Sullair DHL-100 User & Service Manual Download Page 1

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Failure to follow the instructions

and procedures in this manual or,

misuse of this equipment will

VOID its warranty!

WARRANTY NOTICE

USER/SERVICE MANUAL

ESICCANT

EATLESS

EGENERATIVE

OMPRESSED

RYERS

DHL-80

DHL-5000

PART NUMBER:

KEEP FOR
FUTURE
REFERENCE

SULLAIR CORPORATION

02250195-403 R00

The information in this manual is current

as of its publication date, and applies to

compressor

serial number

and all subsequent serial numbers.

SHDIDFAA-0001

Summary of Contents for DHL-100

Page 1: ...ICE USER SERVICE MANUAL DESICCANT HEATLESS REGENERATIVE COMPRESSED AIR DRYERS DHL 80 TO DHL 5000 PART NUMBER KEEP FOR FUTURE REFERENCE SULLAIR CORPORATION 02250195 403 R00 The information in this manu...

Page 2: ...d at Michigan City Indiana Instruction includes training on the function and installation of Sullair service parts troubleshooting common faults and malfunctions and actual equipment operation These s...

Page 3: ...13 3 1 TRANSPORT 13 3 2 INSTALLATION SITE 14 3 3 INSTALLATION LAYOUT 15 3 4 OPERATING CONDITIONS 15 3 5 CONNECTION TO THE COMPRESSED AIR SYSTEM 15 3 6 CONNECTION TO THE ELECTRICAL SUPPLY 15 3 7 INLET...

Page 4: ...O SWITCH ALARM OPTIONAL 41 6 17 CALIBRATION PRESSURES SECTION 7 MAINTENANCE TROUBLESHOOTING SPARES AND DIS MANTLING 43 7 1 CONTROLS AND MAINTENANCE 44 7 2 TROUBLESHOOTING 46 7 3 DISMANTLING OF THE DRY...

Page 5: ...echnical evolution we reserve the right to introduce any necessary change without giving previous notice Should you experience any trouble or for further information please do not hesitate to contact...

Page 6: ...let Outlet Size ____________ NPT ____________ Inlet Design Conditions _________________________ Cycle Time ___________ Standard Short Cycle _______ Flow ________________________SCFM Pressure _________...

Page 7: ...ial and safety regulations dealing with the operation of pressure vessels under compressed air service Also all end user safety rules for the same type of service must be adhered to The following poin...

Page 8: ...ish fire on the dryer or in the surrounding area Danger hazard It s absolutely forbidden to operate the machine when the parts under pressure or electric panels are not in place or have been tampered...

Page 9: ...point Operations which can be worked out by the operator of the machine if qualified 1 In designing this unit a lot of care has been devoted to the protection of the environment Dryer and relevant pac...

Page 10: ...es or for operations leading to direct contact with foodstuff unless subject to further treatments Compressed air is a highly hazardous energy source Never work on the dryer with parts under pressure...

Page 11: ...es 4 Vibration must be eliminated from the equip ment to prevent fatigue failure 5 An internal inspection must be carried out at 12 month intervals to check for pressure equipment corrosion The actual...

Page 12: ...12 NOTES...

Page 13: ...ally present The installator and or the user is responsible for correct installation of the dryer in order to prevent noise propagation to the near work environment The installator and or the user is...

Page 14: ...reduced intermittence and the total consumption equals the compressor flow rate Figure 3 1 Recommended Installation Table 3 1 Correction Factor for inlet Pressure PSIG 50 60 70 80 90 100 110 120 130 1...

Page 15: ...pipes able to insulate the dryer from possible vibrations originating from the line flexible hoses vibration damping fittings etc 3 6 CONNECTION TO THE ELECTRICAL SUPPLY The connection to the electric...

Page 16: ...densate collected in the dryer contains oil particles released in the air by the compressor Dispose the condensate in compliance with the local rules Sullair recommends the installation of an oil wate...

Page 17: ...personnel must wear hearing protection while operating the dryer Each employee must select proper PPD Personal Protection Device hearing protector earmuffs ear canal caps and earplugs in order to prev...

Page 18: ...s there is an alternation of depressurization from tower A to tower B Switching off Check if the inlet filter condensate drain works regularly Stop the air flow Depressurize the dryer Deactivate the o...

Page 19: ...5 208 1 NPT 40x24x87 1010 DHL 300 300 115 208 1 NPT 40x24x87 1200 DHL 400 375 115 208 1 NPT 46x26x88 1350 DHL 500 500 115 208 2 NPT 46x26x88 1460 DHL 600 650 115 208 2 NPT 46x26x88 1790 DHL 800 800 11...

Page 20: ...20 NOTES...

Page 21: ...adsorption dryers of the DHL series are fitted with two tanks filled with activated alumina While the compressed air is dried in one tower the saturated desiccant is regenerated in the second A small...

Page 22: ...ic drain valve 11 1 control air filter 3 1 bi directional purge adjustment valve 12 1 control air tubing 1 4 4 2 angle body purge exhaust valve 13 2 gauge snubber 5 2 purge pilot valve 14 2 outlet che...

Page 23: ...illed with These towers with the same dimensions are alternately crossed from the compressed air The cycle time is set during the manufacturing phase as well as the regeneration nozzle according to th...

Page 24: ...2 4 turns 2 3 turns 2 2 turns 2 0 turns DHL 750 2 7 turns 2 6 turns 2 5 turns 2 4 turns 2 3 turns 2 2 turns DHL 800 2 8 turns 2 7 turns 2 6 turns 2 5 turns 2 4 turns 2 3 turns DHL 900 3 0 turns 2 9 tu...

Page 25: ...on operation while cross ing tower B dries the adsorbent material dragging away the humidity through the PVB solenoid valve and the silencers At the end of this stage the adsorption material of tower...

Page 26: ...clogged LED On device powered LED On outlet filter clogged Flashing under programming LED Alarm DewPoint too high LED On display shows of set load LED Alarm operating cycle did not switch LED On disp...

Page 27: ...the operating status of the dryer precisely 1 At start up both the purge solenoid valves are closed for about 120 seconds therefore the relevant LEDs are off The compressed air passes through both dry...

Page 28: ...probe is installed optional DewPoint under pressure PDP 20 C DewPoint under pressure PDP 40 C Mode TEST Diagnostic cycle with step by step operation to make troubleshooting operations easier Mode FIX...

Page 29: ...he dryer The function can be enabled only if the pressure switch kit is installed optional and only after having correctly set the relating DIP SWITCH see Section 6 9 If the SERVICE LED and the LED of...

Page 30: ...shes for temperatures higher than 10 C whereas LED 10 flashes for temperatures lower than 60 C In case of anomalies on the probe all the LEDs switch off Only qualified personnel must configure the dry...

Page 31: ...E SOL3 LEFT TOWER INLT PILOT SOLENOID VALVE SOL4 RIGHT TOWER INLET PILOT SOLENOID VALVE SOL5 DRAIN SOLENOID VALVE 115 1 60 OR 220 1 50 FS1 OPTIONAL FILTER ELEMENT CHANE SWITCH INLET FILTER FS2 OPTIONA...

Page 32: ...simply changing the set up of the DIP SWITCHES With the switch in the lower position the SHDC 2100 device must be pow ered at 220 240 V With the switch in the upper position the SHDC 2100 device must...

Page 33: ...ecting a work cycle up to 3000 hours year or higher see Section 6 12 OFF up to 3000 hours year standard ON over 3000 hours year DIP D6 Not Used DIP D7 DewPoint probe OFF probe disabled ON probe enable...

Page 34: ...A Time B Time A Time B Time A Time B Time A Time B Time A Time B Time A Time B s s s s s s s s s s s s 100 355 95 240 60 70 50 270 180 180 120 46 74 90 320 130 217 83 64 56 244 206 163 137 42 78 80 2...

Page 35: ...time C fixed determined by the selected operating cycle see Table 6 2 At the end of the regeneration phase tower B is re pressurized and kept in stand by until the DewPoint meter PDP Meter indicates t...

Page 36: ...shows that this mode has been enabled and it remains on together with the LED ODPD and returns to DPD mode when the DewPoint values drop again below the SPC value To better control the DPD cycle the...

Page 37: ...he dryer moves onto the dryer starts from step 1 again Table 6 3 shows the various steps of the dryer Table 6 3 Dryer Steps 10 10 All the LEDs Check operation of LEDs of SHDC 2100 device 9 9 Line Pres...

Page 38: ...Dew Point value on the display of the SHDC 2100 device Enable the operation of the dryer in DPD mode see Section 6 10 2 Enable the HI PDP alarm see v The sampling system includes a cell Pos 2 which h...

Page 39: ...the analog signal 4 20mA for any other operation such as the monitoring of the humidity level etc Hence just simply put the mA meter on terminal S of the SHDC 2100 device as shown in the following il...

Page 40: ...er pressure The system is able to detect an alarm condition if for any reason the flow between the two towers was not switched or the switching was not done correctly The Fail to Switch alarm function...

Page 41: ...ibration values of the pressure switches are indicated below Dryer operating pressure Pressure switch closing pressure Pressure switch opening pressure barg psig barg psig barg psig 4 5 9 58 86 3 43 5...

Page 42: ...42 NOTES...

Page 43: ...e gauge installed Check that the tower switching operation takes place correctly and in the set cycle times Check that the differential pressure gauge of the regenerating tower indicates 0 bar YEARLY...

Page 44: ...he switching cycles see specific point The inlet air is too hot restore the nominal conditions The inlet air pressure is too low verify that the installed regeneration nozzle is for the real working p...

Page 45: ...see specific point The air flow adjuster setting has been changed see Section 6 14 reset nominal value The selector valve of the operating tower see Section 6 14 is blocked replace it Verify the elec...

Page 46: ...the LED SERVICE flashes together with both LEDs the adsorbent material programmed maintenance timer went off replace the desiccant bed PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Part Material Desiccant...

Page 47: ...Section 8 47 DHL HEATLESS REGENERATIVE DRYER ATTACHMENTS...

Page 48: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 48 8 1 ID DHL80 125 02250195 329...

Page 49: ...GUAGE 10 2 PRESSURE RELIEF VALVE SET 200 PSIG 11 2 CONTROL AIR FILTER 12 1 CONTROL AIR TUBING 1 4 13 2 GAUGE SNUBBER 14 2 OUTLET CHECK VALVE 15 1 PURGE ADJUSTMENT VALVE 16 1 AFTER FILTER PARTICULATE...

Page 50: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 50 8 2 ID DHL150 200 02250195 330...

Page 51: ...GUAGE 10 2 PRESSURE RELIEF VALVE SET 200 PSIG 11 2 CONTROL AIR FILTER 12 1 CONTROL AIR TUBING 1 4 13 2 GAUGE SNUBBER 14 2 OUTLET CHECK VALVE 15 1 PURGE ADJUSTMENT VALVE 16 1 AFTER FILTER PARTICULATE T...

Page 52: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 52 8 3 ID DHL250 300 02250195 331...

Page 53: ...GUAGE 10 2 PRESSURE RELIEF VALVE SET 200 PSIG 11 2 CONTROL AIR FILTER 12 1 CONTROL AIR TUBING 1 4 13 2 GAUGE SNUBBER 14 2 OUTLET CHECK VALVE 15 1 PURGE ADJUSTMENT VALVE 16 1 AFTER FILTER PARTICULATE T...

Page 54: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 54 8 4 ID DHL400 600 02250195 332...

Page 55: ...AGE 10 2 PRESSURE RELIEF VALVE SET 200 PSIG 11 2 CONTROL AIR FILTER 12 1 CONTROL AIR TUBING 1 4 13 2 GAUGE SNUBBER 14 2 OUTLET CHECK VALVE 15 1 PURGE ADJUSTMENT VALVE 16 1 AFTER FILTER PARTICULATE TYP...

Page 56: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 56 8 5 ID DHL800 1000 02250195 333...

Page 57: ...TLET CONNECTIONS 3 RF FLG 6 2 OUTLET CHECK VALVE 7 1 PURGE ADJUSTMENT VALVE 8 1 ORIFICE UNION 9 2 PURGE CHECK VALVE 10 1 PURGE PRESSURE GAUGE 0 200 PSIG 11 2 PRESSURE RELIEF VALVE SET 150 PSIG 12 2 TO...

Page 58: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 58 8 6 ID DHL1250 1500 02250195 334...

Page 59: ...TLET CONNECTIONS 3 RF FLG 6 2 OUTLET CHECK VALVE 7 1 PURGE ADJUSTMENT VALVE 8 1 ORIFICE UNION 9 2 PURGE CHECK VALVE 10 1 PURGE PRESSURE GAUGE 0 200 PSIG 11 2 PRESSURE RELIEF VALVE SET 150 PSIG 12 2 TO...

Page 60: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 60 8 7 ID DHL2000 02250195 335...

Page 61: ...ET CONNECTIONS 3 RF FLG 6 2 OUTLET CHECK VALVE 7 1 PURGE ADJUSTMENT VALVE 8 1 ORIFICE UNION 9 2 PURGE CHECK VALVE 10 1 PURGE PRESSURE GAUGE 0 200 PSIG 11 2 PRESSURE RELIEF VALVE SET 150 PSIG 12 2 TOWE...

Page 62: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 62 8 8 ID DHL2500 3000 02250195 336...

Page 63: ...CHECK VALVE 10 1 PURGE PRESSURE GUAGE 3 1 2 DIA 0 200 PSIG 11 2 1 1 2 NPT PRESSURE RELIEF VALVE 12 2 TOWER PRESSURE GAUGE 3 1 2 DIA 0 200 PSIG 13 1 CONTROL AIR FILTER 14 2 DESICCANT TOWER 15 1 ELECTRI...

Page 64: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 64 8 9 ID DHL3500 4000 02250195 337...

Page 65: ...JUSTMENT VALVE 8 1 ORIFICE UNION 9 2 PURGE CHECK VALVE 10 1 PURGE PRESSURE GAUGE 0 200 PSIG 11 2 PRESSURE RELIEF VALVE 12 2 TOWER PRESSURE GAUGE 0 200 PSIG 13 1 CONTROL AIR FILTER 14 2 DESICCANT TOWER...

Page 66: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 66 8 10 ID DHL4000 5000 02250195 338...

Page 67: ...JUSTMENT VALVE 8 1 ORIFICE UNION 9 2 PURGE CHECK VALVE 10 1 PURGE PRESSURE GAUGE 0 200 PSIG 11 2 PRESSURE RELIEF VALVE 12 2 TOWER PRESSURE GAUGE 0 200 PSIG 13 1 CONTROL AIR FILTER 14 2 DESICCANT TOWER...

Page 68: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 68 8 11 P I DHL80 125 02250195 359...

Page 69: ...VALVE 4 2 ANGLE BODY PURGE EXHAUST VALVE 5 2 PURGE PILOT VALVE 6 2 DESICCANT DRAIN PORT 7 4 STAINLESS STEEL DEFUZER 8 2 PRESSURE VESSELS 9 2 PRESSURE GUAGE 10 2 PRESSURE RELIEF VALVE SET 200 PSIG 11...

Page 70: ...DHL HEATLESS REGENERATIVE DRYER SECTION 8 70 8 12 WD DHL80 5000 02250195 362...

Page 71: ...INLT PILOT SOLENOID VALVE SOL4 RIGHT TOWER INLET PILOT SOLENOID VALVE SOL5 DRAIN SOLENOID VALVE 115 1 60 OR 220 1 50 FS1 OPTIONAL FILTER ELEMENT CHANGE SWITCH INLET FILTER FS2 OPTIONAL FILTER ELEMENT...

Page 72: ...579 1 1 1 Air Outlet Filter Element 02250193 580 1 1 Air Outlet Filter Element 02250193 581 1 1 Air Outlet Filter Element 02250193 582 1 Air Outlet Filter Element 02250193 583 1 x 3 4 6 6 8 8 8 Air O...

Page 73: ...lve 3 4 NUPC205 4 2 Outlet Check Valve 1 NUPC205 6 2 2 2 2 Outlet Check Valve 1 5 NUPC205 8 2 2 Outlet Check Valve 2 NUPC205 9 2 2 2 Outlet Check Valve 3 NDR3150SSSV 2 2 2 2 Outlet Check Valve 4 NDR41...

Page 74: ...74 NOTES...

Page 75: ...NOTES 75...

Page 76: ...U S A Specifications subject to change without prior notice E11EP Always air Always there SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A Telephone 1 219 879 5451 W...

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