Table of Contents
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4011196
7610.479.32 Rev. B 6/04
18-3-625
Internal Use Only
479.25D/040625
I I N N S S T T R R U U C C T T I I O O N N M M A A N N U U A A L L
D D G G H H S S e e r r i i e e s s
RATED
MODELS
FLOW
DGH40
40 SCFM
DGH60
60 SCFM
DGH90
90 SCFM
DGH115
115 SCFM
DGH165
165 SCFM
DGH260
260 SCFM
DGH370
370 SCFM
DGH450
450 SCFM
DGH590
590 SCFM
DGH750
750 SCFM
DGH930
930 SCFM
DGH1130
1130 SCFM
DGH1350
1350 SCFM
DGH1550
1550 SCFM
DGH2100
2100 SCFM
DGH3000
3000 SCFM
DGH4100
4100 SCFM
DGH5400
5400 SCFM
Contents
1. GENERAL SAFETY INFORMATION .........................................2
2. RECEIVING, MOVING, UNPACKING........................................2
3. DESCRIPTION ...........................................................................3
4. INSTALLATION ..........................................................................7
5. CONTROLLERS – GENERAL..................................................14
6. CONTROLLER – LEVEL 1.......................................................16
7. CONTROLLER – LEVEL 2.......................................................27
8. OPERATION ............................................................................45
9. MAINTENANCE .......................................................................51
10. TROUBLESHOOTING ...........................................................53
11. NOTES ...................................................................................54
MODEL
REFERENCE
40
60
90
115
165
260
370
450
590
750
930
1130
1350
1550
2100
3000
4100
5400
SERVICE DEPARTMENT (724) 746-1100
P P R R E E S S S S U U R R E E - - S S W W I I N N G G
D D E E S S I I C C C C A A N N T T T T Y Y P P E E
C C O O M M P P R R E E S S S S E E D D
A A I I R R D D R R Y Y E E R R S S
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Table of Contents
Related Manuals for Gardner Denver DGH Series
Summary of Contents for Gardner Denver DGH Series
- Page 1 4011196 7610.479.32 Rev. B 6/04 18-3-625 Internal Use Only 479.25D/040625 I I N N S S T T R R U U C C T T I I O O N N M M A A N N U U A A L L D D G G H H S S e e r r i i e e s s RATED MODEL...
- Page 2 1. General Safety Information 1. General Safety Information 2. Receiving, Moving, Unpacking 1.1 Pressurized Devices: 2.1 Receiving: • • This equipment is a pressure-containing device. This shipment has been thoroughly checked, packed and • inspected before leaving our plant. Do not exceed maximum operating pressure as shown on •...
- Page 3 3. Description 3. Description 3.2 Automatic Purge Saving System 3.1 Dryer Function Featured with the Level 2 Controller, the Automatic Purge Saving System is designed to save energy (purge air) when • Dual tower regenerative desiccant dryers are an pressure-swing dryers are operated at reduced loads. economical and reliable way to dry compressed air to dew The patented Purge Saving System operates by monitoring the points below the freezing point of water (dew points as low...
- Page 4 3. Description 3.3 Description of Operation – Dryer OUTLET 3.3.1 Models 40 to 450 w/ Shuttle Valve (Refer to Fig. 3-1a.) Compressed air flows through inlet switching valve (3A) (normally open) to tower (4A) where the air is dried. After the air is dried it flows through shuttle valve (5) and then to the dryer outlet.
- Page 5 3. Description 3.3.2 Models 590 to 5400 w/ Check Valves OUTLET (Refer to Fig. 3-2a.) Compressed air flows through inlet switching valve (3A) (normally open) to tower (4A) where the air is dried. After the air is dried it flows through outlet check valve (5A) and then to the dryer outlet.
- Page 6 3. Description OUTLET 3.4 Automatic Purge Saving System (Refer to Figure 3-3a for Models 40 through 450 and Figure 3-3b for Models 590 through 5400.) Assume tower A is on-line drying while tower B has just gone off- TOWER TOWER line to be regenerated.
- Page 7 4. Installation 4. Installation 4.1.3 Prefilter(s) – Adequate filtration is required upstream of the dryer in order to protect the desiccant bed from contamination. The following 4.1 Location in the compressed air system filtration, equipped with automatic condensate drains, is recommended: NOTE: The air compressor should be adequately sized to •...
- Page 8 4. Installation prefilter bowls, auto drains and/or sumps, and lower piping with 4.3 Minimum & Maximum Operating Conditions inlet switching and purge/repressurization valves is necessary The compressed air supply to the dryer inlet should be checked to prevent condensate from freezing. If installing heat tracing, periodically to ensure that dryer design specifications are not observe electrical class code requirements for type of duty exceeded.
- Page 9 4. Installation WARNING - Do not operate dryer without installed mufflers. Exhausting 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 dryer is shipped complete with desiccant and is ready to operate after piping and electrical connections are made and controller settings are established.
- Page 10 4. Installation PURGE PRESSURE ADJUSTMENT VALVE PURGE ORIFICE PURGE ORIFICE Ø R MOUNTING HOLES (TYP.) MOISTURE INDICATOR OUTLET OUTLET PURGE SHUTTLE PRESSURE VALVE GAUGE UPPER REAR VIEW TOP VIEW DESICCANT FILL PORT (TYP.) RIGHT TOWER PRESSURE GAUGE PILOT AIR FILTER & REGULATOR LEFT TOWER PRESSURE GAUGE...
- Page 11 4. Installation DIMENSIONS IN INCHES MODEL 16.5 16.5 16.5 4. 5/8 5. 5/32 5. 11/16 6. 11/16 6. 11/16 7. 3/4 8. 3/4 9. 3/8 3/16 3/16 3/16 3/16 3/16 3/16 3/16 3/16 20. 11/16 20. 11/16 22. 5/8 22. 5/8 22.
- Page 12 4. Installation Figure 4-3 (continued on next page) 590-5400 SCFM General Arrangement - 12 – 4. Installation...
- Page 13 4. Installation DIMENSIONS IN INCHES MODEL 1130 1350 1550 2100 3000 4100 5400 49.1/4 50.1/16 55.3/16 58.15/16 59.13/16 65.5/8 72.5/16 75.7/8 85.3/8 95.7/8 46.3/4 47.9/16 52.11/16 56.7/16 57.5/16 63.1/8 69.13/16 73.3/8 82.7/8 93.3/8 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...
- Page 14 5. Controllers – General reduced. This reduction can translate to energy savings at the air compressor. 5. Controllers – General The Level 1 Controller offers 8 selectable fixed-cycle Energy (purge) Saver modes (0% to 70% in 10 % increments) to reduce purge time to match the load on the dryer.
- Page 15 5. Controllers – General 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. 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.
- Page 16 6. Controller – Level 1 • Terminal TB2-7 is the N.O. (normally open) contact connection. 6. Controller – Level 1 • Terminal TB2-8 is the N.C. (normally closed) contact connection. • The alarm relay coil is energized when power is supplied This section provides connection, adjustment and operational to the controller input terminals and there are no alarms.
- Page 17 6. Controller – Level 1 switch to stop a dryer. Closing this switch will affect 6.3.3.2 Desiccant Service the same response as a loss of power. Both inlet- When the service interval for desiccant has expired, the switching valves will open and both purge- following LEDs will blink: repressurization valves will close.
- Page 18 6. Controller – Level 1 not desired. Installed in the ON position when automatic power state (at the beginning of the prior ISO operating cycle) recovery is desired. when power is restored. If power is interrupted while the • controller is in the Manual cycle mode, the controller will Jumper J4 installed in the OFF position –...
- Page 19 6. Controller – Level 1 will illuminate. When in the Manual cycle mode, the dyer 6.4.1 Front Panel LEDs can be advanced one step at a time using the • Power on - green reset/manual advance switch. Refer to section 6.4.2.4. •...
- Page 20 6. Controller – Level 1 Dryer MOP 60-150 psig 120-250 psig ISO Class -73°C -40°C -20°C +3°C -73°C -40°C -20°C +3°C Dew Point -100°F -40°F -4°F +38°F -100°F -40°F -4°F +38°F Cycle Time (minutes) Energy (Purge) Time from start of cycle Time from start of cycle Time Savings Setting...
- Page 21 6. Controller – Level 1 Time (refer to Table 6-3) Process valve name (Process valve state Left Tower Drying Right Tower Drying w/ de-energized pilot solenoid valve) Right Tower Regenerating Left Tower Regenerating Half Cycle Half Cycle Left purge valve Pilot Energized (normally closed) (open)
- Page 22 6. Controller – Level 1 Figure 6-2 Electrical Schematic – Level 1 Controller - 22 – 6. Controller – Level 1...
- Page 23 6. Controller – Level 1 Figure 6-3 Point-to-Point Connection Diagram - Level 1 Controller - 23 – 6. Controller – Level 1...
- Page 24 6. Controller – Level 1 Figure 6-4 (continued on next page) Panel Layouts - Level 1 Controller - 24 – 6. Controller – Level 1...
- Page 25 6. Controller – Level 1 11.5-28 VDC 85-264 VAC 47-63 HZ Figure 6-4 (continued from previous page) Panel Layouts - Level 1 Controller - 25 – 6. Controller – Level 1...
- Page 26 6. Controller – Level 1 CABLE DIAMETER RANGE ENCLOSURE NUMBER CONDUCTOR CONNECTOR HOLE DIA. LOCATION FUNCTION SIZE MIN. DIA. MAX. DIA. SIZE CONDUCTORS (AWG) INCH INCH INCH PRESSURE SWITCH - 0.181 0.312 PG-9 0.599 15.2 LEFT TOWER PRESSURE SWITCH - 0.181 0.312 PG-9...
- Page 27 7. Controller – Level 2 • Terminal TB4-39 is the N.O. (normally open) contact connection. 7. Controller – Level 2 • Terminal TB4-40 is the N.C. (normally closed) contact connection. • The alarm relay coil is energized when power is supplied This section provides connection, adjustment and operational to the controller input terminals and there are no alarms.
- Page 28 7. Controller – Level 2 the same response as a loss of power. Both inlet- • The drains can be manually tested through the Level 2 switching valves will open and both purge- controller Setup Mode. repressurization valves will close. A tower that is •...
- Page 29 7. Controller – Level 2 7.4 Front Panel Overlay – Level 2 Controller Refer to Figure 7-1,Front Panel Overlay – Level 2 Controller for information regarding the location and function of the LEDs, switches, and text display. Left tower pressure Filter service / switch LED: maintenance LED...
- Page 30 7. Controller – Level 2 In the following sections: 7.4.1 Front Panel LEDs • E (enter) represents the button to the right of the • Power on – green (constant when controller is switched text display. on; flashing when controller is energized but switched off.) •...
- Page 31 7. Controller – Level 2 • When finished, press E to save the selection and move DESICCANT SERVCE to Screen 3 (if a dew point sensor is connected to AUX2) RESET? NO or Screen 4 (if one is not). • Press S to toggle between NO and YES.
- Page 32 7. Controller – Level 2 • There are three alarms for each tower that are triggered by the Press S to scroll through the choices: tower pressure switches. These alarms can occur in either the 1: -73°C/-100°F fixed or demand cycle. Following is a brief description of each 2: -40°C/-40°F alarm.
- Page 33 7. Controller – Level 2 7.9.1.8 Alarm Mode Screen 5 – Left Tower, Upper Sensor • If the alarm condition clears for one cycle, then the alarm (Thermistor) Over-Range LED stops blinking (LED on); the alarm message continues to be displayed. ALARM •...
- Page 34 7. Controller – Level 2 7.9.1.15 Alarm Mode Screen 12 – Right Tower, Upper When a service time interval expires, the controller operates as Sensor (Thermistor) Over-Range follows. • The service LED blinks and the appropriate service ALARM message is shown on the text display. (See 7.9.1) RIGHT TOWER •...
- Page 35 7. Controller – Level 2 7.10.8 Display Mode Screen 5 – Dryer inlet pressure, Controller, except in the case of an alarm or service reminder (see 5.b and 7.b in Alarm & Service Mode). (AUX3, analog input). • This screen is not displayed if jumper 4 is not installed. Display Mode is comprised of several screens (described below).
- Page 36 7. Controller – Level 2 Program Step Left tower status drying drying drying drying regen. regen. regen. regen. Right tower status regen. regen. regen. regen. drying drying drying drying Left tower closed at start, open at start, closed closed closed closed closed closed...
- Page 37 7. Controller – Level 2 • • The left tower regenerating light is blinking to indicate the This screen is displayed for 5 seconds if the user attempts thermistor location (lower left) that corresponds to the to exit test mode from step 2, 3, or 4. temperature display.
- Page 38 7. Controller – Level 2 Time (refer to Table 7-4) Process valve name (Process valve state Left Tower Drying Right Tower Drying w/ de-energized pilot solenoid valve) Right Tower Regenerating Left Tower Regenerating Half Cycle Half Cycle Left purge valve Pilot Energized (normally closed) (open)
- Page 39 7. Controller – Level 2 Figure 7-2 Electrical Schematic – Level 2 Controller - 39 – 7. Controller – Level 2...
- Page 40 7. Controller – Level 2 J2 (RPB) Figure 7-3 (continued on next page) Point-to-Point Diagram – Level 2 Controller - 40 – 7. Controller – Level 2...
- Page 41 7. Controller – Level 2 Figure 7-3 (continued from previous page) Point-to-Point Diagram – Level 2 Controller - 41 – 7. Controller – Level 2...
- Page 42 7. Controller – Level 2 Figure 7-4 (continued on next page) Panel Layout – Level 2 Controller - 42 – 7. Controller – Level 2...
- Page 43 7. Controller – Level 2 2 3 4 5 6 7 8 Figure 7-4 (continued from previous page) Panel Layout – Level 2 Controller - 43 – 7. Controller – Level 2...
- Page 44 7. Controller – Level 2 CABLE DIAMETER RANGE # OF CONN- ENCLOSURE HOLE DIA. LOCATION FUNCTION COND- MIN. DIA. MAX. DIA. ECTOR SIZE UCTORS SIZE HUMIDITY-DEW POINT SENSOR DRAIN 1 (POWER & TEST) DRAIN 1 (ALARM) 0.230 0.395 10.0 PG-11 0.733 18.6 DRAIN 2 (POWER &...
- Page 45 8. Operation • Energy (purge) Savings % setting. This setting is applicable to the Level 1 Controller only. 8. Operation 8.1.4.1 Purge Rate Pressure – Models 40 to 450 • Refer to Table 8-4 for the proper purge rate pressure setting corresponding to the conditions listed in Section 8.1 Start-up 8.1.4.
- Page 46 8.1.4.2 Purge Rate Pressure – Models 590 to 5400 Every four hours check moisture indicator. Indicator should be • green. The color change moisture indicator indicates the outlet Refer to Table 8-4 for the proper purge rate pressure relative humidity of the desiccant dryer. setting corresponding to the conditions listed in Section Green indicates a R.H.
- Page 47 8. Operation Level 1 Controllers. Refer to Tables 7-4 and 7-5 for time • Models 590 through 5400 are equipped with multiple sequences for Level 2 Controllers. safety relief valves that have been sized to provide overpressure protection for capacities equal to or greater 8.2.8.1 Valves –...
- Page 48 8.6.2 Minimum Operating Pressures: • For maximum purge flow multiply the Inlet Flow At Rated Conditions from Table 8-1 by Maximum Purge Flow Factor 8.6.2.1 For 150 psig (10.5 kgf/cm ) MOP models - from Table 8-6 that corresponds to the dryer MOP, Cycle •...
- Page 49 8. Operation MODEL 1130 1350 1550 2100 3000 4100 5400 SCFM (1) 1130 1350 1550 2100 3000 4100 5400 /hr(2). 1002 1274 1580 1920 2294 2633 3568 5097 6966 9175 Table 8-1 Maximum Inlet Flow at Rated Conditions psig INLET PRESSURE kgf/cm 10.5...
- Page 50 DRYER MOP 150 psig (10.5 kgf/cm2) INLET PRESSURE (psig) INLET PRESSURE (kg/cm2) 10.5 0.147 0.149 0.151 0.153 0.155 0.151 0.148 0.145 0.143 0.141 0.134 0.136 0.137 0.139 0.141 0.138 0.135 0.133 0.131 0.129 ISO CLASS 1 ENERGY 0.120 0.122 0.124 0.125 0.127 0.124...
- Page 51 9. Maintenance than 50% of maximum rated inlet capacity until the desiccant has regenerated fully. 9. Maintenance 9.2 Purge Mufflers • Purge mufflers should be checked regularly, changed WARNING - The heatless desiccant dryer is a pressure-containing annually. Muffler disseminator elements become clogged device.
- Page 52 9. Maintenance 9.4.2.2 Models 590 through 5400 • Isolate dryer from air supply • De-pressurize dryer by running dryer and allowing system pressure to purge to atmosphere. Loss of pilot pressure will eventually prevent purge/repressurization valves from opening. Remaining pressure can be vented to atmosphere through the manual drain on the pilot air filter.
- Page 53 10. Troubleshooting 10. Troubleshooting SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION No power to unit. Check voltage at terminal board. 10.1 Indicator lights not Off/On switch turned off. Turn on. illuminated Blown fuse. Replace fuse Off/on switch or board malfunction. Replace board. Refer to Sections 4 &...
- Page 54 11. Notes 11. Notes Information from the dryer serial number tag can be recorded in the following table. This information may be necessary when communicating with Service representatives. Allowable Values from Actual Values at Serial Number Tag Fields Serial Number Tag Installation Model Number: Serial Number:...
- Page 55 11. Notes Drains: _________________________________________________________________________________________________________ Delta-P devices:__________________________________________________________________________________________________ Afterfilters: ______________________________________________________________________________________________________ Delta-P devices:__________________________________________________________________________________________________ Blocking or Isolation Valves: ________________________________________________________________________________________ ISO Class Operating Mode:_________________________________________________________________________________________ Energy Savings % Setting (Level 1 controller only): ______________________________________________________________________ Fixed or Demand Cycle Mode (Level 2 controller only): ___________________________________________________________________ Outlet pressure dew point reading: ___________________________________________________________________________________ Additional accessories or special features: _____________________________________________________________________________ _______________________________________________________________________________________________________________ _______________________________________________________________________________________________________________...
- Page 56 MATERIAL IS RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE. For additional information contact your local representative or Gardner Denver Compressor and Pump Division, 1800 Gardner Expressway, Quincy, Illinois 62301 Customer Service Department Telephone: (800) 682-9868 FAX: (217) 228-8243 Sales and Service in all major cities.