GENERAL SAFETY INFORMATION RECEIVING, MOVING, UNPACKING Pressurized Devices Receiving: • This equipment is a pressure-containing device. • This shipment has been thoroughly checked, packed and • Do not exceed maximum operating pressure as shown on the inspected before leaving our plant. equipment serial number tag.
DESCRIPTION Dryer Function Automatic Purge Saving System • Dual tower regenerative desiccant dryers are an economical Featured with the Energy Savings Controller, the Automatic Purge and reliable way to dry compressed air to dew points below the Saving System is designed to save energy (purge air) when freezing point of water (dew points as low as -100°F (-73.3°C) pressure-swing dryers are operated at reduced loads.
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Description of Operation – Dryer 3.3.1 Models 40 to 3000 w/ Shuttle Valve (Refer to Fig. 3-1a.) Compressed air flows through inlet shuttle valve (3) OUTLET 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.
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3.3.2 Models 4100 to 5400 w/ Check Valves (Refer to Fig. 3-2a.) Compressed air flows through inlet switching OUTLET 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.
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3.3.3 Models 40 to 450 (High Pressure Option) (Refer to Fig. 3-3a.) Compressed air flows through inlet switching valve OUTLET (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. A portion of the dry air, the purge stream, branches off from the main air stream prior to the outlet.
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Automatic Purge Saving System (Refer to Figure 3-4a for Models 40 through 3000 and Figure 3-4b for Models 4100 through 5400.) Assume tower A is on-line drying while tower B has just gone off-line OUTLET to be regenerated. At the beginning of tower B’s regeneration cycle a thermistor temperature measurement is made at position B1.
INSTALLATION 4.1.4 Heatless Pressure-Swing Desiccant Air Dryer 4.1.5 Afterfilter(s) – To ensure downstream air purity (prevent desiccant dust from Location in the compressed air system traveling downstream) adequate filtration downstream of the dryer NOTE: The air compressor should be adequately sized to handle is required.
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Minimum Operating Pressures: NOTE: When quarter-turn valves (e.g. ball or butterfly valves) are used for isolation of pressure components, care should be taken to 4.5.1 For 150 psig (10.5 barg) MOP models - open or close valves slowly. • 60 psig (4.1 barg) is the minimum operating pressure for dryers operated on ISO classes 1, 2, 3, and 4.
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(MAX) CENTERLINE OF CUSTOMER INLET/OUTLET CONNECTIONS (MAX) 7/8” X 1 1/4” SLOT (TYP 4 PLCS) [22mm] [32mm] TOP VIEW LIFTING LUG OUTLET SHUTTLE VALVE ASSY AIR OUTLET PILOT AIR FILTER DESICCANT FILL PORT PURGE PRESSURE GAUGE LEFT CHAMBER & REGULATOR PRESSURE GAUGE PURGE ADJUSTING VALVE WARNING: Disconnect the main power...
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CENTERLINE OF CUSTOMER INLET/OUTLET CONNECTIONS (MAX) 7/8” X 1-1/4” SLOT (TYP 4 PLACES) AIR INLET [22mm] [32mm] BOTTOM RIGHT SIDE VIEW (Models 1550, 2100 and 3000) (MAX) RIGHT CHAMBER REMOVED FOR CLARITY TOP VIEW AIR OUTLET DESICCANT FILL PORT PURGE PRESSURE ADJUSTMENT VALVE MOISTURE INDICATOR LIFTING LUG...
CONTROLLERS – GENERAL 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 savings at the air compressor. Overview The Standard Controller offers 8 selectable fixed-cycle Energy (purge) The solid-state dryer controller is located in a polycarbonate, NEMA Saver modes (0% to 70% in 10 % increments) to reduce purge time to Class 4/4X, IP66 rated electrical enclosure mounted to a center panel...
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Table 5-1 (continued from previous page) Notes: The Basic Timer Based Controller will accept AC (Alternating Current) input power. The Standard and Energy Savings Controllers will accept either AC (Alternating Current) or DC (Direct Current) input power. (Standard & Energy Savings 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.
CONTROLLER – BASIC TIMER BASED Connections – Basic Timer Based Controller See Figure 6-2, Point-to-Point Diagram for the location and function of the various cable and cord connectors that are provided on the bottom This section provides connection, adjustment and operational of the Basic Timer Based Controller enclosure.
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Power ON Light Left Tower Right Tower DRYING Light DRYING Light WARNING: Disconnect the main power supply before removing this cover. Figure 6-1 Front Panel Overlay – Basic Timer Based Controller (Note: Figure is representative of Models 40 through 3000.) —...
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BASE BLACK/GREY +VE BLACK FUSE 5 x 20mm VOLTAGE 1 Amp Slow Blow LABEL Live Neutral Black Sleeve Earth White Sleeve SUPPLY 100 - 240v 50/60 Hz INPUT GREEN/YELLOW TERMINALS 100 - 240V 50/60 Hz BLUE EARTH POSITIVE NEGATIVE (CONTROL TIMER BOARD) FUSE 5 x 20mm 1 Amp Slow Blow LEFT TOWER...
CONTROLLER – STANDARD • 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. This section provides connection, adjustment and operational •...
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tower that is actively purging when the power on/off button is 7.3.3.3 Valve Service actuated will be subjected to a rapid repressurization that can When the service interval for valves has expired, the following LEDs lead to fluidization and subsequent abrasion of the desiccant bed. will blink: Ideally, dryers should only be powered off during those portions of •...
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Front Panel Overlay – Standard Controllers Filter service / maintenance LED Left tower pressure switch LED: Filter service / On=switch closed maintenance LED Off=switch open Right tower pressure Left tower drying LED switch LED: On=switch closed Off=switch open Left purge valve LED On=valve open Off=valve closed Right tower drying LED...
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7.4.1 Front Panel LEDs 7.4.2.3 Percent Energy / Purge Savings Selector Switch • Power on - green • If dryer is operated at less than maximum flow capacity a • Alarm – red reduction in purge air usage may be possible. Eight settings (0% •...
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Dryer MOP 60 - 150 psig (4.1 - 10.3 barg) 120 - 250 psig (8.3 - 17.2 barg) 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...
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Time (refer to Table 7-3) Process valve name (Process valve state w/ de-energized Left Tower Drying Right Tower Drying pilot solenoid valve) Right Tower Regenerating Left Tower Regenerating Half Cycle Half Cycle Pilot Energized Left purge valve (normally closed) (open) Left inlet valve (normally open) Pilot Energized (closed) (See NOTE 1)
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AC TO DC CUSTOMER POWER SUPPLY AC POWER TB5-20 SERVICE REMINDER 3 (PRE FILTERS) CONNECTIONS GRN/YEL 85-264 VAC TB5-21 LEFT INLET VALVE OPEN (SEE NOTE 6) 47-63 HZ NEUTRAL TB5-22 LEFT TOWER REGENERATING SEE NOTE 1 TB5-23 LEFT PURGE VALVE OPEN TB5-24 LEFT TOWER DRYING TB5-25...
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JUMPERS JUMPER (SEE NOTE 3) JUMPER NO. & JUMPER JUMPER FUNCTION J1 - MAXIMUM OPERATING PRESSURE 150 PSIG 250 PSIG JUMPER PINS ACTIVATED BY DRYER J2 - COMMON ALARM DEFAULT FAULT ALARM ONLY J3 - SERVICE INTERVAL NORMAL SEVERE J4 - POWER RECOVERY MODE AUTO JUMPER JUMPER...
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ENCLOSURE DOOR EXTERIOR LEGEND COMMON ALARM RELAY ISO CLAS/MANAUL CYCLE SELECTOR SWITCH RIGHT TWR. DRYING (GREEN) SERVICE REMINDER 3 - PREFILTERS (AMBER) POWER ON LED (GREEN) POWER ON/OFF SWITCH LEFT TOWER REGEN. (AMBER) MAIN SERVICE REMINDER (AMBER) ALARM RESET/MANUAL CYCLE INCREMENT SWITCH LEFT PURGE VALVE OPEN (GREEN) COMMON ALARM (RED) ENERGY SAVINGS % SELECTOR SWITCH...
CONTROLLER – ENERGY SAVINGS • 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. This section provides connection, adjustment and operational •...
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pressure. Use of the remote start/stop connections as described Front Panel Overlay – Energy Savings Controller in Section 8.2.3 would be preferable in most cases. Refer to Figure 8-1,Front Panel Overlay – Energy Savings Controller for • Terminals J2-7 and -8 (Remote Alarm Reset Switch) information regarding the location and function of the LEDs, switches, and text display.
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Left tower pressure Filter service / switch LED: maintenance LED On=switch closed Off=switch open Filter service / maintenance LED Left tower drying LED Right tower pressure Left purge valve LED switch LED: On=valve open On=switch closed Off=valve closed Off=switch open Right tower drying LED Right purge valve LED On=valve open...
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Front Panel Operation • NOTE: Time continues to accumulate as long as power is supplied to the controller, whether the controller is switched 1. There are five operating modes for the Energy Savings on or off. Controller. • When finished Press to save the selection and move to a.
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• One of two things will happen upon exiting Setup Mode. 8.9.1.1 Pressure Switch Alarms There are three alarms for each tower that are triggered by the tower 1. The controller will switch to Display Mode if DEMAND pressure switches. These alarms can occur in either the fixed or CYCLE or FIXED CYCLE was selected.
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The following text display is shown for each alarm. The second 8.9.1.11 Alarm Mode Screen 8 - Right Tower Drying – Low line of the alarm screens contains up to three messages, which are Pressure (Open Pressure Switch Circuit) scrolled through, displaying each one for 3 seconds after the alarm ALARM condition clears.
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8.9.1.20 Alarm Mode Screen 17 – Alarm 8.9.2.3 Service Mode Screen 3 – Service valves ALARM SERVICE DRYER LEFT TOWER VALVES DRYING Ensure that valves are cycling properly. Check for switching failure OUTLET DEW POINT alarms and adjust purge pressure. Check for leaks. 8.9.1.21 Alarm Mode Screen 18 –...
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• CAUTION: Do not advance to step 5 until the right tower • Press to advance from one screen (program step) to the has fully pressurized. next. Be sure to read and understand all cautions listed with the • Press to advance to screen 5.
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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 pressure switch open at end closed at end Right tower...
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Dryer MOP 60 - 150 psig (4.1 - 10.3 barg) 120 - 250 psig (8.3 - 17.2 barg) ISO Class Dew Point -73°C -40°C -20°C +3°C -73°C -40°C -20°C +3°C -100°F -40°F -4°F +38°F -100°F -40°F -4°F +38°F Cycle Time (minutes) Time from start of cycle Time from start of cycle Time...
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Time (refer to Table 8-3) Process valve name (Process valve state Left Tower Drying Right Tower Drying w/ de-energized Right Tower Regenerating Left Tower Regenerating pilot solenoid valve) Half Cycle Half Cycle Left purge valve Pilot Energized (normally closed) (open) Left inlet valve (normally open) Pilot Energized (closed) (See NOTE 1)
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SENSOR HIGH HUM./ DEWPOINT CONTROL TB1-7 TB1-8 BOARD OPTIONAL TB6-49 J1-1 CUSTOMER AC POWER TB6-48 J1-34 CONNECTIONS AC TO DC NEUTRAL TB2-19 85-264 VAC TB6-47 J1-2 POWER SUPPLY 1 PHASE BOARD TB6-46 PRESSURE SWITCH 1 (LEFT TOWER) J1-4 47-63 HZ TB2-20 SEE NOTE 1 TB6-45...
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ENCLOSURE DOOR J2 (RPB) ENCLOSURE DOOR INTERIOR REMOTE PUSHBUTTON SWITCH CONNECTIONS SELECT ALARM_RESET ENTER POWER ON / OFF Figure 8-3 Point-to-Point Diagram – Energy Savings Controller (continued on next page) — 44 —...
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ENCLOSURE INTERIOR POWER SUPPLY BLACK CUSTOMER AC POWER WHITE CONNECTIONS 85-264 VAC GRN/YEL 47-63 HZ CUSTOMER BLACK DC POWER CONNECTIONS 11.5-28 VDC 20 21 22 23 24 25 26 27 28 29 40 41 JUMPER JUMPER PINS ALARM CONTACTS RIGHT_BTM_THERM TEST DRAIN 2 JUMPER BASE RIGHT_TOP_THERM...
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VACUUM FLOURESCENT TEXT DISPLAY ENCLOSURE DOOR EXTERIOR LEGEND SERVICE REMINDER 3 - PRE FILTERS (AMBER) 15L COMMON ALARM (RED) RS232 SERIAL I/O CONNECTOR LEFT TOWER REGENERATING (AMBER) 16L PRESSURE SWITCH 2 (RIGHT TOWER) CLOSED (GREEN) PICPROG. CONNECTOR LEFT PURGE VALVE OPEN (GREEN) XILINX PROGRAM CONNECTOR 1PB SELECT SWITCH 2PB POWER ON/OFF SWITCH...
OPERATION 9.1.4.1 Purge Rate Pressure – Models 40 to 3000 • Refer to Table 9-4 for the proper purge rate pressure setting corresponding to the conditions listed in Section 9.1.4. Start-up NOTE: For units with the Energy Savings Controller and the Automatic Purge Saving System in the demand cycle mode use 9.1.1 Controller Settings (Standard or Energy Savings the ISO Class 2 (10 min.) purge pressure settings only.
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• The purge pressure adjustment valve should never be fully closed. 9.2.4.1 Alarms –Standard Controllers Proper purge flow is required to regenerate and re-pressurize the Alarm light will flash if either tower fails to pressurize or de-pressurize offline tower. Should the tower fail to re-pressurize, a switching to the required levels at the proper time.
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• Models 40 through 3000 are equipped with a single safety relief • De-pressurize the dryer by allowing the controller to run through valve that has been sized at a minimum to provide overpressure tower change cycles until pressure gauges on both towers read protection due to a fire for both desiccant towers.
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from freezing. If installing heat tracing, observe electrical class code EXAMPLE requirements for type of duty specified. Purge mufflers and their relief • Find the maximum inlet flow, maximum purge flow, and minimum mechanisms must be kept clear from snow and ice buildup that could outlet flow for a 60 SCFM unit with a MOP of 150 psig operated prevent proper discharge of compressed air.
10. MAINTENANCE 10.3 Valves • Process and pilot valves should be checked frequently for leaks and proper operation. WARNING - The heatless desiccant dryer is a pressure-containing • Purge pressure adjustment valve should be checked frequently device. De-pressurize before servicing. (See Section 3.3) for proper adjustment.
11. TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION 11.1 Indicator lights not No power to unit. Check voltage at terminal board. illuminated Off/On switch turned off. Turn on. Blown fuse. Replace fuse. Off/on switch or board malfunction. Replace board. 11.2 Moisture indica- Design conditions exceeded.
12. 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: Service Code:...
13. REPLACEMENT PARTS Models 40 through 450 REAR VIEW LEFT TOWER RIGHT TOWER AIR OUT AIR IN FRONT VIEW RIGHT SIDE VIEW RIGHT CHAMBER REMOVED FOR CLARITY Gardner Denver Inc. Phone: (800) 682-9868 Web: www.gardnerdenverproducts.com — 58 —...
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1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 2. All quantities for one dryer. 3. ID# correspond to P&ID legend (* Not pictured in diagrams.) Gardner Denver Inc. Phone: (800) 682-9868 Web: www.gardnerdenverproducts.com...
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Models 590 through 930 REAR VIEW LEFT TOWER RIGHT TOWER SIDE VIEW FRONT VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Gardner Denver Inc. Phone: (800) 682-9868 Web: www.gardnerdenverproducts.com — 60 —...
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2. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 3. All quantities for one dryer. 4. ID# correspond to P&ID legend (* Not pictured in diagrams.) 5. N/A - Not Applicable to this Model Size Gardner Denver Inc. Phone: (800) 682-9868 Web: www.gardnerdenverproducts.com — 61 —...
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Models 1130 through 3000 REAR VIEW LEFT TOWER RIGHT TOWER FRONT VIEW RIGHT SIDE VIEW RIGHT CHAMBER REMOVED FOR CLARITY Gardner Denver Inc. Phone: (800) 682-9868 Web: www.gardnerdenverproducts.com — 62 —...
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1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 2. All quantities for one dryer. 3. ID# correspond to P&ID legend (* Not pictured in diagrams.) 4. CF - Consult Factory Gardner Denver Inc. Phone: (800) 682-9868 Web: www.gardnerdenverproducts.com — 63 —...
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Models 4100 through 5400 FLOW FLOW REAR VIEW FLOW FLOW LEFT TOWER RIGHT TOWER 2A 2B FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Gardner Denver Inc. Phone: (800) 682-9868 Web: www.gardnerdenverproducts.com — 64 —...
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1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 2. All quantities for one dryer. 3. ID# correspond to P&ID legend (* Not pictured in diagrams.) Gardner Denver Inc. Phone: (800) 682-9868 Web: www.gardnerdenverproducts.com...