7610.479.

9 1/22/97
®

Instruction Manual
DH Series PRESSURE-SWING
DESICCANT TYPE
COMPRESSED
IMPORTANT:
READ PRIOR TO STARTING THIS AIR DRYERS
GENERAL SAFETY EQUIPMENT
INFORMATION
A. UNPACKING
1. Pressurized devices: This equipment is This shipment has been thoroughly checked,
a pressure containing device. Do not packed and inspected before leaving our plant.
exceed maximum operating pressure as It was received in good condition by the
shown on equipment serial number tag. carrier and was so acknowledged.
Make sure equipment is depressurized 1. Check for Visible Loss or Damage. If this
before working on or disassembling it shipment shows evidence of loss or damage
for service. at time of delivery to you, insist that a notation
2. Electrical: This equipment requires of this loss or damage be made on the delivery
electricity to operate. Install equipment receipt by the carrier’s agent.
in compliance with national and local 2. Check for Concealed Loss or Damage. When a
electrical codes. Standard equipment is shipment has been delivered to you in
supplied with NEMA 4, 4x electrical apparent good order, but concealed damage is
enclosures and is not intended for found upon unpacking, notify the carrier
installation in hazardous environments. immediately and insist on his agent inspecting
Disconnect power supply to equipment the shipment. Fifteen days from receipt of
when performing any electrical service shipment is the maximum time limit for
work. requesting such inspection. Concealed
3. Breathing Air: Air treated by this damage claims are not our responsibility as
equipment may not be suitable for our terms are F.O.B. point of shipment.
breathing without further purification. B. MOVING CAUTION:
Refer to OSHA standard 1910.134 for Do not lift by piping. Use lifting lugs or fork lift.
the requirements for breathing quality
air.

MODEL RATED FLOW DESIGNATED AS MODELS

DH-25 25 SCFM 25
DH-45 45 SCFM 45
DH-6000 60 SCFM 60
DH-80 80 SCFM 80
DH-115 115 SCFM 115
DH-165 165 SCFM 165
DH-260 260 SCFM 260
DH-370 370 SCFM 370
DH-450 450 SCFM 450
DH-590 590 SCFM 590
DH-750 750 SCFM 750
DH-930 930 SCFM 930
DH-1130 1130 SCFM 1130
DH-1350 1350 SCFM 1350
DH-1550 1550 SCFM 1550
DH-2100 2100 SCFM 2100
DH-3000 3000 SCFM 3000
DH-4100 4100 SCFM 4100
DH-5400 5400 SCFM 5400

SERVICE DEPARTMENT (724) 746-1100 1

 CONTENTS

1.0 DESCRIPTION ............................................................................................................................ 4

1.1 Function ...................................................................................................................................... 4
1.2 Description of Operation .......................................................................................................... 5

2.0 INSTALLATION .......................................................................................................................... 6

2.1 Location in a compressed air system ...................................................................................... 6
2.2 Minimum & Maximum Operating Conditions .......................................................................... 6
2.3 Mounting ..................................................................................................................................... 6
2.4 Piping .......................................................................................................................................... 6
2.5 Electrical connections .............................................................................................................. 10
2.6 Provisions for purge exhaust .................................................................................................. 10
2.7 Initial Desiccant Charge ........................................................................................................... 10

3.0 OPERATION .............................................................................................................................. 12

3.1 Start-up ...................................................................................................................................... 12
3.2 Operational check points ......................................................................................................... 14
3.3 Shut-down ................................................................................................................................ 15
3.4 Loss of power ........................................................................................................................... 15
3.5 Design parameters .................................................................................................................. 16
3.6 Determining purge and outlet flows ....................................................................................... 16
3.7 Outlet dew points vs. inlet temperatures ............................................................................... 16

4.0 MAINTENANCE ......................................................................................................................... 18

4.1 Desiccant replacement ............................................................................................................. 18
4.2 Pilot air filter cartridge replacement (models 370 & larger only) ........................................ 18
4.3 Fuse Replacement (automatic purge models only) ............................................................... 19
4.4 Battery replacement (automatic purge models only).. ......................................................... 19
4.5 Test Mode .................................................................................................................................. 19

5.0 TROUBLESHOOTING ............................................................................................................... 21

NOTE
Supplemental instructions for units supplied with the
optional Automatic Purge Saving System are shown in italics.

2
 MINI INSTRUCTIONS
For complete instructions on installation, operation, and maintenance, consult manual.

I . INSTALLATION
1. Install on level surface.
2. Ambient temperature range: 35 to 120°F (1.7 to 49°C) [ if low ambient package supplied: -10 to 120°F (-23 to 49°C) ]
3. Install purge mufflers if shipped separately.
4. Connect air from compressor to inlet.
• Maximum compressed air temperature: 120°F (49°C)
• Maximum compressed air pressure: Refer to serial number tag.
• Minimum compressed air pressure: See section 2.2.1.2 .
5. Connect outlet to air system.
6. Refer to serial number tag for correct voltage. Make electrical connection to terminal strip in electrical enclosure. Standard units: connect
line to position 5, neutral to position 6 and ground to position 7.
Automatic purge saving system: connect wires to positions 2 and 3; ground to position 1.
7. Set controller for 120V or 240V using selector switch.

I I. START UP
1. Set or verify controller settings. See section 3.1.1.
2. SLOWLY pressurize unit.
3. Energize dryer by turning on/off switch on. ("I" is on; "O" is off)
4. Adjust purge air flow rate. Turn purge rate valve until Purge Pressure Gauge reads as shown in the following table.
NOTE: One tower must be purging when setting purge pressure.
150 psig M.W.P. models
INLET PRESSURE 60-100 110 120 130 140 150
(psig)

10 45 43 41 39 37 36
CYCLE Min.
TIME
SETTING 4
70 66 63 60 58 56
Min.

250 psig M.W.P. models

INLET PRESSURE 125 130 135 140 145 150 175 200 225 250
(psig)

10
CYCLE Min. 80 79 78 77 76 75 70 64 60 57
TIME
SETTING 4
Min. — — — — — 132 123 115 108 102

III . OPERATIONAL CHECKPOINTS

1. Check that dryer is energized (indicating lights are illuminated)
2. MOISTURE INDICATOR - Indicator should be green (Allow 4 hours after start up for indicator to turn green).
3. TOWER PRESSURE GAUGES -
• Tower on line should read line pressure
• Tower off line should read 2 psig or less while purging. If pressure exceeds 2 psig replace purge muffler elements.
NOTE: An extra set of elements is shipped with dryer.
4. PURGE PRESSURE GAUGE - Verify proper setting.
5. CHECK FOR ALARM CONDITION.

IV . DEPRESSURIZATION
Isolate dryer. Run timer until both tower pressure gauges read 0 psig.

3
 1.0 DESCRIPTION

1.1 Function
Desiccant is regenerated by driving off (desorbing) the water collected on
1.1.1 Dryer Dual tower regenerative desiccant dryers are an economical its surface. Pressure-swing (also called heatless or heaterless because no
and reliable way to dry compressed air to dew points below the freezing outside heat is added) dryers regenerate by expanding a portion (approxi-
point of water (dew points as low as -150°F [1 ppb @ 100 psig, 7.0 kgf/ mately 14 - 15% at 100 psig, 7 kgf/cm2) of the dried air to atmospheric
cm2] are possible) or reduce the moisture content of compressed air when pressure. This “swing in pressure” causes the expanded air to become
used in critical process applications. very dry (have a very low vapor pressure). This very dry air (called purge
air) plus the stored heat of adsorption allows the moisture to desorb from
These dryers continuously dry compressed air by using two identical the desiccant. The purge air then carries the desorbed water out of the
towers, each containing a desiccant bed. While one tower is on-stream dryer.
drying the compressed air, the other tower is off-stream being regenerated
(reactivated, i.e., dried out). The towers are alternated on- and off-stream
so that dry desiccant is always in contact with the wet compressed air. In
this way a continuous supply of dry air downstream is possible. 1.1.2 Optional Automatic Purge Saving System
The Automatic Purge Saving System is designed to save energy (purge
Desiccant dryers lower the dew point of compressed air by adsorbing the air) when pressure-swing dryers are operated at reduced loads.
water vapor present in the compressed air onto the surface of the The patented Purge Saving System operates by monitoring the changes
desiccant. Desiccant is a highly porous solid containing extensive surface in temperature within the desiccant beds. These changes in temperature
area. are the result of heat (thermal energy) that is released when a bed is on-
line drying (heat of adsorption), and the heat that is used when a bed is
Adsorption occurs until the partial pressure of the water vapor in the air off-line being regenerated (heat of desorption).
and that on the surface of the desiccant come into equilibrium. As The magnitude of these changes in temperature is an indirect measure of
adsorption occurs, heat is released (referred to as the heat of adsorption) the water vapor content in the air being dried. This information is used to
and is stored in the bed for use during regeneration. determine the time a tower stays on line during the drying cycle.

4
1.2 Description of Operation 8 8
5C 5D
1.2.1 Dryer (Refer to Figure 1A.) 7
2
Compressed air flows through inlet switching valve (3A) to tower 6
(4A) where the air is dried. After the air is dried it flows through check 1 5A 5B 1
valve (5A) and then to the dryer outlet. 11
A portion of the dry air, the purge stream, branches off from the
main air stream prior to the outlet. The purge stream flow rate is controlled OUTLET
by the adjustable purge rate valve (6) and the purge orifice (7). TOWER TOWER
4A 4B
The purge flow, which has been throttled to near atmospheric
pressure, is directed through check valve (5D) to tower (4B). As the purge
flow passes over the desiccant in tower (4B), it removes the water vapor
which was deposited there while the tower was on-line drying. The purge 10A 9B 10B
9A 3A 3B
air then passes through purge and repressurization valve (9B) and purge
muffler (10B) to the atmosphere.
After regeneration, purge and repressurization valve (9B) closes
allowing tower (4B) to repressurize slowly. Adequate repressurization time INLET
is allowed so that tower 4B is fully repressurized before switchover. After a
controlled time period, air inlet switching valve (3B) opens and inlet FIGURE 1A
switching valve (3A) closes, purge and repressurization valve (9A) then TOWER 4A DRYING: TOWER 4B REGENERATING
opens.
(Refer to Figure 1B.) Tower (4B) is now drying the main air
8 8
stream while tower (4A) is being regenerated by the purge air stream. The 5C 5D
operation of the inlet switching and purge and repressurization valves is 7
2
sequenced by the control system located in the electrical box.
6
1 5A 5B 1
11
OUTLET
TOWER TOWER
4A 4B

10B
10A 9A 3A 3B 9B
1.2.2 Optional Automatic Purge Saving System (Refer to Figure 1C)
Assume Tower A is on-line drying the air while tower B has just
gone off-line to be regenerated. At the beginning of tower B’s regenera- INLET
tion cycle a temperature measurement is made at position B1. After the FIGURE 1B
tower has been regenerated, another measurement is made at B1. The TOWER 4B DRYING: TOWER 4A REGENERATING
drop in temperature sensed during regeneration is an indirect measure
of the water vapor content of the inlet air. The Purge Saving System’s 1. Pressure Gauges 7. Purge Orifice
2. Purge Pressure Gauge 8. Pressure Relief Valves
microprocessor then uses this information to calculate an allowable 3. Inlet Switching Valves 9. Purge / Repressurization Valves
temperature rise in the bed during the drying cycle. 4. Desiccant Drying Towers 10. Purge Mufflers
5. Check Valves 11. Moisture Indicator
When tower B goes back on-line, a temperature probe at 6. Adjustable Purge Rate Valve
position B2 measures the initial bed temperature at this point and then
monitors the bed until the calculated temperature rise occurs. The
temperature rise occurs as heat of adsorption is released during the
LEGEND
drying process. The time for the temperature rise to occur depends on
flow rate. At 100% flow the temperature rise takes five minutes, at 50%
Process Stream
flow it takes 10 minutes.
When the calculated temperature rise is reached, the towers
switch with tower A now drying and tower B being regenerated. Tower B Purge Stream
regenerates for 3.9 minutes, repressurizes, and remains idle until it is
called upon for the next drying cycle.

OUTLET

A2 B2
TOWER TOWER
A B
INLET
A1 B1

FIGURE 1C

5
 2.0 INSTALLATION
2.1 Location in the compressed air system. 2.2 Minimum & Maximum Operating Conditions
The compressed air supply inlet should be checked periodically to ensure
NOTE that equipment design specifications are not exceeded. Normally the
Air Compressor should be adequately sized to handle air system demands compressor installation includes intercoolers, aftercoolers, separators,
as well as purge loss. Failure to take this into account could result in receivers, or similar equipment which adequately pretreat the compressed
overloading air compressors and/or insufficient air supply downstream. air supply in order to avoid excessively high air temperatures and liquid
slugging of downstream equipment.
NOTE
It is desirable to install dryer where compressed air is at the lowest 2.2.1 Compressed air conditions
possible temperature (downstream of aftercoolers) and the highest 2.2.1.1 Maximum working pressure:
possible pressure (upstream of pressure reducing valves) without Refer to dryer Serial Number Tag.
exceeding the maximum working pressure. (Refer to Figure 2A)
WARNING
(A) AFTERCOOLER/SEPARATOR - Compressed air entering dryer must be Do not operate the dryer at pressures above the maximum
cooled to at least 120°F (49°C). Use aftercooler and separator if higher pressure shown on the tag.
temperatures are present.
2.2.1.2 Minimum working pressures:
NOTE
150 psig (10.5 kgf/cm2) MWP models -
Installation of a refrigerated dryer ahead of a pressure-swing desiccant
dryer does not increase desiccant dryer capacity or reduce purge flow 60 psig (4.2 kgf/cm2) for dryers operated on a 10 minute cycle
requirements. However a cooling unit installed ahead of the desiccant 80 psig (5.6 kgf/cm2) for dryers operated on a 4 minute cycle
dryer reduces the inlet air temperature and outlet air dew point. 250 psig (17.6 kgf/cm2)MWP models -
125 psig (8.8 kgf/cm2) for dryers operated on a 10 minute cycle
150 psig (10.5 kgf/cm2) for dryers operated on a 4 minute cycle.
If lower inlet pressures are encountered, consult factory.
Separator Desiccant
Dryer
2.2.1.3 Maximum inlet compressed air temperature:
120°F (49°C)
Compressor
Aftercooler Receiver Prefilter(s) Afterfilter NOTE
If inlet air is higher than 120°F (49°C) the air must be precooled
with an aftercooler.
FIGURE 2A
2.2.2 Ambient temperatures:
(B & C) PREFILTERS - Adequate filtration is required upstream of the Minimum:
dryer in order to protect the desiccant bed from contamination. The Standard units: 35°F (1.7°C)
following filtration are recommended: Units with optional low ambient package: - 10°F (-23°C)
B - Particulate/Gross Liquid Removal - On heavily contaminated systems Maximum: 120°F (49°C)
use a gross contaminant filter to remove solids and high inlet liquid
concentrations. NOTE
C - Oil Aerosol Removal - On systems with lubricated compressors, use
an oil removal filter to remove oil aerosols and protect desiccant bed from If dryer is installed in ambients below 35°F (1.7°C) heat tracing of
oil contamination. the prefilters and inlet piping and valves is necessary to prevent
(D) DESICCANT DRYER condensate from freezing. If installing heat tracing, observe electrical
(E) AFTERFILTER - To ensure downstream air purity (prevent desiccant class code requirements for type of duty specified.
dust from traveling downstream) adequate filtration downstream of the
dryer is required. Typically 1 micron filtration is specified although finer 2.3 Mounting
filtration is available. Install dryer on a level pad on floor. Holes are provided in the
floor stand base angles for floor anchors if desired.

OR NOTE
Oil Vapor Adsorber - Use as an afterfilter to remove oil vapor and its
Floor anchors must be used if area is subject to vibrations.
subsequent taste and odor and to protect down-stream components from
solid particles 0.01 micron and larger.
2.4 Piping
NOTE 2.4.1 Inlet and Outlet connections
By-pass lines and isolation valves are recommended so that maintenance Observe location of inlet and outlet connections as indicated in
work can be performed without shutting off the air supply. Figure 2B, 2C, or 2D and connect inlet and outlet piping.

NOTE
All piping must be supported so as not to bear on the dryers or
filters.
2.4.2 Isolation valves
If isolation valves are installed, it is recommended that gate
valves be used to ensure that dryer is pressurized slowly. This is
particularly true if isolation valves are placed before and after pre-
and afterfilters where rapid pressurization could cause excessive
pressure drop across filter cartridges.

6
 FIGURE 2B Models 25 through 80

Left Tower Pressure

Gauge

Left Tower Pressure

Relief Valve Right Tower Pressure
Gauge

Desiccant Fill Port

Right Tower
Pressure Relief Valve

Moisture
Indicator
Purge Pressure
Adjustment Valve Purge Pressure
Gauge

Control Panel

Electrical Entry
(7/8")

Purge Muffler
3/4" Dia.
Desiccant Drain Port Mounting Holes

FRONT VIEW RIGHT SIDE VIEW REAR VIEW

7
 FIGURE 2C Models 115 through 2100

Left Tower Pressure

Relief Valve
A
B L

Right Tower Pressure Relief Valve

C
D

3/4" (19mm) Dia. Mounting Holes

* *
2" (51mm) E

Lifting Lugs "G" Air Outlet

K
Desiccant Fill Port Pilot Air Filter (Models 370 & larger)

Purge Pressure Adjustment Valve Moisture Indicator

Right Tower
Left Tower Pressure Gauge Pressure Gauge

Control Panel

Purge Pressure Gauge

F
Electrical Entry
(7/8")

"G" Air Inlet

Purge Muffler
* *
Desiccant Drain Port
J

*Models 115 through 260 use solenoid valves. Models 370 and larger use air operated butterfly valves.

8
 FIGURE 2D Models 3000 thru 5400

P
A

B M

Lifting Lugs

CD Right Tower Pressure

Relief Valve

7/8" Dia. Mounting Holes

Left Tower
Pressure
Relief Valve
Air Outlet
N E
K

Pilot Air Filter

Purge Pressure Desiccant Fill Port
Adjustment Valve
Lifting Lugs
Moisture Indicator
Left Tower
Pressure Gauge Right Tower Pressure
Gauge
Purge Pressure
Gauge Control Panel

F L
Electrical Entry
(7/8") Air Inlet
Purge Mufflers

Desiccant Drain Port

9
 2.5 Electrical Connections
2.5.2.2 Automatic Purge Saving System
2.5.1 Power to Unit
Dry contacts for a remote alarm are supplied at terminals 6 and 7.
Maximum contact rating is:
NOTE 230 VAC - 4.3 amp
Check Serial Number Tag for correct voltage.
115 VAC - 8.7 amp
200 VDC - 0.15 amp
2.5.1.1 Standard Unit 100 VDC - 0.35 amp
Connect wires to terminal strip. Connect line to position 5, neutral 50 VDC - 1.2 amp
to position 6, and ground to position 7. 30 VDC - 4.5 amp
Set the voltage selection switch located at the lower edge of the 25 VDC - 10 amp
control board for the proper supply voltage. 10 VDC - 10 amp
Electrical entry is 7/8" dia. hole for 1/2" nominal conduit entry.

2.5.1.2 Automatic Purge Saving System (Refer to Figure 2F)

Connect wires to terminal strip. Connect line to position 3, 2.6 Provisions for Purge Exhaust -Purge exhaust must be routed through
neutral to position 2 and ground to position 1. Do not make connections the factory supplied mufflers or piped to a remote location.
to terminals labeled with grouding symbol or labeled with RS. 2.6.1 Purge mufflers - If shipped separately, install purge exhaust
Set the voltage selection switch located at the lower edge of mufflers in the locations shown in Figure 2B, 2C or 2D.
the control board for the proper supply voltage. 2.6.2 If purge exhaust is piped to a remote location, choose a pipe size
Electrical entry is 7/8" dia. hole for 1/2" nominal conduit entry. large enough so that back pressure through the piping is not created.

2.5.2 Connections for external alarm WARNING

2.5.2.1 Standard Unit
Dry contacts for a remote alarm are supplied at terminals 20, 21, 22. Do not operate dryer without one of the above measures. Exhausting air will
When the unit is energized and no alarms are in effect, continuity should result in noise levels above OSHA permissible levels and exhausting gas
exist between terminals 20 and 21, with no continuity between terminals could potentially cause harm to persons or property.
21 and 22. Alarm contact is common for switching failure alarm and
optional high humidity alarm. 2.7 Initial Desiccant Charge -The dryer is shipped complete with desiccant
Maximum contact rating is: and ready to operate after piping and electrical connections are made.
240 VAC - 5.0 amps
50 VDC - 1.0 amps

POWER REQUIREMENTS
AMPS
MODEL WATTS
HOLDING INRUSH
STANDARD CONTROL BOARD

25 THRU 60 120V - 60 Hz, 110V - 50 Hz 34.2 0.53 1.28

240V - 60 Hz, 220V - 50 Hz 34.2 0.27 0.64
80 120V - 60 Hz, 110V - 50 Hz 44.1 0.68 2.70
240V - 60 Hz, 220V - 50 Hz 44.1 0.34 1.35
115 THRU 260 120V - 60 Hz, 110V - 50 Hz 49.4 0.70 3.45
240V - 60 Hz, 220V - 50 Hz 49.4 0.35 1.73
370 THRU 5400 120V - 60 Hz, 110V - 50 Hz 34.6 0.53 1.24
240V - 60 Hz, 220V - 50 Hz 34.6 0.26 0.62

AUTOMATIC PURGE SAVING SYSTEM

25 THRU 60 120V - 60 Hz, 110V - 50 Hz 44.2 0.62 1.37

240V - 60 Hz, 220V - 50 Hz 44.2 0.31 0.68
80 120V - 60 Hz, 110V - 50 Hz 54.1 0.77 2.78
240V - 60 Hz, 220V - 50 Hz 54.1 0.38 1.39
115 THRU 260 120V - 60 Hz, 110V - 50 Hz 59.4 0.78 3.53
240V - 60 Hz, 220V - 50 Hz 59.4 0.39 1.77
370 THRU 5400 120V - 60 Hz, 110V - 50 Hz 44.6 0.61 1.33
240V - 60 Hz, 220V - 50 Hz 44.6 0.30 0.66

10
Customer
Power To Solid
Connections Power Off/On State
Switch Timer Purge
and Economizer
Control DIP Switches
Spare Load Connections Circuits

Control Circuit Fuse

Solid State Timer and To Solid 1SOL Energized Indicator (Green)

Control Circuit Step State
Down Transformer Timer 2SOL Energized Indicator (Green)
and
Control 3SOL Energized Indicator (Green)
Circuits
4SOL Energized Indicator (Green)

120/240 VAC Control

Board Inlet Voltage
Selector Switch

Left Tower Drying Indicator (Green)

Solenoid Circuit Fuse
Left Tower Regenerating Indicator (Green)
Right Tower Inlet Right Tower Drying Indicator (Green)
Switching Solenoid
Right Tower Regenerating Indicator (Green)

Left Tower Purge/ 4 Minute Cycle Mode Indicator (Yellow)

Repressurization 10 Minute Cycle Mode Indicator (Yellow)
Solenoid
Test Mode Indicator (Yellow)
Right Tower Purge/ To Solid
State Switching Failure Alarm Indicator (Red)
Repressurization
Solenoid Timer High Humidity Alarm Indicator (Red)
and
Control
Left Tower Inlet Circuits Purge Economizer 100% Setting Indicator (Yellow)
Switching Solenoid
To Solid State Purge Economizer 90% Setting Indicator (Yellow)
Timer Purge Economizer 80% Setting Indicator (Yellow)
and Common Spare Ground
Alarm Relay Connections Purge Economizer 70% Setting Indicator (Yellow)
Control
Circuits Purge Economizer 60% Setting Indicator (Yellow)
Customer Purge Economizer 50% Setting Indicator (Yellow)
Common Common Alarm (See section 2.5.2.1)
Alarm Contacts Purge Economizer 40% Setting Indicator (Yellow)
Connections
Purge Economizer 30% Setting Indicator (Yellow)
To Right Tower Switching Failure Alarm
Solid Pressure Switch Alarm-Reset/Selection Mode Switch
State
Timer Left Tower Switching Failure Alarm Pressure LEGEND
and Switch
Control CR ...................................... CONTROL RELAY
Circuits DS ............................................... DIP SWITCH
FU ........................................................... FUSE
L ............................................................. LIGHT
FIGURE 2E Electrical Schematic (Standard Dryers) PB .......................................... PUSH-BUTTON
PS ................................. PRESSURE SWITCH
Q .................. TRIAC (SOLID-STATE SWTICH)
SOL ................................... SOLENOID VALVE
SS .................................. SELECTOR SWITCH
SST ................. SOLID-STATE TIMER BOARD
T ............................................ TRANSFORMER
TB ..................................... TERMINAL BLOCK
SW ................................. SELECTOR SWITCH

Left Tower Lower Thermistor

Left Tower Upper Thermistor

Right Tower Lower Thermistor

Right Tower Upper Thermistor

Left Tower Pressure Switch

Right Tower Pressure Switch

Left Tower Purge & Repressurization Solenoid

Left Tower Switching Solenoid

Right Tower Purge & Repressurization Solenoid

Right Tower Switching Solenoid

Line
Neutral
GND. } Customer Power
Connection

FIGURE 2F ELECTRICAL SCHEMATIC (DRYERS WITH AUTOMATIC PURGE SAVING SYSTEM) 11

 3.0 OPERATION
3.1 Start-up
3.1.1 Controller Settings- Set or verify settings on controller
3.1.1.1 Standard Unit Control Board - NOTE: Make settings with dryer
de-energized.
3.1.1.1.1 Voltage Selection - Set the voltage selection switch located
at the lower edge of the power board for the proper voltage.

3.1.1.1.2 Dip Switch Settings - NOTE: For ON DIP switch is up; OFF
DIP switch is down

1. Select setting for Standard (150 psig, 10.5 kgf/cm2 MWP) or

High Pressure (250 psig, 17.6 kgf/cm2 MWP) unit (See Serial • TOWER STATUS • ESTADO DE LA TORRE • ETAT DES TOURS
Number Tag)
A. Standard - place switch 4 in OFF position Outlet
B. High Pressure - place switch 4 in ON position Drying
Salida
Drying
Sortie
2. Select Operating Cycle (4 or 10 minute) Secando Secando
Séchage Séchage
A. 10 minute cycle - place switch 5 in OFF position,
Regenerating Regenerating
switch 6 in ON position Regenerando Regenerando
Inlet
B. 4 minute cycle - place switch 5 in ON position, Régénération
Entrada
Régénération

switch 6 in OFF position Entrée

3. To select Test Mode - place switch 5 and 6 in ON position

• CYCLE MODE • MODO DE CICLO
4. Purge Economizer Switch Setting - If dryer is operated at less than • MODE CYCLIQUE • ECONOMIZER SETTING
maximum flow capacity a reduction in purge air usage may be possible. 4 Min. • DEMANDA PROMEDIO
• REGLAGE POUR MODE ECONOMIQUE
Refer to Section 3.5.4 to determine maximum inlet flow capacity at 10 Min.
operating pressure. Divide your actual flow by Maximum Flow to get % of Test Mode Modo de Prueba
Mode d' Essai 100 % 100 %
Maximum Flow. Set switches 1 through 3 as shown 90 % 90 %
80 % 80 %
Alarma por Falla en el
Cambio de Torres 70 % 70 %
EXAMPLE: A 60 scfm unit has a Maximum Rated Inlet Flow of 60 scfm @ Switching
Failure Alarm
Alarme de Non- 60 % 60 %
Alternance des Tours 50 % 50 %
100 psig. Currently only 30 scfm is used. 30/60 = .50 = 50%. To save Restablecer/ 40 % 40 %
purge air, set Purge Economizer Switch for 50%: switches 1 and 3 are ON, Reset/ Selector de Ciclo
Commande de Remise/
30 % 30 %
Selection Mode
switch 2 is OFF. Sélection de Mode

High Alarma por Alta Humedad

Humidity Alarm Alarme de Haute Humidité
TABLE 3A
Purge Economizer Setting Standard or High Cycle/Mode Selection
Pressure Selection I
O
Switch No. 1 2 3 4 5 6
100 OFF OFF OFF Standard 10 minute cycle OFF ON
90 ON OFF OFF 150 psig OFF
MWP
% of 80 OFF ON OFF
4 minute cycle ON OFF
Max. 70 ON ON OFF Standard Control Panel
Flow
60 OFF OFF ON High
50 ON OFF ON pressure ON Test mode ON ON
250 psig
40 OFF ON ON
MWP
30 ON ON ON

NOTE
If full flow is restored, Purge Economizer Switch must be reset for 100%.

Right Inlet Solenoid Energized

Left Purge/Repressurization Solenoid Energized
Right Purge/Repressurization Solenoid Energized
Left Inlet Solenoid Energized

DIP Switches for Economizer Setting,

Standard or HP selection,
Soleniod circuit fuse Cycle/Mode selection
1.6A 250V
Littlefuse #21701.6

Voltage Selection
Switch
Control circuit fuse
125m A 250V
Littlefuse #218.125 Alarm Hook-up

Power Hook-up
FIGURE 3A
12 Standard Control Panel
 3.1.2 SLOWLY pressurize dryer to full line pressure (open
3.1.1.2 Automatic Purge Saving System Control Board inlet valve, outlet valve remains closed).
3.1.1.2.1 Voltage selection - Set the voltage selection NOTE
switch located at the lower edge of the power board for the During initial start-up check entire system for leaks. If neces-
proper voltage. sary, depressurize and correct any leaks.
NOTE:
Make certain that paper insulation in front of battery has been 3.1.3 Energize dryer using the power switch located on the
removed. control panel.
3.1.1.2.2 Cycle selection
A cycle selector allows two choices in the fixed cycle mode and NOTE
three in the demand cycle mode. Cycle selection is accom- Standard controller - Switching failure alarm: alarm (light) may
plished by depressing the cycle selector switch repeatedly until be activated if unit is energized before it is pressurized. To
the light indicating the desired cycle mode illuminates. deactivate alarm, allow dryer to cycle to next step and press
1) Fixed cycle mode the reset button.
10 minute - in this mode the dryer switches towers every 5
minutes. With 100°F (38°C) inlet air, a -40°F (-40°C) pres- 3.1.4 Adjust the purge rate valve.
sure dew point is produced. 3.1.4.1 Determine:
4 minute - In this mode the dryer switches towers every 2 1)Maximum working pressure (MWP) of dryer from the dryer
minutes. With 100°F (38°C) inlet air, a -100°F (-73°C) serial number tag
pressure dew point is produced. 2) Air pressure at inlet to dryer
(2) Demand Cycle Mode 3) Cycle time setting (4 or 10 minutes) For units with optional
In this mode the dryer switches when the desiccant bed is Automatic Purge Saving System in the demand cycle mode
loaded as signalled by a calculated temperature rise. Unit can use the 10 minute setting.
be set to produce three outlet dew points, -40°F (-40°C), 0°F 3.1.4.2 Refer to Table 3B for proper purge rate pressure
(-17.8°C) and 40°F (4.4°C). setting at the conditions found in 3.1.4.1
NOTE: 3.1.4.3 Adjust purge rate valve until purge flow indicator
Automatic control will begin 1/2 cycle after start-up. reads required pressure setting.

NOTE: NOTE
If a cycle change is made while dryer is operating, dryer will Adjustment must be made while a tower is purging (air
finish previous cycle (right tower drying terminates) before exhausting from muffler).
changing. Indicating light of newly selected mode will blink until
changeover is complete. If it is necessary to begin a new IMPORTANT
selection immediately, shut unit off and on. (This is not INSUFFICIENT PURGE AIR WILL EVENTUALLY RESULT IN
recommended if either tower is in the regeneration mode since SATURATION OF DESICCANT BED AND WET AIR DOWN-
rapid repressurization could result.) STREAM. MAKE CERTAIN THAT CYCLE TIME, PURGE
ECONOMIZER SWITCH, AND PURGE PRESSURE ARE
NOTE: CORRECTLY SET.
If switching to a cycle mode producing a lower dew point (e.g.
0°F to -40°F [ -17.8 to -40°C] ) while dryer is operating, one or 3.1.5 Establish normal flow through dryer (open outlet
two days of operation may possibly be needed before the new isolation valve). Close air by-pass valve if present.
dew point is achieved.
TOWER STATUS
NOTE
When dew points below -40°F (-40°C) are required, the dryer
DRYING
OUTLET
DRYING
must be run with an inlet flow rate of less than 50% of maxi-
mum until the desired dew point is attained. Depending on the
REGENERATING
INLET REGENERATING
initial dryness of the desiccant, this can take as long as 2 to 3
days. This stabilization period is required on initial startup,
CYCLE SELECTOR AVERAGE after dryer has been shutdown for extended periods of time, or
DEMAND
4 MINUTES
FIXED
after dryer maintenance (desiccant change, etc.).
10MINUTES CYCLE
100%
40°F/+5°C DEW POINT 3.1.6 With the inlet pressure to the dryer at its minimum
0°F/-18°C DEW POINT
DEMAND
CYCLE
75% level, readjust the purge pressure as determined in 3.1.4.
-40°F/-40°C DEW POINT
50%
TEST MODE
MANUAL TABLE 3B - Purge Rate Pressure Settings (psig)
CYCLE
ALARMS 25%
150 psig, 10.5 kgf/cm2 M.W.P. models
SWITCHING FAILURE

TEMPERATURE PROBE
0% INLET PRESSURE 60-100 110 120 130 140 150
RESET (psig)
10 Min. 45 43 41 39 37 36
CYCLE
4 Min. 70 66 63 60 58 56

250 psig, 17.6 kgf/cm2 M.W.P. models

LFT. P&R INLET PRESSURE 125 130 135 140 145 150 175 200 225 250
LFT. INLET SW. (psig)
RT. P&R
RT. INLET SW.

10 Min. 80 79 78 77 76 75 70 64 60 57
Battery Fuses
CYCLE
Voltage Selection
Switch 4 Min. ___ ___ ___ ___ ___ 132 123 115 108 102

FIGURE 3B
AUTOMATIC PURGE SAVING PANEL
13
3. 2 Operational Check Points 3.2.2. Units with Automatic Purge Saving
System
3.2.1 Standard Unit 3.2.21 Power to unit - Check periodically that there is power
to the unit (indicating lights illuminated).
3.2.1.1 Power to unit - Check periodically that there is power to the
unit (indicating lights illuminated). 3.2.2.2 Moisture Indicator - Every four hours check mois-
3.2.1.2 Moisture Indicator - Every four hours check moisture ture indicator. Indicator should be green. Outlet relative humidity
indicator. Indicator should be green. Outlet relative humidity of the of the desiccant dryer is indicated by the color change humidity
desiccant dryer is indicated by the color change humidity indicator. Green indicator. Green indicates a R.H. below 3% and yellow indicates
indicates a R.H. below 3% and yellow indicates a R.H. above 3%. a R.H. above 3%. Table 3J (page 17) indicates outlet dew point
Table 3J(page 17) indicates outlet dew point when moisture indicator when moisture indicator changes from green to yellow at various
changes from green to yellow at various inlet temperatures. inlet temperatures. During start-up the indicator may be yellow,
however, it should begin to change to green within four hours.
NOTE 3.2.2.3 Purge Flow Indicator -Every four hours check the
During start-up the indicator may be yellow, however, it purge pressure and adjust as required. Adjustment should be
should begin to change to green within four hours. made when the inlet pressure to the dryer is at its minimum level.

3.2.1.3 Purge Flow Indicator -Every four hours check the NOTE
purge pressure and adjust as required. Adjustment should be made Adjustment must be made while a tower is purging (air
when the inlet pressure to the dryer is at its minimum level. exhausting from muffler).

NOTE 3.2.2.4 Alarms

Adjustment must be made while a tower is purging (air exhaust- 3.2.2.4.1 Switching Failure Alarm - The switching failure
ing from muffler). alarm operates by sensing tower pressures after tower
changeover. If towers have failed to pressurize or depressurize
3.2.1.4 Alarms to the required levels, an alarm condition exists. The alarm light
Periodically check for flashing red alarm light. Alarm light will blinks while the alarm condition exists. If the alarm condition
flash if either tower fails to pressurize or depressurize to the required clears for two complete cycles, the light will switch to a steady
levels at the proper time or if optional high humidity alarm indicates glow. Depressing the reset switch will extinguish the light, but will
high exiting dewpoint. not interrupt the drying cycle.
NOTE If the tower being regenerated fails to repressurize, the dryer
Alarm will activate if dryer is energized without being pressur- will not switch towers. The switching failure alarm will be
ized. If this occurs allow dryer to cycle to next step and press reset activated and the dryer will remain in this mode until the tower
button. repressurizes.
NOTE 3.2.2.4.2 Temperature Probe Alarm - (operates in a
Alarm light will continue to flash even if fault clears. To clear demand cycle mode only) This alarm is actuated by a short
alarm, press reset button. circuit, an open circuit, or temperatures below 40°F (4.4°C) or
above 150°F (65.5°C). The alarm light blinks while the alarm
condition exists. After the alarm condition clears for one complete
NOTE cycle, the light will switch to a steady glow. Depressing the reset
If the tower being regenerated fails to repressurize, the dryer switch will extinguish the light, but will not interrupt the drying
will not switch towers. The switching failure alarm will be activated cycle.
and the dryer will remain in this mode until the tower repressurizes. 3.2.2.4.3 Dryer Cycle (operates in demand cycle mode
only) Either alarm will cause the controller to automatically switch
3.2.1.5 Tower Status Lights - illuminated light indicates which to a fixed 10 minute cycle ( cycle mode light will not indicate this).
tower is on-line (pressurized) or off-line regenerating (depressur- After the alarm condition clears and the light stops blinking,
ized) the controller will clear the internal information and switch back to
a demand mode. It is not necessary to push the alarm reset for
3.2.1.6 Tower pressure gauges the dryer to return to the selected demand cycle mode. However,
3.2.1.6.1 Periodically check tower pressure gauges to verify to extinguish the alarm light, press the alarm reset button.
that tower pressure gauge of tower on-line reads line pressure and
tower pressure gauge of tower off-line reads below 2 psig. NOTE
After an alarm condition clears, the dryer will not return to a
NOTE demand cycle mode until the dryer completes two cycles if a
Read off-line tower gauge when tower is purging (air exhausting switching failure alarm is experienced or one cycle if a tempera-
from muffler) ture probe alarm is experienced. This occurs even if the alarm
reset is depressed and the alarm light is extinguished.
3.2.1.6.2 Check mufflers for back pressure
Excessive back pressure may result due to the accumulation of 3.2.2.4.4 Relay for Remote Alarm
dust in the muffler. This sometimes occurs after start-up because of The remote alarm relay will close when an alarm occurs and
dusting of the desiccant during tower filling and dryer transport. remain closed until the alarm clears and is reset. The relay does
If the tower pressure gauge of the off-stream tower rises out of not cycle as the lights blink.
the black area on the gauge dial, muffler elements should be
replaced. A set of purge exhaust muffler replacement elements is
supplied with the dryer.

14
 FIGURE 3C For dryers operating on a 10 minute cycle
3.2.2.5 Tower status lights - indicate when left and right TIME (Min.)
towers are drying and regenerating. VALVE 0 1 2 3 4 5 6 7 8 9 10
3.2.2.6 Valve energized lights 3A OPEN CLOSED
Four LEDs are furnished on controller to indicate which air 3B CLOSED OPEN
control valves are energized at any particular time 9B Cl 6" OPEN (1) Cl CLOSED
9A CLOSED Cl OPEN CLOSED
3.2.2.7 Average Demand Meter 6" (1)
The demand meter displays the average demand on the (1) See table 3C for open times.
dryer for the last 4 cycles. It is determined by dividing 40 (time
TABLE 3C Purge valve open times for dryers operating on a 10 minute cycle.
to complete 4 cycles at full flow) by the actual time to complete
the last 4 cycles. ECONOMIZER SWITCH PURGE TIME
3.2.2.8 Tower pressure gauges PRESSURE
SETTING
3.2.2.8.1 Periodically check tower pressure gauges to 150 psig MWP 100% 234 sec.
verify that tower pressure gauge of tower on-line reads line 90% 211 sec.
pressure and tower pressure gauge of tower off-line reads 80% 187 sec.
below 2 psig. 70% 164 sec.
NOTE 60% 140 sec.
50% 117 sec.
Read off-line tower gauge when tower is purging (air 40% 94 sec.
exhausting from muffler) 30% 70 sec.

3.2.2.8.2 Check mufflers for back pressure 250 psig MWP 100% 174 sec.
90% 157 sec.
Excessive back pressure may result due to the accumu-
80% 139 sec.
lation of dust in the muffler. This sometimes occurs after start- 70% 122 sec.
up because of dusting of the desiccant during tower filling and 60% 104 sec.
dryer transport. 50% 87 sec.
If the tower pressure gauge of the off-stream tower rises 40% 70 sec.
out of the black area on the gauge dial, muffler elements 30% 52 sec.
should be replaced. A set of purge exhaust muffler replace- FIGURE 3D For dryers operating on a 4 minute cycle
ment elements is supplied with the dryer.
TIME (MIN)
VALVE
0 1 2 3 4
3A OPEN CLOSED
3.2.3 All MODELS - Determine if air control valves are
operating and sequencing correctly. 3B CLOSED OPEN
Refer to Section 1.2 and Figure 1A and 1B for a general 9B Cl OPEN CLOSED CLOSED
description of operating sequence. 6" (2)
3.2.3.1 Inlet switching and purge/repressurization valves. 9A CLOSED CI OPEN CLOSED
1) Tower pressure gauge of tower on-line should read line 6" (2)
pressure. No air should be leaking from purge/repressurization (2) See table 3D for open times.
valve of the on-line tower. TABLE 3D Purge valve open times for dryers operating on a 4 minute cycle.
2) Tower pressure gauge of tower off-line should read below 2 ECONOMIZER SWITCH PURGE TIME
psig while tower is purging. If excessive purge air is exhausting PRESSURE
SETTING
during purge cycle, inlet valve may have failed to close or a check
valve may be sticking. 150 psig MWP 100% 66 sec.
90% 59 sec.
3.2.3.2 Check valves 80% 53 sec.
Check valve sticking will result in excessive air discharge 70% 46 sec.
through a muffler. If excessive air is discharged through the muffler 60% 40 sec.
on the left, check if valve 5a or 5d is sticking. If excessive air is 50% 33 sec.
discharged through the muffler on the right, check if valve 5b or 5c 40% 26 sec.
is sticking. 30% 20 sec.

3.2.3.3 Operating Sequence 250 psig MWP 100% 42 sec.

For dryers with standard controller and dryers with automatic 90% 38 sec.
purge saving system operating on a fixed time cycle- 80% 34 sec.
Figure 3C and Table 3C show valve sequence times when 70% 29 sec.
dryer is operating on a 10 minute cycle. Figure 3D and Table 3D 60% 25 sec.
50% 21 sec.
show sequence times when dryer is operating on a four minute
40% 17 sec.
cycle. 30% 13 sec.

3.3 Shut Down

3.3.1 Depressurize dryer
3.3.1.1 Open by-pass valve (if one is installed) and close inlet
and outlet isolation valves.
3.3.1.2 Run timer through a tower change cycle until pressure
gauges on both towers read 0 psig.
3.3.2 De-energize dryer
Turn dryer off using on-off switch (indicating lights extin-
guished).
3.4 Loss of Power
Control valves are designed so that upon loss of power the air
dryer is capable of drying air until the desiccant exposed to the air
flow is saturated.
15
 Determine average outlet flow available by subtracting Aver-
3.5 Verify that dryer is operating within design
age Purge Flow (APF) found in 3.6.1.2 from the inlet flow to the
parameters dryer.
3.5.1 Maximum working pressure: NOTE
Refer to Serial Number Tag to determine maximum working Average outlet flow may be used to determine available down-
pressure of dryer. stream air supply if a storage vessel (e.g. receiver tank) of sufficient
WARNING volume is available between dryer and point of air usage. Otherwise
Do not operate dryer at pressures above the maximum pres- use minimum outlet flow to determine downstream air available.
sure shown on the tag.
EXAMPLE
3.5.2 Minimum working pressures: Find maximum inlet flow, maximum and average purge flows,
150 psig, 10.5 kgf/cm2 MWP models - and minimum and average outlet flows for a 60 scfm unit with a MWP
60 psig (4.2 kgf/cm2) for dryers operated on a 10 minute cycle of 150 psig operated at 120 psig on a 10 minute cycle. Dryer will
80 psig (5.6 kgf/cm2) for dryers operated on a 4 minute cycle operate with an inlet air flow of 46 scfm.
250 psig, 17.6 kgf/cm2 MWP models Step 1: Find Maximum Inlet Flow @120 psig by multiplying
125 psig (8.8 kgf/cm2) for dryers operated on a 10 minute cycle Maximum Inlet Flow at Rated Conditions from Table 3E by Inlet
Pressure Correction Factor for 120 psig from Table 3F : 60 x 1.08 =
150 psig (10.5 kgf/cm2) for dryers operated on a 4 minute cycle. 64.8 scfm.
If lower inlet pressures are encountered, consult factory. Step 2: Find Maximum Purge Flow by multiplying Maximum
3.5.3 Maximum operating temperature: 120°F (49°C). Inlet Flow at Rated Conditions from Table 3E by Maximum Purge
3.5.4 Maximum Inlet Flow Capacity Flow Factor from Table 3G : 60 x .162 = 9.7 scfm.
3.5.4.1 At 100 psig ( 7.0 kgf/cm2): For maximum inlet flow at 100
psig (7.0 kgf/cm2) refer to Table 3E. Step 3: Find Average Purge Flow by multiplying Maximum
Inlet Flow at rated conditions from Table 3E by Average Purge/
3.5.4.2 At pressures other than 100 psig (7.0 kgf/cm2) : Multiply
Repressurization Flow Factor from Table 3H: 60 x 0.097 = 5.8 scfm.
inlet flow from Table 3E by multiplier from Table 3F that corresponds
to system pressure at inlet to dryer. NOTE
At 46 scfm inlet flow, dryer is operating at 70% of maximum flow
found in Step 1: (46/64.8 = 70%.) Average purge flow is based on
3.6 Determining Purge and Outlet Flows:
Economizer Switch setting of 70%.
3.6.1 Purge Flows
3.6.1.1 Maximum Purge Flow.- Maximum Purge Flow (MFP) is
Step 4: Find Minimum Outlet Flow available by subtracting
the amount of purge air flowing through the off-stream tower when
Maximum Purge Flow (Step 2) from inlet flow: 46 - 9.7 = 36.3 scfm.
the purge/repressurization valve is open. After the purge/
repressurization valve closes, the purge flow will gradually decrease Step 5: Find Average Outlet Flow available by subtracting
as the off-stream tower repressurizes to line pressure. Average Purge Flow (Step 3) from inlet flow: 46 - 5.8 = 40.2 scfm.
For maximum purge flow multiply inlet flow at rated conditions
fromTable 3E by Maximum Purge Flow Factor from Table 3G that 3.7 Determining outlet pressure dew point at
corresponds to the dryer MWP, Cycle Time Setting, and air pressure various inlet compressed air temperatures:
at inlet to dryer. For dryers supplied with the optional Automatic The outlet pressure dew point is determined by the compressed
Purge Saving System operating in the Demand Cycle Mode, use 10 air temperature at the inlet to the dryer and cycle time selected ( 4
minutes as the cycle time. or 10 minutes). Use Table 3I to determine outlet dew points at var-
3.6.1.2 Average Purge Flow - For dryers with the standard ious inlet compressed air temperatures and cycle times.
control board and dryers with the Automatic Purge Saving System
operating in the fixed cycle mode:
The Average Purge Flow (APF) is the actual amount of flow
used during the entire purge/repressurization cycle. It includes the
maximum purge flow (MFP) for a portion of the purge/repressurization
time and the volume of air used for repressurization, averaged over
the cycle time.
To determine average purge flow, multiply maximum inlet flow
at rated conditions from Table 3E by Average Purge/Repressurization
Flow Factor from Table 3H that corresponds to the dryer Maximum
Working Pressure, Inlet Pressure, Cycle Time Setting, and Econo-
mizer Switch Setting.
3.6.2 Outlet Air Flow
3.6.2.1 Minimum Outlet Flow
Determine minimum outlet flow available from dryer by sub-
tracting Maximum Purge Flow (MFP) found in 3.6.1.1 from inlet flow
to the dryer.
3.6.2.2 Average Outlet Flow - For dryers with the standard
control board and dryers with the Automatic Purge Saving System
operating in the fixed cycle mode:

16
 TABLE 3E Maximum Inlet Flow at Rated Conditions
MODEL 25 45 60 80 115 165 260 370 450 590 750 930 1130 1350 1550 2100 3000 4100 5400
Inlet @ 100 psig
(7.0 kgf/cm2) 25 45 60 80 115 165 260 370 450 590 750 930 1130 1350 1550 2100 3000 4100 5400
(scfm) (1) (2)

(1) Convert scfm to metric units as follows: 1 scfm = 1.717m3n/h.

(2) "Performance data obtained and presented in accordance with CAGI standard ADF200 - Methods for rating and testing."
Conditions for rating air dryers are: 100 psig (7.0 kgf/cm2) and 100oF (37.8oC)saturated inlet air, and a maximum 5 psi (.4 kgf/cm2) pressure drop. Actual pressure drop for
all units is less than 3 psi at rated conditions.

TABLE 3F Inlet Pressure Correction Factor

INLET psig 60 70 80 90 100 110 120 125 130 140 150 175 200 225 250
PRESSURE kgf/cm2 4.2 4.9 5.6 6.3 7.0 7.7 8.4 8.8 9.1 9.8 10.5 12.3 14.1 15.8 17.6

MULTIPLIER 0.65 0.74 0.83 0.91 1.00 1.04 1.08 1.10 1.12 1.16 1.20 1.29 1.37 1.45 1.52

TABLE 3G Maximum Purge Flow Factor

DRYER MWP 150 psig 250 psig
INLET PRESSURE (psig) 60-100 110 120 130 140 150 125 150 175 200 225 250
CYCLE 10 minute 0.175 0.168 0.162 0.156 0.151 0.146 0.214 0.196 0.184 0.172 0.163 0.155
TIME 4 minute 0.249 0.239 0.230 0.221 0.215 0.207 - 0.326 0.304 0.286 0.270 0.257

TABLE 3H Average Purge/Repressurization Flow

FactorDRYER MWP 150 psig 250 psig
INLET PRESSURE (psig) 60 70 80 90 100 110 120 130 140 150 125 150 175 200 225 250
100% 0.141 0.142 0.143 0.143 0.144 0.139 0.135 0.131 0.128 0.125 0.133 0.125 0.119 0.114 0.111 0.108
90% 0.127 0.128 0.129 0.130 0.130 0.126 0.122 0.119 0.116 0.113 0.120 0.113 0.108 0.104 0.101 0.099
10 ECONOMIZER 80% 0.114 0.114 0.115 0.116 0.117 0.113 0.110 0.107 0.104 0.102 0.108 0.102 0.098 0.094 0.092 0.090
MINUTE SWITCH 70% 0.100 0.101 0.101 0.102 0.103 0.100 0.097 0.095 0.092 0.091 0.096 0.091 0.087 0.084 0.082 0.081
60% 0.086 0.087 0.088 0.088 0.089 0.087 0.084 0.082 0.081 0.079 0.083 0.079 0.076 0.074 0.073 0.072
CYCLE SETTING
50% 0.073 0.073 0.074 0.075 0.076 0.073 0.072 0.070 0.069 0.068 0.071 0.068 0.066 0.064 0.063 0.063
40% 0.059 0.060 0.060 0.061 0.062 0.060 0.059 0.058 0.057 0.056 0.058 0.056 0.055 0.054 0.054 0.054
30% 0.045 0.046 0.047 0.047 0.048 0.047 0.046 0.046 0.045 0.045 0.046 0.045 0.044 0.044 0.044 0.045
100% 0.147 0.149 0.151 0.153 0.155 0.151 0.148 0.145 0.143 0.141 - 0.141 0.137 0.135 0.134 0.134
90% 0.134 0.136 0.137 0.139 0.141 0.138 0.135 0.133 0.131 0.129 - 0.129 0.127 0.125 0.125 0.125
4 ECONOMIZER 80% 0.120 0.122 0.124 0.125 0.127 0.124 0.122 0.120 0.119 0.118 - 0.118 0.116 0.115 0.116 0.116
MINUTE 70% 0.106 0.108 0.110 0.112 0.114 0.111 0.110 0.108 0.107 0.106 - 0.106 0.105 0.105 0.106 0.107
SWITCH
CYCLE 60% 0.093 0.095 0.096 0.098 0.100 0.098 0.097 0.096 0.095 0.095 - 0.095 0.095 0.095 0.097 0.098
SETTING
50% 0.079 0.081 0.083 0.084 0.086 0.085 0.084 0.084 0.084 0.084 - 0.084 0.084 0.085 0.087 0.089
40% 0.065 0.067 0.069 0.071 0.072 0.072 0.072 0.072 0.072 0.072 - 0.072 0.074 0.075 0.078 0.080
30% 0.052 0.053 0.055 0.057 0.059 0.059 0.059 0.060 0.060 0.061 - 0.061 0.063 0.065 0.068 0.071

TABLE 3I Outlet pressure dew points for dryers supplied with Activated Alumina Desiccant
INLET TEMP. °F 35 40 50 60 70 80 90 100 110 120
°C 1.7 4.4 10.1 15.6 21.1 26.7 32.2 37.8 43.3 48.9

. OUTLET P.D.P. °F -75 -70 -65 -60 -55 -50 -45 -40 -35 -30
10 MIN. CYCLE °C -59.4 -56.7 -53.9 -51.1 -48.3 -45.6 -42.8 -40.0 -37.2 -34.4

OUTLET P.D.P. °F -149 -145 -138 -130 -122 -115 -108 -100 -92 -85
4 MIN. CYCLE °C -100.6 -98.3 -94.4 -90.0 -85.6 -81.7 -77.8 -73.3 -68.9 -65.0

TABLE 3J Outlet pressure dew points at moisture indicator color

change
INLET TEMP. °F 35 40 50 60 70 80 90 100 110 120
°C 1.7 4.4 10.1 15.6 21.1 26.7 32.2 37.8 43.3 48.9

°F -34 -28 -22 -16 -10 -4 3 9 15 21

OUTLET P.D.P. °C -36.7 -33.4 -30.0 -26.7 -23.4 -20.0 -16.1 -12.8 -9.5 -6.1

17
 4.0 MAINTENANCE
WARNING
The heatless desiccant dryer is a pressure containing device. 4.2 Pilot Air Filter - Element Replacement -
Depressurize before servicing. (See Section 3.3) Models 370 scfm and larger
4.1 Desiccant Replacement 4.2.1 Frequency of replacement - Pilot air filter contains a filter
NOTE element which should be changed yearly or sooner if pressure drop
The use of the correct replacement desiccant is necessary for across cartridge prevents valves from actuating. Pilot air pressure
proper dryer operation. Never use hygroscopic salts of the type must not drop below 60 psig (4.2 kgf/cm2).
commonly used in “deliquescent” type dryers. 4.2.2 Procedure for cartridge replacement.
4.1.1 Frequency of desiccant replacement
Desiccant should be replaced whenever the required dew point WARNING
cannot be maintained while the dryer is being operated within its THE FILTER IS A PRESSURE CONTAINING DEVICE. DE-
design conditions and there are no mechanical malfunctions. Refer PRESSURIZE DRYER BEFORE SERVICING. (SEE SECTION
to section 5.0 for troubleshooting hints. 3.3)
NOTE
Desiccant life is determined by the quality of the inlet air. Proper
HEAD
filtering of the inlet air will extend the life of the desiccant.
Typically desiccant life is 3 to 5 years. HEAD "O" RING

4.1.2 Procedure for Desiccant Charge Replacement CARTRIDGE "O" RING

4.1.2.1 Depressurize and de-energize the dryer. (See section
3.3) CARTRIDGE
4.1.2.2 Remove the fill and drain FILL
PLUG
plugs from desiccant tower and drain
the spent desiccant. Place a con-
tainer at the base of the vessel to
collect the desiccant. If necessary BOWL
tap the sides of the vessels with a
rubber mallet to loosen desiccant.
4.1.2.3 Replace the drain plug
using teflon tape sealant or equiva-
lent. FIGURE 4B
4.1.2.4 Fill the desiccant drying
tower as full as possible with dry NOTE
desiccant. Do not tamp desiccant. 4.2.2.1 Remove the filter bowl.
4.1.2.5 Replace the fill plug us- DRAIN 4.2.2.2 Clean the filter bowl.
PLUGS
ing teflon tape sealant or equivalent. 4.2.2.3 Remove the old filter element and discard. Also discard
4.1.2.6 Repeat this procedure the small O-ring that seals the filter to the filter assembly head.
for the other drying tower. 4.2.2.4 Insert small replacement O-ring on top of replacement
4.1.3 Insuring desiccant dryness FIGURE 4A
filter element and replace filter element.
4.1.3.1 Replacement desiccant is shipped in air tight contain- 4.2.2.5 After making sure large O-ring in filter head is in place,
ers. Keep the covers on these containers tightly closed until use to reassemble filter bowl to filter head.
avoid moisture contamination. If desiccant is exposed to air it can be 4.3 Fuse Replacement
heated in an oven at 400°F (204°C) for four hours before use, or the 4.3.1 Standard Units Only:
procedure in 4.1.3.2 can be used. 4.3.1.1 Fuses are located on board in electrical enclosure. See
4.1.3.2 If the dryer is not refilled with dry desiccant, it will be Figure 3A or 3B.
necessary to operate the dryer with an inlet flow rate of less than 50%
of maximum to dry the desiccant. To do this, set the Economizer
Switch for 100%, and the purge pressure for 45 psig. (3.2 kgf/cm2)

TABLE 4A Amount of desiccant required for complete change (lb)

MODEL 25 40 60 80 115 165 260 370 450 590

ACTIVATED ALUMINA 48 48 72 106 182 182 316 452 528 710

MODEL 750 930 1130 1350 1550 2100 3000 4100 5400

ACTIVATED ALUMINA 926 1172 1468 1766 2064 2592 3930 4920 7750

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 4.3.2 Fuse Replacement
4.5.2 Test Mode - Automatic Purge Saving System
Only one of the "Valve Power" and one of the "Control
Power" fuses should be installed at any time. 4.5.2.1 Press cycle selector switch until Test Mode Light
illuminates. This change will not be acknowledged by the controller
4.3.2.1 Use 1/8 amp fuse in positions 1 & 2 until the present cycle is completed (right tower drying terminates)
4.3.2.2 Use 1.6 amp fuse in positions 3 & 4. or until the controller is de-energized and re-energized. NOTE: Do
4.3.2.3 Positions 1 & 4 take 5 mm x 20 mm size. not de-energize dryer unless both towers are at line pressure.
4.3.2.4 Positions 2 & 3 take 1/4" x 1 1/4" size. 4.5.2.2 Use the alarm reset switch to step through cycle in the
4.3.2.5 Place fuses in positions 2 & 3 or 1 & 4 only. Do not order shown in 4B.
place fuses in all four positions. 4.5.2.3 The average demand meter will function as a voltmeter
monitoring the voltage from the thermistors. The thermistor being
monitored is indicated in Table 4B. A 0% reading indicates a short
circuit and a 100% reading indicates an open circuit. A curve
relating the demand meter reading to thermistor temperature is
POS. 1 POS.4 shown in Figure 4C, page 20.
4.5.2.4 After troubleshooting is completed, reset the cycle
POS.2 POS. 3 selector to the desired position. Use the reset switch to manually
step through the dryer operating sequence until the left tower drying
4.4 Battery replacement light is illuminated and the reset switch cannot be used to step
Controller contains a battery which requires replacement through the cycle. At this point, the dryer is on automatic control.
every 3 to 4 years. If the battery is dead and the power is turned Verify that the right tower depressurizes and repressurizes auto-
off and back on, a 10 minute fixed cycle will be selected by matically before leaving the dryer.
default. If the dryer is switched from the test mode and the cycle is not
4.5 Test Mode completed using the reset switch, the controller will automatically
4.5.1 Test Mode - Standard Control Panel step through the test mode at a rate of one step every 50 seconds
4.5.1.1 To select test mode, de-energize dryer and place DIP until the cycle is completed. Normal operation will then resume.
switches 5 and 6 in ON position.
4.5.1.2 Use Reset/Selection Mode switch to step through NOTE
cycle in the order shown in Table 4B. Changes in the cycle selector are only acknowledged when the
4.5.1.3 When finished (it is recommended that all 9 steps are present cycle is completed. If in the test mode, continue to step
completed) de-energize dryer, reset DIP switches 5 and 6 to the through dryer operating sequence until left tower drying begins.
cycle time (4 or 10 minutes) desired, and re-energize.
NOTE
Do not de-energize dryer unless both towers are at line
pressure.
Test Mode
TABLE 4B
SOLENOID/TERMINALS THERMISTOR
TOWER STATUS VALVE POSITION ENERGIZED BEING CHECKED
(light illuminated) (automatic purge
saving system)
STEP WHAT
MODE PRESSURE
NUMBER OCCURS L L R R L P/R L IN R P/R R IN T T B B
LT RT LT RT P/R IN P/R IN L R L R

Start D D LP LP C O C O
1 R IN closes D - LP LP C O C C E X
2 (1) R P/R opens D R LP <2 C O O C E E X
3 No change D R LP <2 C O O C E E X
4 (2) (3) R P/R closes D - LP REP C O C C E X
5 R IN opens D D LP LP C O C O
6 L IN closes - D LP LP C C C O E X
7 (1) L P/R opens R D <2 LP O C C O E E X
8 No change R D <2 LP O C C O E E X
9 (2) (3) L P/R closes - D REP LP C C C O E X

NOTES:
(1) Close purge rate valve during this step to check for any valve leaks. No air should exhaust through the muffler. If air is exhausting through the muffler,
check all valves for leaks. After testing for leaks or fixing any leaks, be sure to open the purge pressure valve and reset the purge pressure.
(2) Do not go to the next step until the tower is repressurized.
(3) Switching failure alarm circuit is energized during this step (alarm light should flash until pressure exceeds 40 psig).

CODES:
R IN - Right inlet valve D - Drying E - Energized
R P/R - Right purge/repressurization valve R - Regenerating TL -Top left
L IN - Left inlet valve LP - Line Pressure TR - Top right
L P/R - Left purge/repressurization valve <2 - Less than 2 psig BL - Bottom left
LT - Left tower REP - Repressurizing BR - Bottom right
RT - Right tower C - Closed
O - Open
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 TEMPERATURE RANGE VERSUS AVERAGE DEMAND

THERMISTOR TEMPERATURE RANGE (F)

160

140

120

100

80

60

40

20

0 10 20 30 40 50 60 70 80 90 100

AVERAGE DEMAND READING

FIGURE 4C

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 5.0 TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION

5.1 Indicator lights not illuminated No power to unit Check voltage at terminal board.

On/Off Switch off Turn on.

Switch malfunctioning Replace switch.

5.2 Moisture Indicator Maximum flow being exceeded Refer to Section 3.5.4 to determine maximum flow.

Turns yellow (elevated outlet dew points) Design conditions being exceeded Refer to Section 3.5 to determine if dryer is being operated
within its design limitations.
Desiccant not adsorbing
a. Useful service life has ended Change desiccant.

b. Desiccant is contaminated Take corrective action. Refer to Section 2.1 to determine proper prefiltration
(e.g. with oil) then change desiccant.

c. Premature exhaustion (saturated with water) Refer to 5.3 for corrective action. Desiccant beds may be reactivated
by running at reduced flow until desired outlet dewpoint is achieved.

5.3 Desiccant being exhausted prematurely Insufficient purge rate

a. Improper purge rate Refer to Section 3.1.4 to determine correct Purge Pressure Indicator Setting.

b. Tower not completely depressurized during

purge cycle (Tower pressure gauge should read
lower than 2 psig)

1. Clogged exhaust muffler Replace muffler inserts.

2. Purge valve won't open Check power to valve to determine if valve or timer at fault.
On Models 370 and larger, check pilot air line for obstruction.

3. Check valve stuck open Repair valve.

Insufficient purge time

a. Improper set points Refer to Section 3.1.1 to determine correct Economizer Switch and Cycle Settings.

b. Faulty Timer Refer to Section 3.2.3 to verify proper time sequence.

5.4 Tower fails to pressurize to line pressure Purge repressurization valve won't close Check valve for obstruction. On Models 25 thru 260 this valve is normally closed.
On Models 370 and larger, check pilot solenoid valve and pilot air line for obstruction.
Excessive downsteam air demand

5.5 Tower fails to depressurize to less than 2 Purge rate valve open too far Check Section 3.1.4 for purge rate indicator setting.
psig
Clogged muffler Replace muffler.

Check valve stuck open Repair valve.

Purge repressurization valve won't open Check power to valve (pilot valve on Models 370 and larger)
to determine if valve or timer is at fault.. Models 370 and larger: Check pilot valve,
pilot air line, and purge repressurization valve for obstruction.

5.6 Excessive purge air is discharged during Inlet valve won't close Check power to valve (pilot valve on Models 370 and larger) to determine if valve or timer
purge cycle iis at fault.
Check valve for obstruction. Models 370 and larger: Check pilot valve and pilot air line for
obstruction.

Check valve sticking Refer to Section 3.2.3.2

5.7 Excessive desiccant dust downstream Faulty timer Refer to Section 3.2.3 to verify proper time sequence.

Purge rate valve closed Refer to Section 3.1.4 to determine Correct Purge Pressure setting.

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 WARRANTY
The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with
procedures and recommendations outlined in manufacturer’s instruction manuals, to be free from defects in material or workmanship for a period
of one (1) year from the date of shipment to the buyer by the manufacturer or manufacturer’s authorized distributor, or eighteen months from the
date of shipment from the factory, whichever occurs first, provided such defect is discovered and brought to the manufacturer’s attention within the
aforesaid warranty period. The manufacturer will repair or replace any product or part determined to be defective by the manufacturer within the
warranty period, provided such defect occurred in normal service and not as a result of misuse, abuse, neglect or accident.

The warranty covers parts and labor for the warranty period. Repair or replacement shall be made at the factory or the installation site, at the
sole option of the manufacturer. Any service performed on the product by anyone other than the manufacturer must first be authorized by the
manufacturer. Normal maintenance items requiring routine replacement are not warranted. Unauthorized service voids the warranty and any
resulting charge or subsequent claim will not be paid. Products repaired or replaced under warranty shall be warranted for the unexpired portion
of the warranty applying to the original product. The foregoing is the exclusive remedy of any buyer of the manufacturer’s product. The maximum
damages liability of the manufacturer is the original purchase price of the product or part.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, OR
STATUTORY, AND IS EXPRESSED IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF
FITNESS FOR A PARTICULAR PURPOSE. THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR DAMAGE BY REASON OF STRICT
LIABILITY IN TORT OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN, MANUFACTURE OR INSPECTION OF THE
EQUIPMENT OR ITS FAILURE TO DISCOVER, REPORT, REPAIR, OR MODIFY LATENT DEFECTS INHERENT THEREIN. THE MANUFAC-
TURER, HIS REPRESENTATIVE OR DISTRIBUTOR SHALL NOT BE LIABLE FOR LOSS OF USE OF THE PRODUCT OR OTHER INCIDENTAL
OR CONSEQUENTIAL COSTS, EXPENSES, OR DAMAGES INCURRED BY THE BUYER, WHETHER ARISING FROM BREACH OF
WARRANTY, NEGLIGENCE OR STRICT LIABILITY IN TORT.

The manufacturer does not warrant any product, part, material, component, or accessory manufactured by others and sold
or supplied in connection with the sale of manufacturer’s products. 8/94

AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY

BEFORE MATERIAL IS RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.

SERVICE DEPARTMENT (724) 746-1100

Division Of Hansen Inc.

Canonsburg, PA 15317-1700 U.S.A.

® INTERNATIONAL Tel 724-745-1555 Fax 724-745-6040

E-mail - service@hankisonintl.com

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