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4.1 Description of operation

Figure 3. Schematic of Dryspell Plus dryer

Compressed air containing moisture and oil droplets enters the pre-filter. Bulk liquids are removed from the air by the pre-
filter. The air then flows through the inlet shuttle valve, which diverts it to tower 1. The desiccant in tower 1 dries the
compressed air to -40°F PDP as it flows through. The dried air leaves tower 1 via the after-filter. A small part (15%) of
the compressed air is passed through the purge orifice by means of opening a two-way purge valve and thereby expanded
till its pressure is near-atmospheric. This expansion of the already-dry gas (purge air) to near-atmospheric pressure increases
its capacity to strip adsorbed water vapour from the desiccant bed in tower 2. The purge-air stream passes through tower
2, removing water vapour from the desiccant. This purge operation is carried out for 1 minute and 30 seconds. Then the
purge valve is closed, and the pressure in tower 2 begins to rise again. The repressurisation is carried out for 30 seconds.
The purge valve is opened, and purge air passes through tower 1.

During the first 2 minutes of each 4-minute cycle of operation, the following processes take place:

l

The online tower (tower 1) dries compressed air for 2 minutes.

l

The offline tower (tower 2) regenerates (adsorbed moisture is removed from the desiccant in it) for 1 minute and 30
seconds.

l

The offline tower is re-pressurised for 30 seconds.

During the next half of the cycle, these processes are repeated with tower 2 being the online tower and tower 1 the offline
tower.

INSTRUCTION MANUAL -

Dryspell Plus

Reference : Manual Version

6

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Summary of Contents for DRYSPELL PLUS 10

Page 1: ...DRYSPELL PLUS Desiccant compressed air dryers Models 10 20 30 45 60 100 125 200 250 300 375 MANUAL ...

Page 2: ...nt compressed air dryer Model refer to name plate Serial number Date of manufacture Date of delivery Date of installation Dealer s name code Dealer s signature and stamp Note The warranty on this dryer is valid only if all the details above are filled in and the vendor stamps and signs this page ...

Page 3: ...matics Private Limited s obligation under this warranty shall be limited to repair or replacement at the discretion of Trident of defective goods returned to Trident s plant within one 1 year from the date of commissioning or 18 months from the date of invoicing whichever is earlier Product Model Serial No Quality Assurance Department Trident Pneumatics Private Limited Coimbatore INSTRUCTION MANUA...

Page 4: ......

Page 5: ...97 23 EC Pressurised equipment l 89 392 CEE Machine safety l 89 336 CEE Electromagnetic compatibility l 73 23 CEE Low voltage l OH6629 5C CRN l UL Listed RoHs compliance INSTRUCTION MANUAL Dryspell Plus Reference Manual Version ...

Page 6: ...nditions 11 5 4 Power 11 5 5 Capacity 12 5 6 Air inlet conditions 12 5 7 Air outlet conditions 12 6 Installation 13 6 1 General 13 6 2 Location 13 6 3 Layout 13 6 4 Air line 13 6 5 Manpower required 13 6 6 Tools required 13 6 7 Procedure 13 7 Operation 14 7 1 Do s and don ts 14 7 2 Turning the dryer on 14 7 3 Running 15 7 4 Shutting down 15 8 Maintenance 16 8 1 Monthly inspections 16 8 2 Semi annu...

Page 7: ...cing the bottom shuttle 33 8 5 3 3 Servicing the exhaust valve 34 8 5 3 4 Servicing the non return valve plate 35 8 5 3 5 Changing the inlet tube 36 8 5 4 Dryspell Plus models 100 125 37 8 5 4 1 Changing the desiccant 39 8 5 4 2 Changing the top shuttle 41 8 5 4 3 Changing the inlet valve assembly 42 8 5 4 4 Servicing the exhaust valve 100 above 44 8 5 5 Dryspell Plus models 200 250 45 8 5 5 1 Cha...

Page 8: ... Dryspell Plus dryers are compressed air drying devices manufactured for industrial other uses Water is invariably found in compressed air in the form of vapour and condensed droplets Dryspell Plus dryers remove this water 1 ...

Page 9: ...The polyethylene covers wrapped around the dryers and the bubble wrapping provided around the controllers are recyclable They must be disposed of in accordance with prevailing environmental laws You will find the following in the shipping carton container 1 Dryer assembly 2 User manual this manual 3 Connectors and others 4 Cleansweep filter user manual if pre filter was obtained from Trident If an...

Page 10: ...tal information regarding the installation operation and maintenance of the dryer All the information illustrations and specifications in this manual are based on the latest product information at the time of preparation of the manual Trident reserves the right to make changes in the product at any time without notice Ensure that this manual is available at all times to the personnel operating you...

Page 11: ...lter is fitted on the side The following are among the major components of your Dryspell Plus l Two desiccant towers l Top and bottom blocks including air seals and check valves l Two solenoid valves l Two inbuilt after filters l One electronic control unit and control panel l One pressure gauge optional l Two silencers INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 4 ...

Page 12: ... be an optional pre filter also If present the pre filter is fitted outside the dryer assembly Figure 2 View of Dryspell Plus dryer without canopy The function of each of the major components is outlined in the following description of the operation of the dryer 5 ...

Page 13: ...er vapour from the desiccant bed in tower 2 The purge air stream passes through tower 2 removing water vapour from the desiccant This purge operation is carried out for 1 minute and 30 seconds Then the purge valve is closed and the pressure in tower 2 begins to rise again The repressurisation is carried out for 30 seconds The purge valve is opened and purge air passes through tower 1 During the fi...

Page 14: ...ctical situations the airflow through the dryer is not maintained at the maximum flow value that the equipment is designed for The moisture load may also vary At such times less purge air may be required to remove the moisture from the desiccant in a tower The amount of purge air used can be reduced by reducing the regeneration time Dryspell dryers feature a purge economising feature that can redu...

Page 15: ...Figure 5 Control panel of Dryspell Plus models 100 125 200 250 300 and 375 INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 8 ...

Page 16: ...on of the pre filter drain only in models 10 20 30 45 and 60 To adjust the purge flow press the button marked PURGE OPTIMIZER continuously for 8 seconds and then set the purge flow to the required value 40 60 80 or 100 Setting the Purge economizer Through front panel Steady conditions To set the purge economizer please refer the tables below Inlet Pressure Correction Factor Temperature Correction ...

Page 17: ...he purge flow is correspondingly reduced This is done changing the purge time The purge flow requirement is governed by the Flow rate Inlet air temperature Air pressure and dew point Purge optimizer setting Percentage of rated flow Pressure correction factor temperature correction factor Dew point correction factor e g In a given system the Pressure is 120 PSI Temperature is 1000F Dew point requir...

Page 18: ...45 999 497 313 49 Dryspell Plus 60 1192 523 313 61 Dryspell Plus 100 1603 439 372 106 Dryspell Plus 125 1913 439 372 119 Dryspell Plus 200 1615 449 582 214 Dryspell Plus 250 1925 449 582 238 Dryspell Plus 300 1615 457 764 256 Dryspell Plus 375 1925 457 764 286 5 3 Operating conditions Maximum pressure 16 bar g 225 psi g Rated operating pressure 7 bar g 100 psi g Rated operating temperature 38 C 10...

Page 19: ...yspell Plus 200 200 Dryspell Plus 250 250 Dryspell Plus 300 300 Dryspell Plus 375 375 5 6 Air inlet conditions Rated operating temperature 38 C 100 F Rated operating pressure 7 bar g 100 psi g Oil should be less than 2 ppm As per ISO 7183 option B rated condition 5 7 Air outlet conditions 40 C 40 F PDP ISO 8573 1 2010 E Class 2 INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 12 ...

Page 20: ...d to sources of heat l The temperature of the room must not exceed 43 C 109 F 6 3 Layout l There must be a minimum distance of 3 feet between the dryer and any other equipment around it that uses electricity 6 4 Air line Figure 6 Bypass arrangement to be provided on air line l Install a system of bypass valves between the dryer inlet and outlet as shown in Figure 6 so that the dryer can be service...

Page 21: ...o not turn on or operate the dryer if there is a leak l Make sure that the dryer s protection rating matches the conditions at your installation l Verify that the voltage of the power supply matches the voltage marked on the data label l Do not operate the dryer at pressures above the maximum allowable limits marked on the data label This label is found on the leg of the dryer Figure 7 Name plate ...

Page 22: ...on Each time that a regeneration tower depressurises a loud noise is produced This occurs every 2 minutes In dryer models with pre filters and electronic auto drains every 4 minutes the valve at the bottom of the pre filter opens automatically and discharges condensate for 4 seconds The cycle times are fixed and cannot be adjusted by the user 7 4 Shutting down Follow this procedure when shutting t...

Page 23: ...ess the problem l Verify that the silencers are not clogged There will be no air flow through a silencer that is clogged A clogged silencer must be replaced with a new silencer The silencer may be removed by unscrewing it Fit the new silencer on the exhaust valve and tighten it 8 2 Semi annual inspections l Verify that the dryer is cycling normally l Verify that the silencers are not clogged l Rep...

Page 24: ...he quantity required Figure 8 Changing the desiccant in the Dryspell Plus range of models types of filling item codes and quantities of desiccant required 8 5 Service procedures The procedures to be followed for servicing replacement of sub assemblies in Dryspell Plus dryers are described in this section Servicing replacement must be carried out when there is failure of the respective parts and if...

Page 25: ...8 5 1 Dryspell Plus model 10 INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 18 DRYSPELL PLUS 10 Drw No PD237 ...

Page 26: ... mm l Discard the top diffuser screens two l Remove the tower assembly The bottom screen fits tightly in the bottom assembly l Discard the O ring 55 4 mm 4 mm l Detach the bottom diffusers by pushing them using the rod passing through the tower Discard the bottom diffusers l Empty the desiccant in the tower l Fill the desiccant tower with Activated alumina CD067A and then Molecular sieves CC447 l ...

Page 27: ...ng an M6 25 bolt l Remove the nozzle O rings 15 4 mm 2 21 mm two and discard them l Clean the chamber base nozzle and replace the two O rings 15 4 mm 2 21 mm two l Remove the shuttle and discard it l Replace it with a new shuttle l Coat the nozzle and all the O rings with food grade grease l Fasten an M6 25 bolt in the chamber base nozzle and draw the bolt out l Secure the chamber base plug with O...

Page 28: ...emove the four socket head cap screws l Remove the top cover l Discard the gasket l Push the piston assembly from below l Discard the piston O ring 28 17 mm 2 62 mm l Clean the piston and install a new O ring 28 17 mm 2 62 mm l Discard the O ring 10 mm 2 62 mm inside the valve body l Coat the piston and O ring with food grade grease l Reassemble the parts replacing the discarded components with ne...

Page 29: ... a no 38 spanner remove the two M3 6 0 cheese head screws l Clean the NRV plate l Replace the rubber ball with a new one l Clean the diffuser connector and re install it l Re install the NRV plate and fasten the cheese head screws INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 22 ...

Page 30: ...aust solenoid valve and prefilter solenoid valve l Remove the dome nuts and spring washers l Remove the top block l Discard the inlet air transfer tube l Discard the O rings 10 6 mm 1 83 mm l Replace the inlet transfer tube with a new one l Fix the inlet tube on the bottom block with new O rings l Replace the top block l Complete the reassembly with the spring washers and dome nuts 23 ...

Page 31: ...8 5 2 Dryspell Plus models 20 and 30 INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 24 DRYSPELL PLUS 20 30 Drw No PD238 PD239 ...

Page 32: ... screen fits tightly in the bottom l Discard the tower gaskets bottom l Remove the old dessicant from the tower l Using the rods passing through the towers push the bottom diffusers to detach them from the towers l Fill the desiccant tower with Activated alumina CD067A and then Molecular sieves CC447 Fix new top diffusers l Reassemble the towers in the bottom chamber Replace the discarded componen...

Page 33: ...5 mm 3 mm and discard it l Remove the end bush l Discard the circlip on the guide bush l Remove the hex screw assembly l Remove the guide bush Discard the O ring 21 92 mm 3 mm l Remove the shuttle and discard it l Remove the shuttle guide and clean it Discard the O ring 21 92 mm 3 mm l Apply grease on the various parts l Reassemble the parts of the assembly replacing the discarded parts with new c...

Page 34: ... unscrew the four socket head cap screws holding the valve assembly together l Remove the top cover l Discard the gaskets AG012 and CD116 l Push the piston assembly from below l Clean the piston Apply food grade grease on the piston l Discard the piston O ring 28 17 mm 2 62 mm l Discard the O ring 10 mm 2 62 mm inside the valve body l Replace the discarded components with new spares Coat the pisto...

Page 35: ...bush using an M6 screw l Discard the guide bush circlip l Draw the hex screw assembly using an M6 25 bolt l Remove the guide bush and guide bush O ring 21 92 mm 3 mm Discard the O ring l Remove the shuttle guide O ring l Discard the top shuttle l Clean and replace the shuttle guide with a new O ring 21 92 mm 3 mm l Reassemble the parts Use new parts in place of the discarded components INSTRUCTION...

Page 36: ...en the dome nuts and remove the washers l Remove the top block with the filter and controller l Discard the inlet air transfer tube l Discard the O rings 10 6 1 83 l Fix a new inlet air transfer tube on the bottom block with new O rings l Fix the top block l Fasten the dome nuts with the washers 29 ...

Page 37: ...8 5 3 Dryspell Plus models 45 and 60 INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 30 DRYSPELL PLUS 45 EXPLODED VIEW Drw No PD240 ...

Page 38: ...31 DRYSPELL PLUS 60 EXPLODED VIEW Drw No PD241 ...

Page 39: ...INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 32 8 5 3 1 Changing the desiccant Figure 19 Changing desiccant Dryspell Plus model 45 Figure 20 Changing desiccant Dryspell Plus model 60 ...

Page 40: ...ant bag assembly firstly with a bag of Activated Alumina AD1398 followed by a bag of mixed Activated alumina and molecular sieves AD1624 as shown in the figure 19 Dryspell Plus model 60 Fill the desiccant bag assembly firstly with 2 bags of Activated Alumina AD1398 AD1622 lastly with a bag of Molecular sieves AD1623 as shown in the figure 20 l Reassemble the top compactor plates and the drying tow...

Page 41: ...6 mm 2 4 mm l Remove the shuttle closer and o ring 39 34 2 62 and discard it Replace it with new one l Remove the shuttle inlet and the shuttle closer l Discard the circlip and replace it with a new circlip l Reassemble the parts Replace the discarded parts with new components 8 5 3 3 Servicing the exhaust valve Figure 22 Exploded view of exhaust valve Dryspell Plus models 45 and 60 INSTRUCTION MA...

Page 42: ...iscard the piston O ring l Clean the piston Coat the piston with food grade grease Reassemble the piston assembly with a new O ring Coat the piston O ring food grade grease before assembly l Discard the O ring 10 mm 2 62 mm inside the valve body l Reassemble the exhaust valve with new components in place of the discarded ones l Replace the plug 8 5 3 4 Servicing the non return valve plate Figure 2...

Page 43: ...using with new components l Fix the NRV housing in the top block and reassemble the parts 8 5 3 5 Changing the inlet tube Figure 24 Changing the inlet tube Dryspell Plus models 45 and 60 l Using a 6 mm Allen key remove the socket head cap screws l Remove the top block with the filter and set them aside l Discard the inlet tube and two O rings l Fix a new inlet tube in the bottom block with new O r...

Page 44: ...8 5 4 Dryspell Plus models 100 125 37 DRYSPELL PLUS 100 EXPLODED VIEW Drw No PD242 ...

Page 45: ...INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 38 DRYSPELL PLUS 125 EXPLODED VIEW Drw No PD243 ...

Page 46: ...8 5 4 1 Changing the desiccant Figure 25 Changing desiccant Dryspell Plus model 100 39 ...

Page 47: ...with the controller l Remove the drying tower gasket and replace with new ones l Remove the top compactor plates two l Remove the old desiccant bags l Clean the drying towers l Filling the Desiccant bag assembly Dryspell Plus model 100 Fill the desiccant bag assembly firstly with 3 bags of Activated Alumina AD1398 followed by a bag of molecular sieves AD1424 as shown in the figure 25 INSTRUCTION M...

Page 48: ...enoid coil inlet valve and pilot air connections 8 5 4 2 Changing the top shuttle Figure 27 Exploded view of top shuttle Dryspell Plus 100 125 l Using circlip pliers remove the circlip B 45 l Using an M12 bolt push the shuttle closer assembly out l Discard and replace the O ring 38 5 mm 3 53 mm in the shuttle closure l Clean the shuttle closer l Take the shuttle guide out of the shuttle housing l ...

Page 49: ...embly l Remove the bottom cover and clean it l Discard the O ring 48 mm 3 0 mm l Remove the M8 hex nut and take out the spacer machined Clean the spacer machined l Remove and discard the poppet moulded AD1059 l Discard the O ring 7 6 mm 2 4 mm l Remove the spacer machined and clean it l Using an Allen key remove the screws at the top of the assembly INSTRUCTION MANUAL Dryspell Plus Reference Manua...

Page 50: ...the two holes l Discard the O ring 12 3 mm 2 4 mm that is exposed l Discard the O ring 37 9 mm 3 53 mm and U ring l Reassemble the guide bush assembly with new components and place it in the valve housing l Grease the stem machined AD1113 and fit it inside the Housing valve AD1535 l Reassemble the stem indicator AD1057 and spacer machined with new O rings and a new poppet moulded l Replace the spr...

Page 51: ...rom the valve housing l Remove M 20 cap screw to remove the adapter cover l Remove the adapter cover and discard the gasket non metal and replace with new one l Push the poppet assembly outside l Replace the O ring 47 2 5 33 andO ring 18 72 3 53 l Reassemble the piston assembly into housing valve l Fix the top adaptor cover l Reassemble the O ring 7 6 2 4 into the housing valve l Reassemble the Se...

Page 52: ...8 5 5 Dryspell Plus models 200 250 45 DRYSPELL PLUS 200 EXPLODED VIEW Drw No PD244 ...

Page 53: ...DRYSPELL PLUS 250 EXPLODED VIEW Drw No PD245 INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 46 ...

Page 54: ...8 5 5 1 Changing the desiccant Figure 30 Changing desiccant Dryspell Plus model 200 Figure 31 Changing desiccant Dryspell Plus model 250 47 ...

Page 55: ...with 3 bags of Activated Alumina AD1398 followed by a bag of molecular sieves AD1424 as shown in the figure 30 Dryspell Plus model 250 Fill the desiccant bag assembly firstly with 3 bags of Activated Alumina AD1398 followed by a bag of mixed Activated alumina and Molecular Sieves AD1425 lastly with a bag of molecular sieves AD1424 as shown in the figure 31 l Replace the top compactor plate with ne...

Page 56: ... and replace the O ring 66 03 mm 3 54 mm in the shuttle closure l Clean the shuttle closer l Take the shuttle guide out of the shuttle housing l Clean the shuttle guide l Discard and replace the O ring 66 03 mm 3 54 mm in the shuttle guide l Replace with new shuttle l Reassemble the parts in the shuttle housing 49 ...

Page 57: ...8 5 5 3 Changing the inlet valve assembly Figure 33 Exploded view of inlet valve assembly Dryspell Plus model 200 250 INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 50 ...

Page 58: ...l Discard the O rings 69 4 mm 5 33 mm and 7 6 mm 2 4 mm and remove the spacer machined l Take out the stem machined AD1089 l Rotate and remove the guide bush using the two holes l Discard the O ring 12 3 mm 2 4 mm that is exposed l Discard the O ring 37 9 mm 3 53 mm and U ring l Reassemble the guide bush assembly with new components and place it in the valve housing l Grease the stem machined AD10...

Page 59: ...8 5 6 Dryspell Plus models 300 375 DRYSPELL PLUS 300 EXPLODED VIEW Drw No PD246 INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 52 ...

Page 60: ...DRYSPELL PLUS 375 EXPLODED VIEW Drw No PD247 53 ...

Page 61: ...8 5 6 1 Changing the desiccant Figure 34 Changing desiccant Dryspell Plus model 300 INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 54 ...

Page 62: ...pilot air connection from the top block assembly l Remove the socket head cap screws M8 40 l Remove the top chamber with the controller l Remove the drying tower gasket and replace with new ones l Remove the top compactor plates Six l Remove the old desiccant bags l Clean the drying towers l Filling the desiccant bag assembly 55 ...

Page 63: ... of mixed Activated alumina and Molecular Sieves AD1425 lastly with a bag of molecular sieves AD1424 as shown in the figure 35 l Replace the top compactor plate with new one l Fix the top block assembly and tighten the cap screws l Connect the solenoid coil inlet valve and pilot air connections l Fasten the towers in the bottom by tightening the screws For changing the top shuttle in dryspell plus...

Page 64: ...8 5 6 2 Changing the inlet valve assembly Figure 36 Exploded view of inlet valve assembly Dryspell Plus model 300 375 57 ...

Page 65: ...ottom plug by using spanner l Discard and replace the o ring 71 2 3 53 l Remove M10 Nylock nut l Remove spacer machined and poppet moulded l Discard and replace the o ring 12 3 2 4 l Remove spacer machined l Remove stem machined AD1861 l Remove guide bush l Discard and replace the o ring 71 2 3 53 and 12 3 2 4 l Discard and replace the u ring l Reassemble all the parts For servicing the Exhaust va...

Page 66: ... elements and other spare parts of the dryer is to be done in accordance with the pollution control norms prevailing at the time of dryer installation or use Dryer parts that are replaced have metal and rubber components These may be disposed in accordance with the pollution control regulations 59 ...

Page 67: ...wer 1 1 Shuttle not closing 1 Clean the shuttle valve 2 Exhaust valve not closing 2 Call Trident for service support Purge loss excessive 1 Outlet shuttle not closing 1 Clean the shuttle 2 Silencer choked 2 Clean the silencer High pressure drop across dryer 1 Pre filter clogged 1 Replace filter elements 2 Dryer overflowing 2 Reduce the flow rate Moisture at the outlet or low 1 Purge economiser mod...

Page 68: ...als and O ring spare kit Dryspell Plus 45 15 AS693 Dryspell Plus 60 Filter element assembly T250P 16 SK286A Seal kit with desiccant Dryspell Plus 60 17 SK222A Exhaust valve spare kit Dryspell Plus 20 30 and 45 18 SK285A Seals and O ring spare kit Dryspell Plus 60 19 AS693 Dryspell Plus 100 Filter element assembly T250P 20 SK272A Desiccant with seal kit Dryspell Plus 100 21 SK266A Shuttle valve ass...

Page 69: ... Plus 100 48 SK243A Seals and O ring spare kit Dryspell Plus 200 and 250 49 AS697 Dryspell Plus 300 Filter element assembly T600P 50 SK276A Desiccant with seal kit Dryspell Plus 300 51 SK270A Shuttle valve assembly spare kit Dryspell Plus 300 52 SK251A Pilot operated valve assembly spare kit 53 AD1540 Inlet valve assembly 54 SK239A Exhaust valve spare kit Dryspell Plus 100 55 AD1541 Exhaust valve ...

Page 70: ...INSTRUCTION MANUAL Dryspell Plus Reference Manual Version 64 Appendix Conversion tables ...

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