Sullair DBP Series User & Service Manual
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Sullair DBP Series User & Service Manual

Sullair DBP Series User & Service Manual

Desiccant blower purge regenerative dryer
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USER/SERVICE MANUAL
D
B
P
ESICCANT
LOWER
URGE
R
D
EGENERATIVE
RYER
DBP S
(800-10,000 CFM)
ERIES
PART NUMBER:
02250195-405 R00
KEEP FOR
FUTURE
WARRANTY NOTICE
REFERENCE
SULLAIR CORPORATION
©
Failure to follow the instructions
The information in this manual is current
and procedures in this manual or,
as of its publication date, and applies to
misuse of this equipment will
compressor serial number:
VOID its warranty!
SBPIABIABA-0001
and all subsequent serial numbers.

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  • Page 1 PART NUMBER: 02250195-405 R00 KEEP FOR FUTURE WARRANTY NOTICE REFERENCE SULLAIR CORPORATION © Failure to follow the instructions The information in this manual is current and procedures in this manual or, as of its publication date, and applies to misuse of this equipment will...
  • Page 2 AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility located at Michigan City, Indiana.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1—INTRODUCTION SECTION 2—SAFETY SAFETY INFORMATION DEFINITION OF THE SAFETY SYMBOLS USED WARNINGS PROPER USE OF THE DRYER INSTRUCTIONS FOR THE USE OF PRESSURE EQUIPMENT SECTION 3—SPECIFICATIONS TYPE OF CONSTRUCTION AMBIENT CONDITIONS OPERATIONAL DATA PRESSURE VESSEL DESIGN AND CONSTRUCTION DATA PIPE MANIFOLD DETAILS ELECTRICAL DATA TIME, PRESSURE, TEMPERATURE, AND DEWPOINT SETTINGS...
  • Page 4 TABLE OF CONTENTS 5.10 ID—DBP 650 5.11 ID—DBP 800-1000 5.12 ID—DBP 1250-1500 5.13 ID—DBP 2000 5.14 ID—DBP 2500-3000 5.15 P&I 5.16 WD—DBP 500 5.17 WD—DBP 650 5.18 WD—DBP 800 5.19 WD—DBP 1000 5.20 WD—DBP 1250 5.21 WD—DBP 1500 5.22 WD—DBP 2000 5.23 WD—DBP 2500 5.24...
  • Page 5 TABLE OF CONTENTS SECTION 9—SPARE PARTS LIST SPARE PARTS LIST...
  • Page 6 TABLE OF CONTENTS...
  • Page 7 Follow all instructions carefully to ensure a trouble Sullair reserves the right to make changes or free life. modifications to the equipment designs without Our guarantee is affected if you fail to observe the notice.
  • Page 8 NOTES...
  • Page 9 The equipment design, development, production, • Never weld on any pressure vessel or mod- assembly and customer service fall under the Sullair ify it in any way quality control system. • All maintenance on “pressure parts” must The dryer is state of the art.
  • Page 10 NOTES DEFINITION OF THE SAFETY SYMBOLS USED Before attempting any intervention on the dryer, read carefully the instructions reported in this use and maintenance manual. General warning sign. Risk of danger or possibility of damage to the machine. Read carefully the text related to this sign. Electrical hazard.
  • Page 11 SECTION 2 SAFETY—REGENERATIVE DRYERS Maintenance and/or control operation to be very carefully performed by qualified personnel 1. Compressed air inlet connection point. Compressed air outlet connection point. Condensate drain connection point. Operations which can be worked out by the operator of the machine, if qualified 1. NOTE Text to be taken into account, but not involving safety precautions.

  • Page 12: Warnings

    SAFETY—REGENERATIVE DRYERS SECTION 2 WARNINGS Compressed air is a highly hazardous energy source. Never work on the dryer with parts under pressure. Never point the compressed air or the condensate drain jet towards anybody. The user is responsible for the installation of the dryer, which has to be executed on the basis of the instructions given in the “Installation”...

  • Page 13: Instructions For The Use Of Pressure Equipment

    SECTION 2 SAFETY—REGENERATIVE DRYERS INSTRUCTIONS FOR THE 5. An internal inspection must be carried out at USE OF PRESSURE 12 month intervals to check for pressure EQUIPMENT equipment corrosion. The actual wall thick- ness of the tower after corrosion should not ensure safe operation...
  • Page 14 NOTES...
  • Page 15 DBP BLOWER PURGE HEATED DRYER Section 3 SPECIFICATIONS Inlet Flow Inlet/Outlet Dimensions Weight Model # Capacity Voltage Connections L x W x H (Lbs) @100 PSIG (inches) (inches) 500-DBP 230/460/3/60 2” NPT 90x42x90 2890 650-DBP 230/460/3-60 2” NPT 90x42x90 3500 800-DBP 230/460/3-60 3”...

  • Page 16: Type Of Construction

    DBP BLOWER PURGE HEATED DRYER SECTION 3 TYPE OF CONSTRUCTION 3.3.1 C OOLING • Designed for operation indoors in a Non- Medium Compressed air or ambient air hazardous location. The electrical equip- ment is constructed to Nema 12 standards. Nominal flow rate _____scfm •...

  • Page 17: Electrical Data

    SECTION 3 DEX HEATED REGENERATIVE DRYER ELECTRICAL DATA DIMENSIONS AND WEIGHT Power Supply 480 volt, 3 phase, 60 Hz Width _____”inches Installed power _____KW Height _____”inches Electrical Encolsure NEMA 12 Depth _____”inches Control voltage 120 Volts A.C. Weight Approx. _____lbs Solenoid coil voltage 120 Volts A.C.
  • Page 18 NOTES...
  • Page 19 DBP BLOWER PURGE HEATED DRYER Section 4 INSTALLATION The dryer should be installed on a level location that • Up to 20 feet long use one size bigger pipe. is selected to provide easy access to all parts of the •...
  • Page 20 NOTES...

  • Page 21: Adsorption

    DBP BLOWER PURGE HEATED DRYER Section 5 OPERATION ADSORPTION provided by PLC temperature controller )Type K thermocouple). Compressed air flows through the system prefilter and into the bottom of the online desiccant chamber COOLING via the inlet switching valve and desiccant support screen.

  • Page 22: Dewpoint Controlled Vessel Change Over (Option)

    DBP BLOWER PURGE HEATED DRYER SECTION 5 DEWPOINT CONTROLLED Prior to starting the regeneration the complete VESSEL CHANGE OVER installation should be checked over to verify the (OPTION) following points. 1. Are the connections to and from the system The vessel change over will be initiated by the PLC inlet and outlet made? Are the correct size control system when the timed adsorption phase for and pressure rated connections used?

  • Page 23: Equipment Shut Down

    SECTION 5 DBP BLOWER PURGE HEATED DRYER EQUIPMENT SHUT DOWN PLANNED SHUTDOWNS, RECOMMENDED COMPLETE The Dryer can essentially be shut down under any REGENERATION PROCESS (HEATING “emergency conditions” at any time in the cycle. It COOLING) PRIOR TO STOPPING THE DRYER. is advisable to be fully familiar with the dryer and its This ensures that the full heating and cooling cycle operation to avoid any possible hazard or injury as...
  • Page 24 ID—DBP 500 02250195-346...

  • Page 25: Id-Dbp

    NOTES BLOWER SAFETY PRESSURE SWITCH, 1/4” NPT ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED BLOWER INTAKE FILTER SILENCER MARK/TAG COMPONENT WITH SULLAIR PART NUMBER AND REVISION 2” NPT BLOWER-PURGE ADJUSTMENT GLOBE VALVE PAINT PER SULLAIR SPEC. 02250055-350 <NOT USED>...

  • Page 26: Id-Dbp 650

    5.10 ID—DBP 650 02250195-347...
  • Page 27 NOTES RANGE ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED BLOWER SAFETY PRESSURE SWITCH, 1/4” NPT MARK/TAG COMPONENT WITH SULLAIR PART NUMBER AND REVISION BLOWER INTAKE FILTER SILENCER PAINT PER SULLAIR SPEC. 02250055-350 2” NPT BLOWER-PURGE ADJUSTMENT GLOBE VALVE <NOT USED>...

  • Page 28: Id-Dbp 800-1000

    5.11 ID—DBP 800-1000 02250195-348...
  • Page 29 5.11 ID—DBP 800-1000 ITEM DESCRIPTION ITEM DESCRIPTION HEATER HOUSING PLC STEP PUSH BUTTON ‘K’ TYPE THERMOCOUPLE FOR HEATER TEMPERATURE DEMAND CYCLE CONTROL SWITCH CONTROL/PURGE AIR TEMP. DRY COOLING SWITCH DESICCANT TOWER COMMON ALARM LIGHT <RED> HEATER 460VAC-3PH-60HZ ALARM RESET 3” FLG OUTLET CHECK VALVE HEATER TEMPERATURE CONTROLLER BLOWER, REGENERATIVE TYPE, 3 1/2 H.P.

  • Page 30: Id-Dbp 1250-1500

    5.12 ID—DBP 1250-1500 02250195-349...
  • Page 31 BLOWER SAFETY PRESSURE SWITCH, 1/4” NPT NOTES BLOWER INTAKE FILTER SILENCER ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED BLOWER-PURGE ADJUSTMENT VALVE MARK/TAG COMPONENT WITH SULLAIR PART NUMBER AND REVISION <NOT USED> PAINT PER SULLAIR SPEC. 02250055-350 POWER ON LIGHT, GREEN POWER OFF/ON SWITCH...

  • Page 32: Id-Dbp 2000

    5.13 ID—DBP 2000 02250195-350...
  • Page 33 NOTES BLOWER INTAKE FILTER SILENCER BLOWER ISOLATION VALVE ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED <NOT USED> MARK/TAG COMPONENT WITH SULLAIR PART NUMBER AND REVISION POWER ON LIGHT, GREEN PAINT PER SULLAIR SPEC. 02250055-350 POWER OFF/ON SWITCH PLC DISPLAY...

  • Page 34: Id-Dbp 2500-3000

    5.14 ID—DBP 2500-3000 02250195-351...
  • Page 35 BLOWER INTAKE FILTER SILENCER NOTES: BLOWER ISOLATION VALVE ALL DIMNSIONS ARE IN INCHES UNLESS OTHERWISE NOTED. <NOT USED> MARK/TAG COMPONENT WITH SULLAIR PART NUMBER AND REVISION POWER ON LIGHT, GREEN PAINT PER SULLAIR SPEC. 02250055-350 POWER OFF/ON SWITCH PLC DISPLAY...
  • Page 36 5.15 P&I 02250195-361...

  • Page 37: P&I

    5.15 P&I ITEM DESCRIPTION ITEM DESCRIPTION HEATER HOUSING HEATER TEMP./PURGE TEMP. CONTROLLER (N.S) ‘K’ TYPE THERMOCOUPLE FOR HEATER TEMPERATURE HEATER HI LIMIT/MID RANGE CUTOUT TEMP. CONTROLLER CONTROL/PURGE AIR TEMP. (N.S) DESICCANT TOWER (NOT USED) HEATER (NOT USED) WAFER STYLE OUTLET CHECK VALVE (NOT USED) BLOWER BLOWER FILTER ELEMENT DP INDICATOR (NOT SHOWN)

  • Page 38: Wd-Dbp 500

    5.16 WD—DBP 500 02250195-378...
  • Page 39 5.16 WD—DBP 500 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 40: Wd-Dbp 650

    5.17 WD—DBP 650 02250195-379...
  • Page 41 5.17 WD—DBP 650 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 42: Wd-Dbp 800

    5.18 WD—DBP 800 02250195-380...
  • Page 43 5.18 WD—DBP 800 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 44: Wd-Dbp 1000

    5.19 WD—DBP 1000 02250195-381...
  • Page 45 5.19 WD—DBP 1000 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 46: Wd-Dbp 1250

    5.20 WD—DBP 1250 02250195-382...
  • Page 47 5.20 WD—DBP 1250 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 48: Wd-Dbp 1500

    5.21 WD—DBP 1500 02250195-383...
  • Page 49 5.21 WD—DBP 1500 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 50: Wd-Dbp 2000

    5.22 WD—DBP 2000 02250195-384...
  • Page 51 5.22 WD—DBP 2000 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 52: Wd-Dbp 2500

    5.23 WD—DBP 2500 02250195-385...
  • Page 53 5.23 WD—DBP 2500 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 54: Wd-Dbp 3000

    5.24 WD—DBP 3000 02250195-386...
  • Page 55 5.24 WD—DBP 3000 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 56: Wd-Dbp 3500

    5.25 WD—DBP 3500 02250195-387...
  • Page 57 5.25 WD—DBP 3500 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 58: Wd-Dbp 4000

    5.26 WD—DBP 4000 02250195-388...
  • Page 59 5.26 WD—DBP 4000 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 60: Wd-Dbp 5000

    5.27 WD—DBP 5000 02250195-389...
  • Page 61 5.27 WD—DBP 5000 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 62: Wd-Dbp 6000

    5.28 WD—DBP 6000 02250195-390...
  • Page 63 5.28 WD—DBP 6000 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 64: Wd-Dbp 7000

    5.29 WD—DBP 7000 02250195-391...
  • Page 65 5.29 WD—DBP 7000 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 66: Wd-Dbp 8000

    5.30 WD—DBP 8000 02250195-392...
  • Page 67 5.30 WD—DBP 8000 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 68: Wd-Dbp 9000

    5.31 WD—DBP 9000 02250195-393...
  • Page 69 5.31 WD—DBP 9000 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...

  • Page 70: Wd-Dbp 10000

    5.32 WD—DBP 10000 02250195-394...
  • Page 71 5.32 WD—DBP 10000 1. Wire Colors: D.C. Positive Wiring Color: Solid Blue D.C. Negative Wiring Color: White with Blue Stripe A.C. Hot Control Wiring Color: Solid Red A.C. Neutral Control Wiring Color: Solid White A.C. Power Wiring Color: Solid Black ‘K’...
  • Page 72 NOTES...

  • Page 73: Section 6-Troubleshooting

    DBP BLOWER PURGE HEATED DRYER Section 6 TROUBLESHOOTING Symptom Probable Cause Remedy High humidity alarm (with The regeneration of the desiccant Reset the alarm with the “Alarm Reset” optional dew point monitor) beds is insufficient. push button. Verify the heating and cooling operations by observing regenerations.
  • Page 74 DBP BLOWER PURGE HEATED DRYER SECTION 6 Symptom Probable Cause Remedy Vessel #2 Re-pressurization The re-pressurization valve did not Check the pilot solenoid valve for correct open. operation. Check the valve actuator for correct operation. Vessel re-pressurized but the Check pressure switch PSH-2 for correct alarm is on.

  • Page 75: Section 7-System Maintenance

    DBP BLOWER PURGE HEATED DRYER Section 7 SYSTEM MAINTENANCE WITH YOUR DRYER ONLINE • Replace seats and shaft seals on all ball valves. The following points must be verified at regular • Dismantle the double acting pneumatic intervals actuators. Inspect internal components for visual signs of wear and replace parts as •...
  • Page 76 NOTES...

  • Page 77: Section 8-Technical Description Of Components

    DBP BLOWER PURGE HEATED DRYER Section 8 TECHNICAL DESCRIPTION OF COMPONENTS VALVES Basic devices used in the dryer system are described in this section. For more detailed additional information refer to the component bulletins included Inlet valves are Piston type Bronze valves, dryers up in the rear of this manual.
  • Page 78 NOTES...
  • Page 79 DBP BLOWER PURGE HEATED DRYER Section 9 SPARE PARTS LIST...
  • Page 80 SPARE PARTS LIST DBP Series Blower purge Dryers 02250194-366-XXX Applicable Model Number DBP-XXXXx 0500 0650 0800 1000 1250 1500 2000 2500 3000 3500 4000 5000 6000 7000 8000 9000 10000 Part Description Part Number Pilot Air Filter Element 02250193-577 PLC Siemens...
  • Page 81 DBP Series Blower purge Dryers 02250194-366-XXX Applicable Model Number DBP-XXXXx 0500 0650 0800 1000 1250 1500 2000 2500 3000 3500 4000 5000 6000 7000 8000 9000 10000 Part Description Part Number Lbs of Desiccant NACF-200-316 1000 1250 1562 1900 2500...
  • Page 82 DBP Series Blower purge Dryers 02250194-366-XXX Applicable Model Number DBP-XXXXx 0500 0650 0800 1000 1250 1500 2000 2500 3000 3500 4000 5000 6000 7000 8000 9000 10000 Part Description Part Number Outlet Check Valve (8") NOR8150WSSSV Ourge Check Valve (2") NSCY-200 Purge Check Valves (3")
  • Page 83 NOTES...
  • Page 84 Always air. Always there. WWW.SULLAIR.COM SULLAIR CORPORATION 3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A. Telephone: 1-219-879-5451 Printed in the U.S.A. Specifications subject to change without prior notice. E11EP...

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