyst Service

When the service interval for catalyst has expired the following LEDs will blink:

• Service LED (amber)

• Catalyst Service LED (amber)

To extinguish the blinking LEDs and restart the timer for a new service interval, press the alarm reset button.

NOTE: Time continues to accumulate as long as power is supplied to the controller, whether the controller is switched on or off.

Use the following sequence to manually reset the accumulated service interval time for all timers.

• Pause for about 1 second at each instruction. If the sequence is executed too quickly it will not work.

• With the controller already on, press and hold the alarm reset button.

• Press and hold the on/off button.

• Release the on/off button.

• Release the alarm reset button. The service interval time is now reset; the maintenance LED flashes three times to acknowledge the action.

Service Item (Customer check points are listed for each item)

Normal Service Interval

(J3 OFF)

Severe Service Interval

(J3 ON)

Filters

1. Check prefilter Delta-P

2. Ensure prefilter drain is discharging

3. Check afterfilter Delta-P

4,000 Hours

2,000 Hours

Desiccant

1. Check moisture indicator

2. Check dryer outlet dew point

3. Inspect mufflers for excessive dusting

8,000 Hours

4,000 Hours

Valves

1. Ensure valves are cycling properly

2. Check for switching failure alarms

3. Inspect valves for leaks - adjust purge valve as needed

4,000 Hours

2,000 Hours

Catalyst

1. Check moisture indicator

2. Check carbon monoxide concentration at outlet

4,000 Hours

2,000 Hours

Table 6-2 Jumper J3 – Service Reminder Intervals

6.3.4 Jumper J4 – Power Recovery Mode

Jumper J4 is used to select the power recovery mode. When power to the controller is interrupted, the position of this jumper controls the recovery mode of the dryer when power is restored. Installed in the OFF position when automatic power recovery is not desired. Installed in the ON position when automatic power recovery is desired.

• Jumper J4 installed in the OFF position – Automatic power recovery is turned off. The controller returns to the off state when interrupted power to the controller is restored.

• Jumper J4 installed in the ON position – Automatic power recovery is turned on. The controller remembers its state (on or off) prior to a power interruption and returns to that state (at the beginning of the prior ISO operating cycle) when power is restored. If power is interrupted while the controller is in the Manual cycle mode, the controller will return to the prior ISO operating cycle and not the Manual cycle when power is restored.

— 13 —

6.4 Front Panel Overlay – Level 1 Controller

Left tower pressure switch LED:

On=switch closed Off=switch open

Left tower drying LED

Left purge valve LED On=valve open Off=valve closed

Left tower regenerating

LED

Filter service / maintenance LED

Power On LED

Power On / Off Switch

Communications icon

Catalyst service / maintenance LED

Filter service / maintenance LED

Right tower pressure switch LED:

On=switch closed Off=switch open

Right tower drying LED

Right purge valve LED On=valve open Off=valve closed

Right tower regenerating LED

Maintenance / service reminder LED

Alarm LED

Reset switch for alarm and maintenance reminder – Advance switch for manual cycle

P1 P2

P3

P2

P3 P4

P1

Figure 6-1 Front Panel Overlay – Level 1 Controller

— 14 —

6.4.1 Front Panel LEDs

• Power on - green

• Alarm – red

• Service / maintenance reminder – amber

• Filters (pre, after) and catalytic converter cartridge service / maintenance reminders - amber

• Purge / repressurization valve status (On = valve open; Off = valve closed) – green

• Left and right tower status (regenerating) - amber

• Left and right tower status (drying) - green

• Left and right tower pressure switch status (On = switch closed;

Off = switch open) - green

6.4.2 Front Panel Switches

The front panel contains two momentary-contact push button switches.

Refer to Figure 6-1, Front panel Overlay – Level 1 Controller for the appropriate icon associated with each switch. Pushing on the overlay icon actuates the switch. Switching can be affected remotely by wiring external pushbuttons to the J2 terminals located on the rear of the display board. Refer to Section 6.2.4.

6.4.2.1 Purifier On / Off Switch

This switch is used to turn the Purifier on (run) or off (stop).

CAUTION: In the event of a loss of power, either intentional or un-intentional, both purge-repressurization valves will close. A tower that is actively purging when the power off button is actuated will be subjected to a rapid repressurization that can lead to fluidization and subsequent abrasion of the desiccant bed.Ideally, dryers should be powered off at the end of any half cycle when both desiccant towers are at full operating pressure.

Power recovery after an external loss of power is affected by the position of control board jumper J4 (power recovery mode). Refer to Section

6.3.4 for additional information.

6.4.2.2 Reset Switch

• This switch is normally used to reset an alarm or service reminder.

6.4.3 Switching Failure Alarms

• When a tower does not de-pressurize, the Alarm LED, Pressure

Switch LED, and Tower Regenerating LED will blink.

• When a tower does not re-pressurize, the Alarm LED, Pressure

Switch LED, and Tower Drying LED will blink.

• To extinguish the blinking LEDs, correct the fault condition and press the alarm-reset button.

• Refer to Table 6-4.

6.5 Fixed Cycle Timing

Refer to Table 6-3 for the fixed cycle timing for the Level 1 Controller.

6.6 Event Sequence and Component Status

Refer to Table 6-4 for the event sequence and component status for the Level 1 Controller.

Dryer MOP 60-150 psig

ISO Class 1 2

Dew Point -73°C -40°C

-100°F -40°F

Cycle Time (minutes) 4 10

Time Time from start of cycle

(minutes : seconds) t0 00:00 00:00 t1 00:02 00:02 t2 00:06 00:06 t3 01:12 04:00 t4 02:00 05:00 t5 02:02 05:02 t6 02:06 05:06 t7 03:12 09:00 t8 04:00 10:00

Reference Data

Purge time (min:sec) 01:06 03:54

Purge time (min:sec) 00:48 01:00

Table 6-3 Fixed Cycle Timing – Level 1 Controller

— 15 —

Process valve name (Process valve state w/ de-energized pilot solenoid valve)

Time (refer to Table 6-3) t0 t1 t2 t3 t4 t5 t6 t7 t8

Left Tower Drying Right Tower Regenerating

Half Cycle

Right Tower Drying Left Tower Regenerating

Half Cycle

Left purge valve (normally closed) Pilot Energized (open)

Right purge valve (normally closed) Pilot Energized (open)

Normal status of pressure switches

Left tower pressure switch closed closed closed closed closed closed closed for < 5 sec. then open open at t7, closed before t8

Right tower pressure switch closed closed closed for < 5 sec. then open open at t3, closed before t4 closed closed closed closed

Pressure switch status that causes an alarm

Left tower drying Low tower pressurea open1 open1

Left tower regenerating Fail to de-pressurizeb closed1

Left tower regenerating Fail to re-pressurizec open2

Right tower drying Low tower pressured open1 open1

Right tower regenerating Fail to de-pressurizee closed1

Right tower regenerating Fail to re-pressurizef open2

Note Stop cycle on fault Comments

1: Check for fault condition at 15, 25, 35,... seconds into half-cycle no

If the fault condition is clear for 2 cycles: the alarm LED stays on (without blinking); the tower and pressure switch LEDs stop blinking (return to normal operation). Once the fault condition is clear, pressing the reset button will clear the alarm LED (and the tower and pressure switch LEDs if they are still blinking).

2: Check for fault condition just before the end of the half-cycle yes If the fault condition clears: resume cycling; the alarm LED stays on (without blinking); the pressure switch LED stops blinking

(returns to normal operation). Once the fault condition is clear, pressing the reset button will clear the alarm LED.

a: Blink the following LEDs: Alarm + P1 + Left tower drying b: Blink the following LEDs: Alarm + P1 + Left tower regenerating c: Blink the following LEDs: Alarm + P1 d: Blink the following LEDs: Alarm + P2 + Right tower drying e: Blink the following LEDs: Alarm + P2 + Right tower regenerating f: Blink the following LEDs: Alarm + P2

Table 6-4 Event Sequence and Component Status – Level 1 Controller

— 16 —

Figure 6-2 Electrical Schematic – Level 1 Controller

NOTES:

1. CUSTOMER POWER CONNECTIONS WHEN SUPPLY VOLTAGE IS AC (ALTERNATING CURRENT). TERMINALS TB5-21, TB5-23 AND TB5-25 CAN BE USED TO PROVIDE ACCESSORY POWER AT THE SAME VOLTAGE AND

FREQUENCY. AC POWER IS DIRECTED TO POWER SUPPLY BOARD WHERE IT IS CONVERTED TO 12 VDC AND RETURNED TO THE CONTROL BOARD.

2. CUSTOMER POWER CONNECTIONS WHEN SUPPLY VOLTAGE IS DC (DIRECT CURRENT). RED AND BLACK WIRES FROM THE POWER SUPPLY BOARD SHOULD BE REMOVED AND THE CUSTOMER SHOULD MAKE THEIR

POWER CONNECTIONS AT TERMINALS TB4-18 AND TB4-19.

3. VOLTAGE RATING OF VALVES IS 12 VDC.

4. VOLTAGE RATING OF SWITCHES IS 5 VDC.

5. WITH UNIT ON AND NO ALARMS, THERE SHOULD BE CONTINUITY BETWEEN TERMINALS TB2-7 AND TB2-9.

CONTROL BOARD

COMMON

ALARM

CONNECTIONS

SEE NOTE 5

TB2-8

TB2-9

TB2-7

TB1-6

TB1-5

TB1-4

TB1-2

TB1-3

TB1-1

+ TB3-16

TB3-17

TB3-15

+5

PRESSURE SW. 2

RIGHT TOWER

LEFT TOWER

LEFT PURGE VALVE

NOT USED

+5

+5

PRESSURE SW. 1

EXT. CONTACT

+12

DC INPUT

CUSTOMER

DC POWER

CONNECTIONS

11.5-28 VDC

SEE NOTE 2

TB3-13

TB3-14

TB3-12

NEG.

POS.

TB4-19-

TB3-11

TB3-10

TB4-18+

CUSTOMER

AC POWER

CONNECTIONS

85-264 VAC

47-63 HZ

SEE NOTE 1

TB5-21

HOT

BLK

NEUTRAL

WHT

TB5-25

TB5-24

TB5-23

TB5-22

GRN/YEL

PE TB5-20

RIGHT PURGE VALVE

NOT USED

+12

+12

+12

BLACK

RED

HOT

AC TO DC

POWER SUPPLY

NEG.

J2-7

REMOTE SW. CONNECTIONS = J2

J2-8

ALARM RESET/MANUAL INCREMENT

DISPLAY BOARD

MULTIPLEXED LED BUS

J2-5

J2-3

J2-1

G

G

G

G

G

G

G

G

G

G

G

G

J2-6

J2-4

J2-2

POWER ON/OFF

NOT USED

NOT USED

+5

+5

+5

NOT USED

+5

Y

G

Y

Y

G

Y

G

G

G

Y

G

Y

Y

G

Y

G

Y

SERVICE REMINDER 1 (CATALYTIC CONVERTER CARTRIDGE)

PRESSURE SW. 2 (RIGHT TOWER) CLOSED

SERVICE REMINDER 2 (AFTER FILTERS)

RIGHT TOWER DRYING

NOT USED

MAIN SERVICE REMINDER

COMMON ALARM

POWER ON

RIGHT PURGE VALVE OPEN

RIGHT TOWER REGENERATING

NOT USED

PRESSURE SW. 1 (LEFT TOWER) CLOSED

SERVICE REMINDER 3 (PRE FILTERS)

NOT USED

LEFT TOWER DRYING

LEFT PURGE VALVE OPEN

LEFT TOWER REGENERATING

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

LCD

H

G N

H

N

G

CO MONITOR

— 17 —

Figure 6-3 Point-to-Point Connection Diagram - Level 1 Controller

JUMPERS

(SEE NOTE 3)

JUMPER NO. &

FUNCTION

JUMPER

OFF

JUMPER

ON

J1 - CYCLE TIMES

J2 - COMMON ALARM

J3 - SERVICE INTERVAL

J4 - POWER RECOVERY MODE

10 MINUTE 4 MINUTE

DEFAULT ACTIVATED BY DRYER

FAULT ALARM ONLY

NORMAL SEVERE

OFF AUTO

ENCLOSURE

DOOR

INTERIOR J2

DISPLAY BOARD

ALARM RESET

POWER ON/OFF SWITCH

UNUSED

UNUSED 1

J2

+5

+5 1 4

4 1

EXT. CONTACT

PRESSURE SWITCH 1

(LEFT TOWER)

PRESSURE SWITCH 2

(RIGHT TOWER)

UNUSED

RIGHT PURGE VALVE UNUSED

LEFT PURGE VALVE

+12

+12

+12

+12

NO

NC

CO

M

ALARM

CONTACT

DC

POWER

INPUT

11.5-28 VDC

AC

POWER

INPUT

85-264 VAC

1 PHASE

47-63 HZ

PE

NE

U

HO

T

JUMPER

JUMPER PINS

JUMPER BASE

JUMPER

OFF

JUMPER

ON

ENCLOSURE

INTERIOR

AC TO DC

POWER SUPPLY

RED WIRE

TO TB4-18

BLK WIRE

TO TB4-19

CONTROL BOARD

TB1 TB2 TB3 TB4

TB5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 J1

J2

J3

J4

NOTES:

1. SEE FIGURE 6-5 FOR RECOMMENDED AWG CONDUCTOR SIZES.

2. CUSTOMER SUPPLIED AC (ALTERNATING CURRENT) INPUT POWER CONNECTIONS SHOULD BE MADE AT TERMINALS TB5-21, TB5-23, AND TB5-25. FOR CUSTOMER SUPPLIED DC (DIRECT CURRENT) POWER, THE RED AND BLACK WIRES FROM THE POWER SUPPLY BOARD SHOULD BE REMOVED AND THE CUSTOMER POWER CONNECTIONS SHOULD BE MADE AT TERMINALS TB4-18 AND TB4-19.

3. IN THE “JUMPER OFF” POSITION, THE JUMPER CAN BE COMPLETELY REMOVED OR STORED ON A SINGLE PIN. IN THE “JUMPER ON” POSITION, THE JUMPER IS INSTALLED ACROSS BOTH PINS TO PROVIDE

CONTINUITY.

4. WITH THE UNIT ON AND NO ALARMS, THERE SHOULD BE CONTINUITY BETWEEN TERMINALS TB2-7 AND TB2-9.

— 18 —

Figure 6-4 Panel Layouts - Level 1 Controller

(continued on next page)

LEGEND

CR COMMON ALARM RELAY

1L SERVICE REMINDER 3 - PREFILTERS (AMBER)

3L LEFT TOWER REGEN. (AMBER)

4L LEFT PURGE VALVE OPEN (GREEN)

5L LEFT TOWER DRYING (GREEN)

6L PRESS. SWITCH 1 - L. TWR. CLOSED (GREEN)

7L SERVICE REMINDER 1 - CATALYTIC CONVERTER

CARTRIDGE (AMBER)

8L SERVICE REMINDER 2 - AFTERFILTERS (AMBER)

10L R. TWR REGEN. (AMBER)

11L RIGHT PURGE VALVE OPEN (GREEN)

12L RIGHT TWR. DRYING (GREEN)

13L POWER ON LED (GREEN)

14L MAIN SERVICE REMINDER (AMBER)

15L COMMON ALARM (RED)

16L PRESS. SWITCH 2 - R. TWR. CLOSED (GREEN)

CNTRLPCB CONTROL BOARD

DISPCB DISPLAY BOARD

JMP CONFIGURATION JUMPERS (MAX. OPER. PRESS.,

SERVICE INTERVAL, & POWER RECOVERY MODE)

2PB POWER ON/OFF SWITCH

3PB ALARM RESET/MANUAL CYCLE INCREMENT SWITCH

RS232 SERIAL I/O CONNECTION

PS AC TO DC POWER SUPPLY

J2 REMOTE SWITCH TERMINALS

TB1 EXTERNAL CONTROL INPUT TERMINALS

TB2 COMMON ALARM CONTACT TERMINALS

TB3 VALVE OUTPUT TERMINALS

TB4 DC POWER INPUT TERMINALS

TB5 AC POWER INPUT TERMINALS

ENCLOSURE DOOR EXTERIOR

13L 14L 15L2PB

3PB

10L

11L

12L

16L

7L 8L

6L

5L

4L

3L

1L

P1 P2

P3

P2

P3 P4

P1

— 19 —

Figure 6-4 Panel Layouts - Level 1 Controller

(continued from previous page)

47-63 HZ

85-264 VAC 11.5-28 VDC

— 20 —

Figure 6-5 Enclosure Penetrations - Level 1 Controller

LOCATION FUNCTION # OF

CONDUCTORS

AWG

SIZE

CABLE DIAMETER RANGE

CONNECTOR

SIZE

ENCLOSURE

HOLE DIA.MIN. DIA. MAX. DIA.

in. mm in. mm in. mm

FACTORY

CONNECTIONS

STANDARD

DEVICES

PRESSURE SWITCH - RIGHT TOWER 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2

2 PRESSURE SWITCH - LEFT TOWER 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2

3 SOLENOID - LEFT PURGE VALVE 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2

4 SOLENOID - RIGHT PURGE VALVE 2 18 0.181 4.6 0.312 7.9 PG-9 0.599 15.2

USER

CONNECTIONS

ALARM CONTACTS 2 16 0.181 4.6 0.312 7.9 PG-9 0.599 15.2

6 REMOTE STOP / START 2 16 0.181 4.6 0.312 7.9 PG-9 0.599 15.2

7 RS232 3 22 0.114 2.9 0.250 6.4 PG-7 0.492 12.5

8 INPUT POWER 3 14 0.230 5.8 0.395 10.0 PG-11 0.733 18.6

4.17" [106 mm]

5.35" [136 mm]

6.54" [166 mm]

7.72" [196 mm]

8.90" [226 mm]

10.00" [254 mm]

0.87" [22 mm] 1.97" [50 mm]

2.74" [70 mm] 3.45" [88 mm]

— 21 —

7.0 Controller – Level 2

This section provides connection, adjustment and operational informa-tion for the Level 2 Controller featuring the Automatic Purge Saving System (APSS). Similar information can be found in Section 6 for the Level 1, Fixed Cycle Controller.

7.1 Reference Figures – Level 2 Controller

• Figure 7-1, Front Panel Overlay – Level 2 Controller

• Figure 7-2, Electrical Schematic – Level 2 Controller

• Figure 7-3, Point-to-Point Diagram – Level 2 Controller

• Figure 7-4, Panel Layouts – Level 2 Controller

• Figure 7-5, Enclosure Penetrations – Level 2 Controller

7.2 Connections – Level 2 Controller

See Figure 7-5, Enclosure Penetrations – Level 2 Controller for the loca-tion, size and function of the various cable and cord connectors that are provided on the bottom of the Level 2 enclosure.

7.2.1 Connections - Input Power

7.2.1.1 VAC Input Power Connections

Single-phase, alternating current (AC) input power connections ranging from 85-264 VAC and 47 to 63 Hz. can be made at terminals TB6-45, -47, and –49. See reference figures for proper polarity. These terminals are connected to accessory output terminals TB6-44, -46, and –48 respectively.