Sullair DEX Series, User & Service Manual

Page 1: ...ranty WARRANTY NOTICE USER SERVICE MANUAL HEATED REGENERATIVE DRYERS DEX SERIES PART NUMBER KEEP FOR FUTURE REFERENCE SULLAIR CORPORATION 02250195 404 R00 The information in this manual is current as of its publication date and applies to compressor serial number and all subsequent serial numbers SEHIBAAA 0001 ...

Page 2: ...ed 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 seminars are recommended for maintenance contractor maintenance and service personnel For detailed course outlines schedule and cost information contact SULLAIR TRAINING DEPARTMENT 1 888 SULLAIR or 21...

Page 3: ...CONSTRUCTION 14 3 2 AMBIENT CONDITIONS 14 3 3 OPERATIONAL DATA 14 3 4 PRESSURE VESSEL DESIGN AND CONSTRUCTION DATA 14 3 5 PIPE MANIFOLD DETAILS 15 3 6 ELECTRICAL DATA 15 3 7 TIME PRESSURE TEMPERATURE AND DEWPOINT SETTINGS 15 3 8 DIMENSIONS AND WEIGHT 15 3 9 FILTER MODELS SECTION 4 INSTALLATION SECTION 5 OPERATION 19 5 1 ADSORPTION 19 5 2 REGENERATION 19 5 3 COOLING 19 5 4 TIME CONTROLLED VESSEL CH...

Page 4: ...SYSTEM MAINTENANCE 37 7 1 WITH YOUR DRYER ONLINE 37 7 2 MONTHLY INSPECTIONS 37 7 3 QUARTERLY INSPECTIONS 37 7 4 YEARLY INSPECTIONS 37 7 5 DESICCANT CHANGE OUT 37 7 6 FILTER ELEMENT CHANGE OUT SECTION 8 TECHNICAL DESCRIPTION SECTION 8 OF COMPONENTS 39 8 1 ADSORBER 39 8 2 DESICCANT 39 8 3 HEATER 39 8 4 VALVES 39 8 5 ACTUATORS 39 8 6 REGENERATION BLOWER 39 8 7 PRESSURE GAUGE SECTION 9 SPARE PARTS LIS...

Page 5: ...llair before making any changes that may void the equipment warranty Our after sales service department will be happy to provide advice service or any spare parts that you need Quote the model number serial number and date of manufacture on all correspondence with Sullair This is very important particularly when ordering spare parts Sullair reserves the right to make changes or modifications to th...

Page 6: ...onsibility for direct or indirect damages to persons animals or equipment caused by improper usage or maintenance and it s limited to manufacturing faults only The right to warranty repairs is subordinated to the strict compliance with the installation use and maintenance instructions contained in this manual The warranty will be immediately voided in case of even small changes or alterations to t...

Page 7: ...rial 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 points list some of the important factors dealing with this type of equipment Never make any structural changes to the equipment Use only original spare parts and accesso ries Never weld on any pressure ...

Page 8: ...uish 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 with and changed Danger hazard machine level noise could be higher than 85 dBA It is mandatory to install the machine in dedicated area where people are not normally present The installator and or th...

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 packaging composed of recyclable materials Energy saving design Not to spoil our commitment the user should follow the few ecological suggestions marked with this sign NOTE Text to be taken into account...

Page 10: ...ses 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 Never point the compressed air or the condensate drain jet towards anybody The user is responsible for the installation of the dryer which has to be executed on the basis of the instructions given in...

Page 11: ...ces 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 wall thick ness of the tower after corrosion should not be less than the data indicated on the chart located on the side on the tower 6 Condensate drains should be checked for operation every day to...

Page 12: ...12 NOTES ...

Page 13: ...300 300 230 460 3 60 1 1 2 NPT 40x40x83 1250 DEX 375 375 230 460 3 60 1 NPT 50x44x85 1400 DEX 500 500 230 460 3 60 2 NPT 50x45x90 1600 DEX 650 650 230 460 3 60 2 NPT 50x45x90 1900 DEX 800 800 230 460 3 60 3 FLG 70x 55x 105 2900 DEX 1000 1000 230 460 3 60 3 FLG 70x55x105 4190 DEX 1250 1250 230 460 3 60 3 FLG 80x60x109 4550 DEX 1500 1500 230 460 3 60 3 FLG 80x60x109 5360 DEX 2000 2000 230 460 3 60 3...

Page 14: ...r Condition Free from dirt oil condensation and aggressive contaminants Inlet Flow _____scfm Inlet Pressure 100 psig minimum Adsorption capacity Saturated inlet air at 100 F Outlet pressure dewpoint 40 F with dry air cooling Desiccant type Activated Alumina F 200 Amount per vessel _____lbs Medium Atmospheric air Nominal flow rate _____scfm Regeneration temperature 400 F Regeneration time 180 minut...

Page 15: ... Adsorption time 240 minutes Regeneration time 240 minutes Heating time 140 minutes Cooling time 100 minutes Heater outlet temperature 350 F Regen heater sheath over temp 650 F Adsorption pressure 100 Psig minimum Dewpoint controlled changeover 40 F High Dewpoint alarm setting 32 F Width _____ inches Height _____ inches Depth _____ inches Weight Approx _____lbs Pre filter Model _____ Pre filter el...

Page 16: ...16 NOTES ...

Page 17: ...e regeneration air outlet connection Up to 20 feet long use one size bigger pipe Up to 50 feet long use two sizes bigger pipe DO NOT use plastic pipe as the exhaust temperatures may reach 300 degrees F or hotter It is important that the operating conditions listed in the Specifications are observed Failure to do so may result in premature failure of the desiccant due to low operating pressure or h...

Page 18: ...PSIG Maximum Operating Pressure ________________ PSIG Temperature ________ 100 ________ F Minimum Operating Pressure ________________ PSIG Outlet Dew Point _________ F PDP Above Conditions Maximum Operating Temperature _________________ F Purge Flow __________ PSIG SCFM _____________ Minimum Operating Temperature _________________ F Power Supply _________V_________PH_________HZ Current Draw ______...

Page 19: ... monitored and controlled by a thermocouple and PLC Heater sheath over temperature control is provided by PLC temperature controller Type K thermocouple 5 3 COOLING The cooling process takes place in the same flow pattern as regeneration except the regeneration heater is turned off The cooling cycle will operate until the cooling period time is complete At this point purge exhaust valves will clos...

Page 20: ...e in the open position 4 With the system outlet valve and bypass valves closed slowly open the dryer inlet block valve to pressurize the system Check the complete dryer system for leaks at this time All leaks must be repaired and re tested 5 Verify that all instrument and pilot air tubing fittings are tight and that the pilot air service valve is open 6 With the power on verify that the PLC is in ...

Page 21: ...21 NOTES ...

Page 22: ...DEX HEATED REGENERATIVE DRYER SECTION 5 22 5 9 ID DEX 200 02250195 339 ...

Page 23: ...AUST PILOT SOLENOID VALVE 3 WAY 34 1 TOWER SELECTOR VALVE 4 WAY 2 POS DUAL SOL 35 1 L TOWER DEPRESSURIZATION PILOT SOL VALVE 3 WAY 36 1 R TOWER DEPRESSURIATION PILOT SOL VALVE 3 WAY 37 1 LEFT TOWER DEPRESSURIZATION VALVE 38 1 RIGHT TOWER DEPRESSURIZATION VALVE 39 1 DEPRESSURIZATION EXHAUST MUFFLER 40 1 CONTROL AIR FILTER 41 1 CONTROL AIR PRESSURE REGULATOR 42 1 CONTROL AIR PRESSURE GAUGE 43 2 LEFT...

Page 24: ...DEX HEATED REGENERATIVE DRYER SECTION 5 24 5 10 ID DEX 250 300 02250195 340 ...

Page 25: ...URGE EXHAUST PILOT SOLENOID VALVE 3 WAY 34 1 TOWER SELECTOR VALVE 4 WAY 2 POS DUAL SOL 35 1 L TOWER DEPRESSURIZATION PILOT SOL VALVE 3 WAY 36 1 R TOWER DEPRESSURIZATION PULOT SOL VAVLE 3 WAY 37 1 LEFT TOWER DEPRESSURIZATION VALVE 38 1 RIGHT TOWER DEPRESSURIZATION VALVE 39 1 DEPRESSURIZATION EXHAUST MUFFLER 40 1 CONTROL AIR FILTER 41 1 CONTROL AIR PRESSURE REGULATOR 42 1 CONTROL AIR PRESSURE GAUGE ...

Page 26: ...DEX HEATED REGENERATIVE DRYER SECTION 5 26 5 11 ID DEX 400 600 02250195 341 ...

Page 27: ...OWER PURGE EXHAUST PILOT SOLENOID VALVE 3 WAY 34 1 TOWER SELECTOR VALVE 4 WAY 2 POS DUAL SOL 35 1 L TOWER DEPRESSURIZATION PILOT SOL VAVLE 3 WAY 36 1 R TOWER DEPRESSURIZATION PILOT SOL VALVE 3 WAY 37 1 LEFT TOWER DEPRESSURIZATION VALE 38 1 RIGHT TOWER DEPRESSURIZATION VALVE 39 1 DEPRESSURIZATION EXHAUST MUFFLER 40 1 CONTROL AIR FILTER 41 1 CONTROL AIR PRESSURE REGULATOR 42 1 CONTROL AIR PRESSURE G...

Page 28: ...DEX HEATED REGENERATIVE DRYER SECTION 5 28 5 12 P I DEX 200 3500 02250195 360 ...

Page 29: ... ONLY NOT SHOWN 32 1 ALARM RESET PUSHBUTTON NOT SHOWN 33 1 COMMON ALARM LIGHT RED NOT SHOWN 34 1 TEXT DISPLAY NOT SHOWN 35 1 HEATER TEMP PURGE TEMP CONTROLLER N S 36 1 HEATER HI LIMIT MID RANGE CUTOUT TEMP CONTROLLER N S 37 NOT USED 38 NOT USED 39 NOT USED 40 1 NOT USED 41 1 NOT USED 42 1 NOT USED 43 1 PRESSURIZATION BALL VALVE 44 2 PURGE EXHAUST OPEN SLOW CONTROL VALVE 45 1 HEATER HIGH LIMIT THER...

Page 30: ...DEX HEATED REGENERATIVE DRYER SECTION 5 30 5 13 ELECTRICAL SCHEMATIC TYPICAL EXTERNALLY HEATED See table ...

Page 31: ...TER 5 KW 7 5 F L A 02250195 368 CUSTOMER POWER IN 460VAC 3PH 60HZ TOTAL FLA 15 AMPS HEATER 7 5 KW 11 F L A 02250195 369 CUSTOMER POWER IN 460VAC 3PH 60HZ TOTAL FLA 15 AMPS HEATER 9 KW 13 F L A 02250195 370 CUSTOMER POWER IN 460VAC 3PH 60HZ TOTAL FLA 20 AMPS HEATER 10 KW 15 F L A 02250195 371 CUSTOMER POWER IN 460VAC 3PH 60HZ TOTAL FLA 20 AMPS HEATER 12 KW 17 F L A 02250195 372 CUSTOMER POWER IN 46...

Page 32: ...DEX HEATED REGENERATIVE DRYER SECTION 5 32 5 14 ELECTRICAL SCHEMATIC 02250195 367 ...

Page 33: ...l Wiring Color Solid Red A C Neutral Control Wiring Color Soild White A C Power Wiring Color Solid Black K Type Thermocouple Wire Positive White K Type Thermocouple Wire Negative Red Ground Wire Color Green 2 A C and D C to have Separate Ground Points 3 A C and D C to have Separate Terminal Strips ...

Page 34: ...DEX HEATED REGENERATIVE DRYER SECTION 5 34 ...

Page 35: ...fective Check the operating conditions to see if the motor is operating overloaded as a result of a problem with the blower or motor bearing etc Vessel 1 De pressurization failure The depressurization valve did not open Check the solenoid valves for correct operation Check the valve actuator for correct operation Vessel did not depressurize Check if the depressurization muffler is plugged Vessel d...

Page 36: ...essure during regeneration Compressor not running Check compressor for operation System manual inlet isolation valve closed Check all manual valves upstream of the dryer and open as required Regeneration heater sheath over temperature failure Defective or open circuit thermocouple Replace the thermocouple Low or no regeneration blower flow Check the regeneration blower motor motor overloads and in...

Page 37: ... shaft seals on all ball valves Dismantle the double acting pneumatic actuators Inspect internal components for visual signs of wear and replace parts as necessary Dismantle and inspect solenoid valve inter nal components for visual signs of wear Replace parts as necessary Check the function of all temperature con trols 7 5 DESICCANT CHANGE OUT Depending on the air quality and service conditions t...

Page 38: ...38 NOTES ...

Page 39: ...provide sheath over temperature protection 8 4 VALVES Inlet valves are Piston type Bronze valves dryers up to 650 CFM and High performance Butterfly valves for 800 CFM and up are used for tower switching and are equipped with a Normally open pneumatic actuator Purge Exhaust valves are piston type up to 650 CFM and high performance butterfly valve 800 CFM Valves are equipped with Spring Load Normal...

Page 40: ...40 NOTES ...

Page 41: ...Section 9 41 DEX HEATED REGENERATIVE DRYER SPARE PARTS LIST ...

Page 42: ... 1 1 1 Pressure switch6 30 N3460K41 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Pressure switch 20 120 N3460K61 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Temperature controller NETR 9300 411111 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Control Transformer N 250VA 480X120 1 1 1 1 1 1 1 1 1 1 1 1 1 Control Transformer N 500VA 480X120 1 1 Fuse primary NFNQ R 3 1 1 1 1 1 1 1 1 1 1 1 Fuse primary NFNQ R 5 1 1 1 1 Thermocouple wire Type K T...

Page 43: ...2 Air Inlet valve 6 N400600 11001066 2 Outlet Check Cvalves 1 NUPC205 6 2 Outlet Check Valves 1 1 2 NUPC205 8 2 2 Outlet Check Valves 2 NUPC205 9 2 2 2 2 2 2 Outlet Check Valves 3 NDR3150SSSV 2 2 2 2 2 2 Outlet Check Valves 4 NDR4150WSSSV 2 2 Outlet Check Valves 6 NDR6150WSSSV 2 Purge Check Valves 1 NSCY 100 2 Purge Check Valves 1 1 2 NSCY 150 2 2 Purge Check Valves 2 NSCY 200 2 2 2 Purge Check Va...

Page 44: ...ubing NUP 44 GN 100FT 100FT 100FT 100FT 100FT 100FT 150FT 150FT 150FT 150FT 200FT 200FT 200FT 200FT 200FT DEX Externally Heated Dryers 02250194 329 XXX 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 Applicable Model Number DEX XXXX 0200 0250 0300 0400 0500 0600 0800 0900 1000 1250 1500 2000 2500 3000 3500 Part Description Part Number Qty Qty Qty Qty Qty Qty Qty Qty Qty Qty Qty Qty Qty...

Page 45: ...Section 10 45 DEX HEATED REGENERATIVE DRYER COMPONENT BULLETINS ...

Page 46: ...46 NOTES ...

Page 47: ...NOTES 47 ...

Page 48: ...e 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 WWW SULLAIR COM ...