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INSTRUCTION MANUAL
COMPRESSED AIR DRYERS
MODELS: DEB0525, DEB0775, DEB1050, DEB1300, DEB1575, DEB1825,
DEB2100, DEB2625, DEB3150, DEB3675, DEB4200, DEB4725, DEB5250, DEB5800
1.0 General Information
1.1 General Safety Information
A. Pressurized Device
This equipment is a pressure containing device. Do
not exceed maximum operating pressure as shown
on equipment serial number tag. Depressurize
equipment before working on or disassembling it for
servicing.
B. Electrical
This equipment requires electricity to operate. Install
equipment in compliance with national and local
electrical codes. Equipment supplied as standard is
not intended for installation in hazardous environ-
ments. Disconnect power supply to equipment when
performing any electrical service work.
C. Breathing Air
Air treated by this equipment may not be suitable for
breathing without further purification. Refer to OSHA
standard 1910.134 for the requirements for breath-
ing quality air.
D. Hot Surfaces
Certain parts of the dryer (the lower purge piping,
the outlet piping, vessel weld caps, etc.) are not
insulated and they may become hot during normal
operation of the dryer. Do not touch any of these
areas without first determining the surface tempera-
ture.
DEB SERIES DESICCANT
SERVICE DEPARTMENT: (724) 746-1100
Contents
1.0 GENERAL INFORMATION ...................................
2.0 EQUIPMENT FUNCTION ....................................
3.0 INSTALLATION ...................................................
4.0 OPERATION .......................................................
5.0 TROUBLESHOOTING GUIDE ............................... 14
6.0 MAINTENANCE ................................................. 19
WARRANTY .............................................................. 20
7610.460.3
Rev. A 10/02
18-3-610
2
nd
Edition
Internal Use Only
460-1A / 021044
1
2
3
5
1
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Summary of Contents for Gardner Denver DEB Series
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Page 1: Table Of Contents
Rev. A 10/02 INSTRUCTION MANUAL 18-3-610 Edition Internal Use Only 460-1A / 021044 DEB SERIES DESICCANT COMPRESSED AIR DRYERS MODELS: DEB0525, DEB0775, DEB1050, DEB1300, DEB1575, DEB1825, DEB2100, DEB2625, DEB3150, DEB3675, DEB4200, DEB4725, DEB5250, DEB5800 Contents 1.0 General Information 1.0 GENERAL INFORMATION ........ -
Page 2: Equipment Function
B. One Stage Regeneration (Standard) 1.2 Receiving, Storing, and Moving When a tower is placed off-line, it is slowly depressur- ized and the desiccant is regenerated as follows. The A. Receiving - This shipment has been thoroughly blower draws in ambient air which is heated. This checked, packed and inspected before leaving our heated air flows through the desiccant bed, desorbs plant. -
Page 3: Installation
3.0 Installation 3.2 Ambient Temperature Limitations The dryer should not be installed in an area where the 3.1 Location in Compressed Air System ambient temperature will exceed 120°F (49°C) or fall The dryer should be located downstream of an below 40°F (4.4°C) unless the unit has been equipped aftercooler and separator for best performance. - Page 4 Blower Left Tower Right Tower Left Purge Intake Check Valve Filter Right Purge Check Valve Left Outlet Check Valve Right Outlet Check Valve Repressurization Valve & Repressurization Outlet Right Tower Left Tower Pilot Valve Heater Relief Valve Left Purge Pilot Valve Right Purge Pilot Valve Right Inlet Valve Left Inlet Pilot Valve...
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Page 5: Operation
Operation fixed cycle; when the dryer is returned to normal operation (auto-stop disabled) the dryer will return 4.1 Controls to demand cycle operation. A programmable logic controller (PLC) controls valve, blower, and heater operation, monitors all critical Auto-stop is enabled or disabled through the opera- operating conditions, and indicates operating status and tor interface. - Page 6 Connections - An air sample for the transmitter is Next, the right depressurization valve (V6) is taken from the dryer outlet. An isolation valve is opened and the right tower is slowly depressurized. provided in the sample line in case the transmitter Air exits through an exhaust muffler (M2).
- Page 7 B. Fixed Cycle - Two Stage Regeneration (Optional) A portion of the dry air from the left tower now flows through repressurization valve (V15). This air is (1) Left Tower Drying - Right Tower Regenerating throttled to near atmospheric pressure by two orifices (O1,O2).
- Page 8 If the offline tower pressure switch is open, the 4.4 Operator Interface program will not advance from step L03 (or R03) A. General Information to step L04 (or R04). The operator interface displays messages that it If the offline tower pressure switch is closed, the receives from the programmable controller.
- Page 9 • Ensure drains on pre-filters (if so equipped) are 4.5 Start-up Procedure draining properly. A. Slowly pressurize the dryer. Wait for the tower(s) to • On dryers equipped with the demand cycle option, pressurize completely before proceeding. Do not ensure isolation valves (V18,V19) are fully opened start air flow to downstream equipment at this time.
- Page 10 4.8 Manual Advance C. Compare the LED indicator for each input and output on the programmable controller with Figure 4.7 or 4.8 The manual advance feature is used to verify proper for the current step of the operating cycle. Any operation of the dryer and to help identify the cause of differences indicate a potential problem with the an alarm.
- Page 11 Figure 4.7 - Operating Schedule: Fixed Cycle PLC Inputs Left Tower Drying and Outputs Step Number I/O No. Device L00 L01 L02 L03 L04 L05 L06 L07 L08 L09 L10 L11 L12 L13 L14 L15 I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7...
- Page 12 Figure 4.8 - Operating Schedule: Demand Cycle PLC Inputs Left Tower Drying and Outputs Step Number I/O No. Device L00 L01 L02 L03 L04 L05 L06 L07 L08 L09 L10 L11 L12 L13 L14 L15 I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7...
- Page 13 Figure 4.9 - Operating Schedule: Cycle Times 6 Hour Cycle (3 Hour Drying Per Tower) Fixed Cycle Step Length (Minutes) Step One Stage Regeneration Two Stage Regeneration Step Number (Standard) (Optional) Description L00, R00 Open inlet valve to on-line tower L01, R01 Close inlet valve to off-line tower L02, R02...
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Page 14: Troubleshooting Guide
5.0 Troubleshooting Guide The troubleshooting guide lists each alarm, along with suggested causes and remedies. The alarms are displayed on the operator interface (see Section 4.4). When any alarm is active, the red ALARM light on the main enclosure door and the remote alarm relay will be energized. - Page 15 POSSIBLE CAUSES CORRECTIVE ACTION 5.3 Alarm L3 - Failure to depressurize, left tower, regeneration cycle 1. Faulty left tower pressure switch (PS1) • See Section 5.1.3. 2. Left depressurization muffler (M1) • Examine inner core and clean or replace as necessary. clogged 3.
- Page 16 POSSIBLE CAUSES CORRECTIVE ACTION 5.7 Alarm L7 - Failure to repressurize, left tower, regeneration cycle 1. Faulty left tower pressure switch (PS1) • See Section 5.1.3. 2. Left purge valve (V3) failed to close • See Section 5.1.5. 3. Left depressurization valve (V5) •...
- Page 17 POSSIBLE CAUSES CORRECTIVE ACTION 5.10 Alarm R2 - Early dew point breakthrough, right tower, drying cycle (Optional) 1. Desiccant bed overloaded • See Section 5.2.1. 2. Insufficient sample flow to dew • See Section 5.2.2. point sensor (DPS) 3. Air sampling valve (V20) failed to switch •...
- Page 18 POSSIBLE CAUSES CORRECTIVE ACTION 5.14 Alarm R6 - Incomplete heating, right tower, regeneration cycle 1. Desiccant bed overloaded on previous • See Section 5.10.1. drying cycle 2. Heater outlet temperature too low • Incorrect (low) setting on heater temperature controller (TC1) - adjust to factory setting.
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Page 19: Maintenance
6.0 Maintenance 6.5 Desiccant Replacement WARNING: Before performing any electrical or mechani- Each tower is fitted with flanged fill and drain ports for cal repairs or maintenance, or removing or disassembling desiccant replacement. Replace the desiccant in both any component, be sure to de-energize and depressurize vessels when the designed outlet dew point can not be the dryer. -
Page 20: Warranty
RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE. SERVICE DEPARTMENT: (724) 746-1100 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.
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