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AIRTEKPREMIUM PRODUCTS FOR INDUSTRYTWP & TWBHeat Reactivated Desiccant Dryers

Externally Heated andBlower Purge Desiccant Air DryersAirtek heat reactivated desiccant airdryers use the adsorption method toremove moisture from compressed air.Pressure dew points ranging from minus40 O F (-40 O C) to minus 100 O F (-73 O C) areachieved by directing the flow ofsaturated compressed air over a bed ofdesiccant. The most commonly useddesiccant is activated alumina, aspherically shaped, hygroscopic material,selected for its consistent size, shape andextreme surface to mass ratio. Thisphysically tough and chemically inertmaterial is contained in two pressurevessels commonly referred to as “dual”or “twin” towers. As the saturatedcompressed air flows through the bed ofthe “on-line” tower, its moisture contentadheres to the surface of the desiccant.The dry compressed air is thendischarged from the vessel into thedistribution system.A master controller cycles the flow ofcompressed air between the towers.While one tower is “on-line” drying, theother tower is “off-line” regenerating.Regeneration, sometimes referred to as“purging”, is the process of stripping theaccumulated moisture from the “off-line”bed.Both types of Airtek heat reactivateddryers combine heat with either a smallportion of the dried compressed air orwith forced ambient air to affectregeneration.As heated, low pressure, purge air flowsgently through the regenerating bed, itdesorbs the moisture that hadaccumulated on the surface of thedesiccant during the drying cycle andexhausts it to the atmosphere.2

Flow SchematicAirtek’s patented Multi-PortRegeneration System (TWP Series)affects superior desiccant bedregeneration and, as a result, providesbetter and more consistent performance.The Multi-Port Regeneration Systeminjects heated purge air at precise pointsup and down the towers length providinga more balanced distribution of heat. Thissystem prevents the desiccant on topfrom prematurely deteriorating whileproviding the bottom of the chamber withenough heated purge air to allowcomplete regeneration on every cycle.The energy saving temperature monitoringsystem senses the exiting purge airtemperature. When the purge airtemperature increases to a pre-set pointat which the desiccant bed is fully heatedand regenerated, the blower and heaterare turned off.Airtek’s Secondary Blowdown System isstandard on all TWP Series and TWBSeries heat reactivated air dryers 1000SCFM and larger. It improves performanceand efficiency while increasingdesiccant life. The depressurization stagestrips moisture from the bottom of thetank through a purge muffler. Oncedepressurization is complete, the systemswitches to the main exhaust where finalregeneration is accomplished with lowpressure purge air. Bypassing the exhaustmufflers eliminates back pressure andallows for more thorough regeneration.Airtek Externally Heatedwith Patented Multi-Port(TWP)DryingAir OutPurgeRegulatorHeaterPurgingAir Out1% CooldownValveExhaustMufflersAir InPre-Exhaust ValveMain Exhaust ValveInlet ValveDryingHeaterPurgingBlowerExhaustMufflersAir InAirtek Blower Purge (TWB)Pre-Exhaust ValveMain Exhaust ValveInlet Valve3

Control CenterAirtek’s Control Center for HeatReactivated Desiccant Air Dryersfeatures a complete complement of dataacquisition functions. The easy to useControl Center affords superior dryer controlalong with digital telemetry forremote analysis of performance.Features:RemoteWatch TM Software : virtual control, diagrams and graphicsStarWatch TM ready w/68 channels of data & over 60 process valuesTemperature & pressure instrumentation packageEnergy Management-PowerLoc TM dew point digital readout w/Power Save4-20mA input w/setpoint and alarm for connection to your flow meterIntelligent display w/operational informationFull system retentive alarm network (event) logProgrammable process setpointsDryer operating “state” annunciation displayAutomatic data logging 24/7, 365 days of all operational information16 channel “programmable” common alarmRS-232 communications port (Optional RS-485)Access system via StarWatch TM or Modbus protocols.160 fields of operational information.Connectivity: telco line, cellular wireless modem, cellular wirelessinternet, EthernetDual Mode communications. Modbus Protocol, and StarWatch TM Protocol.UL RatedWith StarWatch TM activated Airtek canmonitor and analyze every moment ofoperation, 24-7; it can be done wirelessly.When StarWatch TM is active on aninstallation, it is as if an Airtek factoryemployee is right in your plant, advisingyour process engineer.Control Center Monitors:TEMPERATURE (thermistor sensors)Purge Air“Special” (fail-safe) Heater Over TemperatureLeft ExhaustRight ExhaustDryer InletDryer OutletPRESSURE (Transducer signals can be either 4-20ma or 1-5 volt DC)InletLeft TowerRight TowerPurgePre-Filter PSID(Package “E” only 400 SCFM models & larger)After Filter PSID(Package “E” only 400 SCFM models & larger)DEW POINT (Energy Management) - OPTIONALPowerLoc(“Fast Response” Digital Readout with Power Save feature)4

Quick Glance Operational StatusDigital ReadoutThe Control Center features a backlit four line characterdisplay that monitors operation and status. Includingregenerating countdowns and time remaining.Sequence AnnunciatorIndicates the status of each tower. LED’s indicate whichtower is “on-line” drying, “off-line” regenerating as wellas the regeneration stages.Manual SteppingAllows the operator to quickly and safely step the dryerthrough a complete 8 hour cycle, in a matter of minutes.ThermaLoc (10 Year Heater Warranty)The Control Center also controls Airtek’s “ThermaLoc”heater protection system. ThermaLoc ensures maximumreliability and eliminates the safety concerns oftenassociated with heat reactivated dryers. Heaters areprotected by a totally redundant dual shutdown system thatutilizes independent mercury contactors. In addition to theredundant temperature controllers, the system monitorspressure and shuts the heater down in the event of low linepressure. Blower purge dryers have controls to prevent theheater from energizing if the blower is not running.Dual Mode Heatless Back Up SystemAllows the dryer to function in either the primary heated mode orthe auxiliary heatless mode. Should the system experience atemporary overload or a heater failure, the dryer can easily beswitched over to operate in the heatless mode. This way the dryerwill remain on line until such time as service can be convenientlyscheduled. The Dual Mode Back Up System offers unparalleledflexibility, eliminates downtime and prevents businessinterruptions.5

Switching ValvesNon-Lubricated ValvesDryers up to 800 SCFM are equipped with our time-proven anddependable non-lubricated switching valves. These independent, airoperated valves are specifically designed for compressed air service.They are resistant to desiccant dust and can be maintained without beingremoved from the dryer.Rotary Actuated ValvesHigh Performance, Rotary Actuated Switching Valves are standard ondryers 1000 SCFM and larger. These premium, air operated butterflyvalves are specifically designed for compressed air. They provide moreopening and closing force compared to other types of valves. An indicatorshows the “opened/closed” position of the valve and service can beperformed without disturbing dryer piping.These valves are so reliable, they carry a Three Year Factory Warranty.Tower InsulationThe tower, heater, and purge lines are insulated to increase dryerperformance and efficiency by reducing radiant heat loss. It also keepsthe unit within the safety parameters set forth by OSHA. Insulationsuitable for indoor service is standard on all Airtek Heat ReactivatedDryers (Insulation suitable for outdoor service is an available option).Design ParametersAirtek Externally Heated and Blower Purge dryers are designed to process a specific volume ofcompressed air and deliver it to the discharge at a desired pressure dew point. Both dryers are rated fora -40 O F (-40 O C) pressure dew point. Dew point spikes, inherent on all blower purge dryers, can bereduced by activating Airtek’s standard Supplemental Cooldown Purge feature. Standard ratings arebased on inlet conditions of +100 O F (38 O C), 100 PSIG (6.9 Bar) and 100% flow.(Dryer performance will vary with different inlet conditions).Moisture load, velocity, contact time and cycle time determine the amount of desiccantrequired. To assure design performance, each tower is carefully sized to allow a minimumcontact time of 7 seconds. To prevent bed movement, desiccant dusting andfluidization, air flow velocity is kept below 55 feet per minute. ExternallyHeated and Blower Purge dryers are designed for an eight-hour cycle(four hours “on-line” drying, four hours “off-line” regenerating,cooling and repressurizing). For significant energy savingsand Digital Dew Point Readout, all Airtek desiccantdryers can be equipped with an optionalPowerLoc Demand Control Module.6

Complete Air Treatment SystemWithout proper filtration, desiccant air dryers will not work. Desiccant dryers are designed toadsorb vapor from compressed air; they are not designed for liquid. When liquid, especiallyoil, is allowed to enter the desiccant chamber, it coats the desiccant material preventing anyfurther adsorption. Oil coated desiccant can not be regenerated, and must be replaced. Toprotect the desiccant from contact with liquids, a coalescing pre-filter is required. Thepre-filter must be properly sized and properly installed with a dependable automatic drainand a visual indicator to determine element condition. To protect downstream equipment frompotential damage caused by the abrasive effects of desiccant dust, a particulate after-filter isalso required.Most field problems experienced with desiccant air dryers are the result of improper filterselection, installation, maintenance, and/or draining of condensate.Considering the importance of filtration to dryer performance, Airtek recommends that alldesiccant dryers be ordered as a complete, factory assembled Air Treatment System. TheOptional Airtek Package “E” includes: properly sized, factory installed coalescing prefilterand particulate after filter with electronic drain system (No Loss Demand Drains standard on400 SCFM and larger), and integrated digital element condition indicators.Factory packaging, with matched components and single point connections reducesinstallation costs, ensures performance and allows Airtek to assume total responsibility forsystem integrity.7

Apex Filter ElementAir OutFiltersAirtek Package “E” systems match our TWP and TWB dryerswith Airtek high performance filters. In-line filters (JW) areused on systems 100 through 300 SCFM and two stage (JLA)severe duty filters are used on systems 400 SCFM and larger.Mist eliminators are available as extra protection.The coalescing pre-filter is installed at the dryer inlet.It protects the dryer by removing liquids and reducing thecontamination level of the compressed air to .01 PPM byweight. The element is DOP rated at 99.9+% efficient in the0.3 to 0.6 micron range. An integrated digital indicator isprovided to determine element condition. An electronic drainvalve is provided on systems 100 through 300 SCFM toensure proper drainage. On systems 400 SCFM and larger azero air loss demand drain is provided. The drain controllerincludes push to test, drain alarm, and common alarm contact.Second StageAir In2nd StageDrainFirst StageTo protect downstream equipment from desiccant dust aparticulate after-filter is installed at the dryer discharge.The after-filter element is designed to remove solidparticulates from compressed air. The hybrid pleated filtermedia provides high dirt retention, low pressure drop, andlong element life. The element is 99+% effective in removingparticles 0.9 micron and larger. A integrated digital elementcondition indicator is also provided.Note: Optional Mist Eliminators are available as extraprotection for standard packages.Quiet Zone1st StageDrainPackage “E”Package SchematicPackage “EB”PFDRYER AFIncludes dryer with factory installedpre-filter and after-filter.PFDRYER AFIncludes dryer with factory installed pre-filterand after-filter with system bypass.Package “EC”PFPFDRYERAFIncludes dryer with factory installed dualselectable pre-filters and single after-filter.Package “ED”PFPFDRYERAFAFIncludes dryer with factoryinstalled dual selectablepre and after-filters.8

PowerLoc SystemThe Control Center is designed to accommodate Airtek’soptional PowerLoc Demand Controller.PowerLoc automatically adjusts energy use to actualmoisture load. Moisture loading is affected by inlettemperature, pressure, relative humidity and flow. Theseconditions vary throughout the day and rarely combine insuch a manner as to produce maximum moisture loads. Aninlet temperature reduction of just 20 O F (-7 O C) will reduce themoisture load by almost 50%. Desiccant dryers arenormally sized for “worst case” operation with the cyclefixed to accommodate maximum moisture loads. Because thefixed cycle does not compensate for fluctuating loads, dryersnot equipped with PowerLoc waste energy by regeneratingmore often than necessary. PowerLoc eliminates thisunnecessary use of energy by delaying regeneration until thetotal design moisture load is achieved. The system monitorsactual moisture loading and limits the number of purge cyclesaccordingly.At $0.08 per KWH, the PowerLoc would save $6,730annually when used with a 1000 SCFM externally heateddryer operating at 75% load for 8,000 hours, at an average inlet temperature of +80 O F (27 O C).Digital dew point control provides for additional energy savings by allowing the operator to selecthigher dew points when appropriate. The moisture probe is contained in and protected by a rugged,stainless steel housing that also contains an electronics package for continuous self calibration,temperature compensation, and signal stabilization. Due to less frequent cycling, switching valvesand desiccant will last longer and require less maintenance.The PowerLoc ceramic sensor is made from state-of-the-art metalized ceramic and replacestraditional materials such as aluminum, silicon and hydroscopic salts. This fast reponse sensor ismade from a ceramic tile that is plated and vapor deposited to form a surface that is very sensitiveto small changes in water vapor pressure.The proprietary coating processes make the ceramic sensor inherently faster to respond than otherimpedance or capacity sensors currently available. The ceramic sensor features the latest digitaltechnology with calibration data stored directly in the sensor’s memory, and is equipped with abuilt-in thermistor for automatic temperature compensation. The PowerLoc is traceable to theNational Institute of Standards and Technology. A certificate of traceability is available.The PowerLoc ceramic sensor is protected by an 80 micron sintered metal guard and is enclosed ina rugged, stainless steel housing with a pressure rating of 5000 PSIG. This housing increases thesensor’s ability to withstand reasonable shock and vibration.Effects of Inlet Temperatureon Moisture Load100 O F (38 O C)95 O F (35 O C)90 O F (32 O C)85 O F (29 O C)80 O F (27 O C)Inlet Temperature75 O F (24 O C).47 .55 .65 .75 .87 1.0Factor9

Engineering Data SpecificationsTWP Externally Heated Desiccant Air DryerMODELCapacitySCFM@ 100 PSIG(Nm 3 /min@6.9 Bar)ApproximatePurge SCFM(Nm 3 /min)HeaterKWAverageKWRecommendedPackage "E"Length(mm)Dryer with Package "E"Width(mm)Height(mm)WeightLbs (Kg)AirIn/Out(mm)PowerSupplyVolts/Phase/HzTWP100TWP130TWP200TWP250TWP300TWP400100 (2.8)135 (3.8)200 (5.7)250 (7.1)300 (8.5)400 (11.3)7 (.2)9.5 (.27)14 (.4)17.5 (.5)21 (.6)28 (.8)1.51.53346.741.01.51.92.33.0TA-PE 0111TA-PE 0151TA-PE 0201TA-PE 0301TA-PE 0301TA-PE 040137 (940)37 (940)44 (1118)45 (1143)47 (1194)74 (1880)33 (838)33 (838)39 (991)39 (991)39 (991)41 (1041)82 (2083)82 (2083)82 (2083)84 (2134)84 (2134)90 (2286)680 (308)720 (327)920 (417)1180 (535)1370 (621)1400 (635)1" (25.4)1" (25.4)1-1/2" (38.1)1-1/2" (38.1)1-1/2" (38.1)2-1/2" (50.8)120 / 1 / 60120 / 1 / 60240 / 1 / 60240 / 1 / 60480 / 3 / 60480 / 3 / 60TWP500TWP600TWP800500 (14.1)600 (17.0)800 (22.7)35 (1.0)42 (1.2)54 (1.5)6993.74.56.0TA-PE 0601TA-PE 0601TA-PE 090174 (1880)74 (1880)96 (2438)41 (1041)41 (1041)48 (1219)90 (2286)96 (2438)90 (2286)2060 (934)2350 (1066)3035 (1377)2-1/2" (50.8)2-1/2" (50.8)2-1/2" (50.8)480 / 3 / 60480 / 3 / 60480 / 3 / 60TWP1000TWP1200TWP15001000 (28.3)1250 (35.4)1500 (42.5)70 (2.0)84 (2.4)105 (3.0)1313187.48.911.2TA-PE 1001TA-PE 1251TA-PE 160196 (2438)96 (2438)144 (3658)48 (1219)48 (1219)72 (1829)101 (2564)101 (2564)101 (2564)4195 (1903)5215 (2365)5715 (2592)3" FL3" FL4" FL(76.2)(76.2)(101.6)480 / 3 / 60480 / 3 / 60480 / 3 / 60TWP2000TWP2600TWP30002200 (62.3)2600 (73.6)3000 (84.9)140 (4.0)182 (5.1)210 (5.9)25253016.419.322.3TA-PE 2001TA-PE 2601TA-PE 3001144 (3658)144 (3658)144 (3658)72 (1829)72 (1829)72 (1829)101 (2564)101 (2564)110 (2794)6250 (2835)6750 (3062)7055 (3200)4" FL4" FL6" FL(101.6)(101.6)(152.4)480 / 3 / 60480 / 3 / 60480 / 3 / 60TWP4000TWP5000TWP60004000 (113.3)5000 (141.6)6000 (169.9)280 (7.9)350 (9.9)420 (11.9)38506029.737.044.6TA-PE 4001TA-PE 5001TA-PE 6001168 (4267)210 (5334)210 (5334)78 (1981)90 (2286)90 (2286)114 (2896)114 (2896)114 (2896)18080 (8201)20710 (9394)25200 (11431)6" FL6" FL6" FL(152.4)(152.4)(152.4)480 / 3 / 60480 / 3 / 60480 / 3 / 60TWP7500TWP90007500 (212.4)9000 (254.8)525 (14.9)630 (17.9)8510056.069.7TA-PE 7501TA-PE 9001210 (5334)210 (5334)90 (2286)96 (2438)114 (2896)114 (2896)27100 (12292)28600 (12973)8" FL8" FL(203.2)(203.2)480 / 3 / 60480 / 3 / 60TWB Blower Purge Desiccant Air DryerMODELCapacitySCFM@ 100 PSIG(Nm 3 /min@6.9 Bar)BlowerHPHeaterKWAverageKWRecommendedPackage "E"Length(mm)Dryer with Package "E"Width(mm)Height(mm)WeightLbs (Kg)AirIn/Out(mm)PowerSupplyVolts/Phase/HzTWB100TWB200TWB300100 (2.8)200 (5.7)300 (8.5).75.751.53661.82.94.7TA-PE 0112TA-PE 0202TA-PE 030254 (1372)54 (1372)66 (1676)42 (1067)42 (1067)48 (1219)78 (1981)78 (1981)86 (2184)1050 (476)1500 (680)1900 (862)1" (25.4)1-1/2" (38.1)1-1/2" (38.1)120 / 1 / 60480 / 3 / 60480 / 3 / 60TWB400TWB500TWB600400 (11.3)500 (14.1)600 (17.0)1.522912125.97.48.6TA-PE 0402TA-PE 0602TA-PE 060274 (1880)74 (1880)96 (2438)41 (1041)41 (1041)48 (1219)90 (2286)90 (2286)96 (2438)2180 (989)2840 (1288)3420 (1551)2-1/2" (50.8)2-1/2" (50.8)2-1/2" (50.8)480 / 3 / 60480 / 3 / 60480 / 3 / 60TWB800TWB1000TWB1200800 (22.7)1000 (28.3)1250 (35.4)555.518182513.415.718.4TA-PE 0802TA-PE 1002TA-PE 1252108 (2743)108 (2743)108 (2743)54 (1372)54 (1372)54 (1372)90 (2286)101 (2565)113 (2870)4490 (2037)5700 (2585)6300 (2858)2-1/2"3" FL3" FL(50.8)(76.2)(76.2)480 / 3 / 60480 / 3 / 60480 / 3 / 60TWB1500TWB2000TWB26001500 (42.5)2200 (62.3)2600 (73.6)7.57.51030385023.531.638.3TA-PE 1602TA-PE 2002TA-PE 2602144 (3658)144 (3658)156 (3962)72 (1829)72 (1829)84 (2134)100 (2540100 (2540)110 (2794)8250 (3742)9850 (4468)12210 (5538)4" FL4" FL4" FL(101.6)(101.6)(101.6)480 / 3 / 60480 / 3 / 60480 / 3 / 60TWB3000TWB4000TWB50003000 (84.9)4000 (113.3)5000 (141.6)101515607510042.958.670.2TA-PE 3002TA-PE 4002TA-PE 5002156 (3962)204 (5182)204 (5182)84 (2134)96 (2438)96 (2438)111 (2819)114 (2896)114 (2896)15170 (6881)18910 (8577)21590 (9793)6" FL6" FL6" FL(152.4)(152.4)(152.4)480 / 3 / 60480 / 3 / 60480 / 3 / 60TWB6000TWB7500TWB90006000 (169.9)7500 (212.4)9000 (254.8)20253011513515086.0107.0129.0TA-PE 6002TA-PE 7502TA-PE 9002204 (5182)210 (5334)220 (5588)96 (2438)96 (2438)102 (2591)114 (2896)114 (2896)126 (3200)26500 (12020)28800 (13063)32100 (14560)6" FL8" FL8" FL(152.4)(203.2)(203.2)480 / 3 / 60480 / 3 / 60480 / 3 / 60Notes:Dimensions and weight are for dryer with Package E installed.Dimensions measured in inches and millimeters.Weight measured in pounds and kilograms and includes desiccant (shipped loose models 1500 and up).Specifications and dimensions are subject to change without notice.10

EquipmentStandard EquipmentAlarm, Failure to SwitchAlarm, Contacts for CommonAnnunciator, Systems SequenceBlower Flow Interlock (TWB Models)Blower Silencer (TWB Models)Compressor Surge ProtectionControl CenterControl System, Dual Redundant (ThermaLoc)Cycle SteppingDual Mode, Heatless BackupFail-Safe OperationFilter, Control AirHeater, Long Life, Low Watt DensityIndependent Switching ValvesIndicator, MoistureIndicator, Purge FlowInstrumentation, FullInsulation, Indoor TowerOver-Temperature Safety ControlPorts, Separate Tower Fill/DrainPower Saver Exhaust ShutdownPressure EqualizationScreens, Stainless Steel DiffuserSolid State SensorsStandby ModeThermostats, Dual HeaterValves, Cushioned Seat CheckValves, High Performance Butterfly (1000 SCFM & Larger)Vessels, ASME CodedWarranty, 10-Year HeaterWarranty, 3-Year Valve (1000 SCFM & larger)Optional EquipmentActuator Valve Limit SwitchFilters, Pre and After SetsInsulation, OutdoorMOD-BUSNEMA Classifications, AllNon-Yellow MetalsPressure to 1000 PSIGStarWatch TMVoltages, Non-StandardCapacity Correction FactorsAPSIBARFACTOR503.5.56INLET AIR PRESSURE CORRECTION604.1.65704.9.74805.5.83906.2.911006.911107.61.091208.31.181309.01.271409.71.3715010.31.43BTEMP O F OCFACTORTEMPERATURE CORRECTION90321.3595351.1610038110541.8511043.7411546.6412049.56EXAMPLE CALCULATIONSTWP500 Corrected for 120 PSI (8.3 Bar) +110 O F ( 43 O C)CORRECTED CAPACITY= (RATED CAPACITY) X (PSI Correction) X (Temperature Correction)= 500 SCFM (13.9 Nm 3 /min) X (1.18) X (.74)= 437 SCFM (12.1 Nm 3 /min)AIRTEKPREMIUM PRODUCTS FOR INDUSTRYPatents issued: 6,099,620; 5,207,072; 5,099,655; 5,062,571; other patents pending. The equipmentindicated in the catalog is meant for use in operating “compressed air driven” apparatuses. At no timeshould any Airtek equipment be used for breathing air situations unless all government regulationsregarding breathing air are met.Airtek ®, Smart Cycle®, Cold Trap®, StarWatch® and Powerloc® are Registered Trademarks of RaycoEnterprises, Inc. DBA Airtek© 2001 Rayco Enterprises, Inc. DBA Airtek, Lancaster, New York Printed in U.S.A.Brochure ID # DES 1-2006114087 Walden AvenueLancaster, New York 14086Ph. 716.685.4040 Fx.716.685.1010Email: airtek@airtek.com

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