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User manual

DTX
Models
DTX0170 - DTX0650
DTX0850 - DTX1530
DTX1680 - DTX4000

(Dryer shown DTX0240)

DTX Heatless Desiccant


Compressed Air Dryers

CONTENTS
1

GENERAL INFORMATION....................................................................................................................... 4
1.1
1.2

PRE-FILTER ............................................................................................................................................. 4
AFTER-FILTER ......................................................................................................................................... 5

INSTALLATION/START UP...................................................................................................................... 5
3.1
3.2

DAMAGE CLAIMS .................................................................................................................................... 4


DRYER SERVICE / ASSISTANCE INFORMATION .......................................................................................... 4

FILTERS ...................................................................................................................................................... 4
2.1
2.2

PAGE

INSTALLATION......................................................................................................................................... 5
START UP ................................................................................................................................................ 6

DESCRIPTION OF OPERATION .............................................................................................................. 7


4.1
4.2
4.3
4.4

DTX DOWNFLOW TYPE DRYER ( DTX 0850 DTX 1530 ).............................................................. 7


DRYER OPERATING SEQUENCE ( NO CONTROL OR ALARM OPTIONS )................................................ 8
DRYER OPERATING SEQUENCE ( WITH DEWPOINT DEPENDANT SWITCHING - DDS OPTION) ............. 9
ALARMS ................................................................................................................................................ 11

MAINTENANCE SCHEDULE.................................................................................................................. 12

TROUBLE SHOOTING ............................................................................................................................ 14

DESICCANT REPLACEMENT............................................................................................................... 15

DRYER SHUTDOWN & STORAGE ...................................................................................................... 16


8.1
8.2

SHUTDOWN .......................................................................................................................................... 16
RE-STARTING THE DRYER ..................................................................................................................... 16

SPARE PARTS.......................................................................................................................................... 17

10

DDS ( OPTIONAL ) ................................................................................................................................... 18


10.1
10.2
10.3
10.4
10.5
10.6
10.7

11

DESCRIPTION OF DDS............................................................................................................................ 18
HOW DDS WORKS ................................................................................................................................. 19
SIMPLIFIED MAINTENANCE ..................................................................................................................... 19
SENSOR MAINTENANCE .......................................................................................................................... 19
EXTENDED WARRANTY .......................................................................................................................... 19
START-UP .............................................................................................................................................. 19
MAINTENANCE ...................................................................................................................................... 20

PURGE FLOW ADJUSTMENT................................................................................................................ 23


11.1
11.2
11.3

PURGE FLOW CALCULATION ......................................................................................................... 23


PURGE PRESSURE CALCULATION ................................................................................................. 23
SETTING THE PURGE PRESSURE ....23

12 WARRANTY............................................................................................................................................... 27
13 DRAWINGS

28

dtxdownflowmanual-rev04sept00
supercedes dtxdownflowmanual -rev03mar99

WARNING:

REMOVE THE MUFFLERS BEFORE START-UP.


USE EAR AND EYE PROTECTION WHEN THE
UNIT IS OPERATING WITHOUT THE MUFFLERS.

DO NOT ADJUST THE PURGE FLOW WITHOUT


CONSULTING DOMNICK HUNTER. INCORRECT
ADJUSTMENT TO THE PURGE FLOW COULD
RESULT IN DAMAGE TO DRYER AND
DEWPOINT LOSS.
IF DDS OPTION HAS BEEN PURCHASED SENSOR
PROBE IS LOCATED IN DESICCANT TUBE IN
CONTROL PANEL. THE PROBE SHOULD NOT BE
INSTALLED UNTIL AFTER DRYER HAS RUN
FOR AT LEAST 1-2 HOUR BREAK-IN PERIOD.
THE DESICCANT FOR THIS DRYER HAS BEEN
SHIPPED SEPARATELY. CHECK THE SPARE
PARTS SHEET OF THIS MANUAL TO
DETERMINE THE CORRECT AMOUNT OF
DESICCANT.

General information
1.1

Damage Claims
Inspect the dryer on receiving for damage that may have incurred during
shipment. In case of damage, immediately enter a damage claim with carrier and
inform domnick hunter.
This manual has been devised to provide basic information on Classic type DTX
DOWNFLOW heaterless air dryers. It should be carefully studied by anybody
involved in the installation, operation and maintenance of the dryer to insure
satisfactory performance of the unit.
It is recommended to keep on hand all recommended spare parts as listed later in
the manual to prevent possible unnecessary downtime of the dryer.
domnick hunter cannot be responsible for any improper functioning of the unit
caused by usage of parts other than those specified in this manual.

1.2

Dryer Service / Assistance Information


When contacting domnick hunter for dryer service/assistance please provide the
following information:
1)
2)
3)
4)
5)

Dryer model number


Dryer serial number
Actual dryer inlet pressure
Actual dryer inlet temperature
The approximate length of dryer service

Filters
2.1

Pre-filter
The pre-filter is perhaps the single most important item determining the long-term
performance of a desiccant type air dryer. It is essential that the pre-filter receive
periodic maintenance. Failure to maintain an efficient pre-filter will produce the
following results:
A)

Damage to the desiccant, i.e. oil contamination is irreparable and will


directly affect the ability of a desiccant dryer to produce an acceptable
dew point. Replacement is the only solution after contamination.

B)

Potential contamination of the after-filter elements which will require


replacement.

C)

Contamination of downstream instrumentation.

Pre-Filter Maintenance
Ensure the pre-filter has a functioning automatic drain installed which receives
daily attention. A pre-filter with a differential pressure reading above 5-PSID
should be replaced. A pre-filter element has an expected life span of between 6
months to 1 year.
2.2

After-Filter
The after-filter is designed to remove dust caused from desiccant movement, it
will protect instrumentation downstream where even minimal dust is not
acceptable. The after-filter element should be replaced when the differential
pressure is greater than 5-PSID. Potential contamination of the after-filter
element will require replacement.

Installation/Start Up
3.1

Installation
3.1.1 Locate the dryer in an environment where the temperature range is
between 40F (4oC) and 120F (49oC). Temperature environments outside
this scope will directly affect the dryers ability to produce dew point.
3.1.2 Do not hydrostatically test the dryer. Classic DTX air dryers are factory
hydrostatically tested to the required design pressure. The dryer has also
been pressure tested at the working pressure with air prior to shipment.
3.1.3 Review the enclosed general arrangement for dryer inlet and outlet
locations at the end of this manual. The inlet piping to the dryer must be
arranged to prevent accumulated entrained water slugging the dryer when
bypassing the pre-filter. The preferred installation is to mount the prefilter bypass line at a higher level than the contaminated air inlet line.
Globe or ball valves are recommended as by-pass valve as they will
provide air/bubble tight sealing.
3.1.4 The purge exhaust may be piped to an open vent. Noise levels at the dryer
may be reduced by extending the purge exhaust piping to a remote
location. Refer to the purge piping selection chart below to prevent back
pressure build-up.

EXTENDED LENGTH PIPE SIZE REQUIRED


TO 10 FEET
TO 25 FEET
TO 50 FEET
TO 100 FEET

SAME SIZE AS DRYER EXHAUST


1 SIZE LARGER THAN DRYER EXHAUST
2 SIZES LARGER THAN DRYER EXHAUST
3 SIZES LARGER THAN DRYER EXHAUST

Extending purge exhaust piping should not affect the back pressure of a
chamber being regenerated. A pressure reading of 3-PSIG is considered
too high and the dryer will not regenerate efficiently.
3.1.5 Connect dryer to a proper electrical supply, review the enclosed electrical
wiring schematic. Install a disconnect switch with overload protection.
Ground the frame of the dryer.
3.1.6 The desiccant for the dryer was shipped separate from the dryer and must
be installed.

The correct quantity of desiccant per tower is noted on the spare parts
sheet.
When filling, rap the tower to ensure the desiccant packs tightly. Do
not tamp the desiccant.
WARNING:

THE DESICCANT SHOULD BE FILLED TO THE


POINT WHERE IT DOES NOT COME IN CONTACT
WITH THE DESICCANT SCREEN

Re-install the fill caps with Teflon tape.

3.1.7 Prior to placing the dryer into operation, verify tightness of tubing joints
and lights that may have loosened during transit. Soap test all joints when
the system is pressurized. Small leaks in the inlet piping will not affect
dryer operation other than the loss of compressed air. However all leaks
in the purge manifold and dryer outlet piping must be repaired to ensure
proper dew point of the outlet air.

3.2

Start Up
3.2.1 Remove purge exhaust mufflers for the initial 1 to 2 hours of operation.
3.2.2 Slowly open the inlet isolation valve to pressurize the dryer. The outlet
isolation valve should remain closed for the initial 1 to 2 hours of
operation preventing moist air from travelling downstream of the dryer.
Allow both chambers to reach line pressure before proceeding.

3.2.3 Energize the electrical circuit by closing the disconnect switch and the
ON-OFF switch on the panel of the dryer. Operate the dryer for 1 to 2
hours.
3.2.4 After 1 to 2 hours of operation, de-energize the electrical circuit of the
dryer at the end of a re-pressurization period. Both towers should be at
equal pressure.
3.2.5 Re-install the purge exhaust mufflers.
3.2.6 Energize the electrical circuit allowing the dryer to cycle and then slowly
open the outlet isolation valve admitting dry air down-stream. When
pressurizing down stream piping the pressure of the dryer should not
drop below 95% of the operating pressure of the dryer.
Note a dryer will take several hours to produce and maintain dew point to
specification.

Description of operation
4.1

DTX DOWNFLOW TYPE DRYER ( DTX 0850 DTX 1530 )


4.1.1. The Classic DTX dryer has a NEMA cycle time of 10 minutes or 4
minutes depending upon the air quality desired. In a 10 minute cycle, 5
minutes is dedicated to drying for each chamber (5 minutes half cycle). In
a 4 minutes cycle, the half cycle is then 2 minutes.
4.1.2. Through the 3-way inlet switching valve wet air enters either desiccant
chamber at the inlet (top) and is dried as it flows downward through the
desiccant bed. Dry air exits the dryer through the outlet check valve.
4.1.3. At the outlet of each chamber, a portion of the dry air (purge air) is
diverted to the regenerating chamber. The dry air, at near atmospheric
pressure, will remove previously adsorbed moisture as it flows upward
through the desiccant bed exiting through the purge exhaust muffler.
4.1.4. The purge air is controlled by a purge adjusting valve and purge orifices
located in the purge line. Purge pressure can be monitored on the optional
purge pressure gauge.
4.1.5. Near the end of each half cycle, the chamber being regenerated will be repressurized. For this to occur, the exhaust valve of the chamber being
regenerated closes while purge air continues to flow. Re-pressurizing the
regenerated chamber to operating pressure before placing it into service
minimizes fluidization of the desiccant and helps prevent desiccant
abrasion which causes desiccant dust to prematurely block pilot and afterfilter elements.
Dryers operating at pressures greater than 120-125 PSIG or in an
accelerated NEMA cycle are fitted with a re-pressurizing valve. This
valve assists the regenerated chamber to reach dryer operating pressure
before chamber switchover.
4.1.6. Chamber switchover takes place when both towers are fully pressurized to
minimize desiccant movement. 3-way solenoid valves control pilot air
directed to the main switching valve actuator (double acting type) and to
the purge exhaust valves.
When switchover is complete, the regenerated tower will be placed into
service and the exhausted tower will begin a depressurization/regeneration
cycle.

4.2

DRYER OPERATING SEQUENCE ( No control or alarm options )

The DTX downflow air dryer uses a Siemens PLC as its standard controller. In
the event of a power failure both exhaust valves will close and the dryer will
pressurize both chambers. Since this control panel uses retentive programming the
dryer will return to the same step in the cycle the dryer was in before power was
lost.
Energizing control panel.
Power is turned ON electrical circuit energized. (SEE NOTE 2)
STEP 1 Select left chamber drying.
De-energize solenoid EV-1L.
Energize solenoid EV-1R.
Inlet valve positioned for left chamber drying.
When 4 seconds have passed, go to STEP 2

STEP 2 Right chamber de-pressurization.


Keep energized EV-1R
Energize EV-2R opening right chamber dump/exhaust valve.
After 10 seconds have passed energize EV-4 opening purge exhaust
valve.
When regeneration time has passed go to STEP 3
STEP 3 Right chamber repressurization.
Keep energized EV-1R.
Deenergize EV-2R closing right chamber dump/exhaust valve.
Deenergize EV-4 closing purge exhaust valve.
Energize EV-3 opening the repressurization valve. The repressurization
timer begins a countdown of 40 seconds. (See Note 1)
Inlet valve remains in current position.
When repressurization time have passed, go to STEP 4

STEP 4 Right chamber drying.


De-energize solenoid EV-1R
Energize solenoid EV-1L.
Inlet valve positioned for right chamber drying.
When 4 seconds have passed, go to STEP 5.

STEP 5 Left chamber depressurization.


Keep energized EV-1L
Energize EV-2L, opening right chamber dump/exhaust valve.
After 10 seconds have passed, energize EV-4, opening purge exhaust
valve.
When regeneration time has passed go to STEP 5.
STEP 6 Right chamber repressurization.
Keep energized EV-1L.
Deenergize EV-2L closing right chamber dump/exhaust valve.
Deenergize EV-4 closing purge exhaust valve.
Energize EV-3, opening the repressurization valve. The repressurization
timer begins a countdown of 40 seconds. (See Note 1)
Inlet valve remains in current position.

The dryer has completed 1 full cycle and will repeat steps 1 through 6 until power
is removed from the control panel.

4.3

OPERATING SEQUENCE (DDS OPTION)


The DTX downflow air dryer uses a Siemens PLC as its standard controller. In
the event of a power failure both exhaust valves will close and dryer will
pressurize both chamber. Since this control panel uses retentive programming the
dryer will return to the same step in the cycle dryer was in before power was lost.
(See NOTE 2)
Energizing control panel
Power is turned ON electrical circuit energized. (SEE NOTE 2)
STEP 1 Select left chamber drying.
De-energize solenoid EV-1L.
Energize solenoid EV-1R.
Inlet valve positioned for left chamber drying.
When 4 seconds have passed, go to STEP 2
STEP 2 Right chamber depressurization.
Keep energized EV-1R
If not in ecotronic mode, energize EV-2R opening right chamber
dump/exhaust valve.
After 10 seconds have passed energize EV-4 opening purge exhaust
valve.
When regeneration time has passed go to STEP 3
STEP 3 Right chamber repressurization.
Keep energized EV-1R.
De-energize EV-2R closing right chamber dump/exhaust valve.
De-energize EV-4 closing purge exhaust valve.
Energize EV-3 opening the repressurization valve. The repress timer
begins a countdown of 40 seconds. (See Note 1)
Inlet valve remains in current position.
When repressurization time have passed, go to STEP 4
STEP 4 Right chamber drying.
De-energize solenoid EV-1R
Energize solenoid EV-1L.

Inlet valve positioned for right chamber drying.


When 4 seconds have passed, go to STEP 5.
STEP 5 Left chamber depressurization.
Keep energized EV-1L
If not in ecotronic mode then energize EV-2L opening right chamber
dump/exhaust valve.
After 10 seconds have passed energize EV-4 opening purge exhaust
valve.
When regeneration time has passed go to STEP 6.
STEP 6 Right chamber repressurization.
Keep energized EV-1L.
De-energize EV-2L closing right chamber dump/exhaust valve.
De-energize EV-4 closing purge exhaust valve.
Energize EV-3 opening the repressurization valve. The repressurization
timer begins a countdown of 40 seconds. (See Note 1)
Inlet valve remains in current position.
NOTE 1:EV-3 and repress valves are used only if dryer operating at pressure
above 120 PSI (G) and / or dryer operating on a timing cycle other than
10 minute cycle.
NOTE 2:If power failure occurs to the dryer or unit is turned off both exhaust
valves will close. The inlet valve will remain in the same position as
before power was removed. The dryer will re-pressurize both chambers
but continue to dry through the same chamber.

NOTE 3:The actual timer setting may differ from the previously noted sequence.
Example: A dryer requiring 30 seconds to re-pressurize the regenerating
chamber will have a regeneration time of 4 minutes and 30 seconds.
The half cycle time will remain at 5 minutes and full cycle at 10
minutes.
NOTE 4:The regeneration and re-pressurization times should be adjusted by
domnick hunter trained personnel only. Changing the factory settings
will result in loss of dew point and/or failure to re-pressurize before
changeover.

4.4

Alarms
** If any alarms options are supplied with dryer then printed circuit board does
not apply. A PLC will control the timing of the dryer.
4.4.1. Common alarm relay
Common alarm relay comes with any optional alarm. If any one of the
alarms are activated, the common alarm relay will also be activated and
remote a dryer failure alarm.
4.4.2. Switching Failure Alarm (Optional, Included with DDS-1 option)
Two pressure switches, sensing desiccant chamber pressure, are provided.
An alarm will be activated if both chambers remain at full pressure when
regeneration is required. Furthermore, if pressure in both chambers
remain below set pressure, after depressurization an alarm will be
activated. In both cases, the dryer will continue to cycle.
NOTE:

Dryers equipped with DDS and operating in the DDS mode do


not depressurize during the purge cycle (and do not purge) when
an acceptable dew point is maintained. During this condition
the switching failure alarm is cancelled.

4.4.3. Low Purge Flow Alarm (Optional, Included with DDS-1 option)
A pressure switch sensing purge pressure upstream of the purge orifice
initiates an alarm if purge pressure falls below an acceptable set point. An
alarm light is provided.
4.4.4. High Humidity Alarm (Optional, Included with DDS-1 option)
The hygrometer provided has been programmed to initiate an alarm if the
dryer outlet dew point falls below the setting. An alarm light is provided.
4.4.5 If the hygrometer board to probe connection fails then a fault will
observed by the hygrometer. The high humidity alarm light will flash on
and off. The dryer will go into a fixed cycle mode.

Maintenance Schedule
Classic DTX heaterless air dryers will give trouble free operation if the following
maintenance schedule is observed.
DAILY

A)

Check pre-filter drain operation.

MONTHLY

A)
B)

Check operating conditions. Check purge rate.


Check pressure drop across each filter ( to be less than 35
kPa 5 PSIG).
Check dryer operation schedule ( follow program steps
listed in Description of Operation section).

C)

EVERY 3 MONTHS

A)
B)

Check outlet dew point.


Blow down relief valves ear and eye protection needed.

EVERY 6 MONTHS

A)

Inspect filter elements. Replace if necessary.

EVERY 12 MONTHS

A) Inspect desiccant and replace if badly broken or


contaminated with oil.
B) Inspect check valve seats.
C) Inspect pilot operated air valves.
D) Inspect solenoid valves.

Maintenance & Examination Record

OWNERSHIP DATA
MODEL NO: ...............................................

COMMISSIONED BY: .........................................

SERIAL NO: ...............................................

COMPANY NAME:..............................................

INSTALLATION DATE: ............................

TELEPHONE NO: ................................................

COMMISSIONING DATE:.........................

SERVICE PLAN: ..................................................

INSPECTION /EXAMINATION
Name

Signature

REPAIR/MAINTENANCE (IF ANY)


Date

Summary Remarks

Trouble Shooting

Problem

Possible Cause

Loss of dew point

3
4

5
6

Solution

Insufficient purge air flow for Check purge flow required and
reactivation or backpressure on adjust purge flow valve.
reactivating chamber.
Inlet air pressure below the Check this condition, the
designed condition.
efficiency of this dryer decreases
as the working pressure decrease.
Inlet air flow higher than the Check the SCFM flow of air
designed condition.
being dried.
Liquids entering the wet air inlet.

Check the incoming line. Inspect


pre-filters and be certain that
automatic traps are not clogged.
Inlet air temperature above the Check the compressor afterdesigned conditions.
cooler and cooling system.
Desiccant broken and coated Replace desiccant and correct the
with oil.
source of trouble.
Check pre-filter.
Mufflers dirty resulting in Replace mufflers.
chamber backpressure.

Excessive pressure drop in filters

Filters dirty.

Replace element(s) as required.

Excessive pressure drop in dryer

Inlet and/or outlet screen dirty

Inspect and clean.

Excessive flow rate.

No input power.

Defective solenoid valves.

Check the SCFM flow of air


being dried.
Check wiring.
Check fuse.
Check for burned coil,
Check for plugged or leaking
valve body.
Clean or replace solenoid plunger
as required.

No pilot air.

Failure to switch

Back pressure on reactivating 1


chamber

Check valves leaking.

Excessive purge flow.

Leaking inlet switching valve.

4
5

Check pilot air line.


Be certain shut-off valve is open
and in-line filter is clean.
Verify O-Ring seats.
Check for foreign material under
seat.
Check required purge flow.

Inspect seats and seals.


Clean and replace as required.
Re-pressurization valve Failed- Inspect and clean or replace as
open.
required.
Depressurizing
and
purge Replace mufflers.
exhaust mufflers plugged.

Desiccant Replacement

Isolate, de-energize and depressurize the dryer unit and prepare a suitable
container to catch desiccant.

Remove the bottom drain plugs and assist the flow of desiccant by rapping on the
tower or by pushing a small diameter rod through the drain port.

When empty re-install the drain plugs using Teflon tape, remove the fill port cap
and proceed to fill the tower. The correct quantity of desiccant per tower is noted
on the specification and data sheet.

When filling, rap the tower to ensure the desiccant packs tightly. Do not tamp the
desiccant.
WARNING:

THE DESICCANT SHOULD BE FILLED TO THE


POINT WHERE IT DOES NOT COME IN CONTACT
WITH THE DESICCANT SCREEN

Re-install the fill caps with Teflon tape, pressurize the system and soap test both
fill and drain ports for leaks.

Return the dryer to service following the procedure listed in section 3.2.

Only use domnick hunter specified/supplied desiccant.

Dryer Shutdown & Storage


8.1

Shutdown

Close outlet isolation valve.

Cycle the dryer for several complete cycles and ensure the pre-filter drain bowl is empty
of any coalesced liquids.

When the dryer is in a re-pressurizing mode, then de-energize the equipment.

Close the inlet isolation valve.

Depressurize the equipment.

!
8.2

CAUTION:
Ensure that the equipment is depressurized.

Re-Starting the Dryer

Disassemble the pre-filter and inspect the element and its seals. Replace if necessary.
Inspect the automatic drain assembly and verify that it is operational.

Disassemble the after-filter and inspect the element and its seals. Replace if necessary.

Repeat the start-up procedure as listed earlier in this manual in section 3.2.

The correct operation of the dryer should be verified at this point to ensure that there are
no leaks caused by dry seals. Any leaks must be corrected at this time.

SPARE PARTS
BASIC DRYER MODEL
DESCRIPTION

DTX0850

DTX1040

DTX1240

DTX1530

SOLENOID VALVE

V005-024

V005-024

V005-024

V005-024

PILOT LIGHT BULB

E004-009

E004-009

E004-009

E004-009

INLET VALVE KIT

V003-001VK1

V003-001VK1

V003-001VK1

V003-001VK1

ACTUATOR KIT

V003-001AK1

V003-001AK1

V003-001AK1

V003-001AK1

V002-065K1

V002-065K1

V002-065K1

V002-065K1

V004-024BK1

V004-024BK1

V004-024BK1

V004-024BK1

V019-006K1

V019-006K1

V019-006K1

V019-006K1

CHAMBER PRESSURE GAUGE

B002-023

B002-023

B002-023

B002-023

RELIEF VALVE

V006-008

V006-008

V006-008

V006-008

EXHAUST MUFFLER

F006-017

F006-017

F006-017

F006-017

920 LBS

1120 LBS

1320 LBS

1700 LBS

PILOT AIR FILTER ELEMENT

K003AO

K003AO

K003AO

K003AO

PREFILTER ELEMENT 0.01 MIC

K430AA

K620AA

K620AA

K620AA

AFTERFILTER ELEMENT 1 MIC.

K430AO

K620AO

K620AO

K620AO

PURGE & CHAMBER PRESSURE GAUGE

B002-012

B002-012

B002-012

B002-012

PREFILTER FLOAT DRAIN

60864

60864

60864

60864

DIFFERENTIAL PRESSURE GAUGE

DPGL

DPGL

DPGL

DPGL

MOISTURE INDICATOR SILICA GEL

M001-007R

M001-007R

M001-007R

M001-007R

MANUAL PURGE CONTROL VALVE KIT


(MPC)

V018-004K1

V018-004K1

V018-004K1

V018-004K1

B002-023

B002-023

B002-023

B002-023

V013-004K1

V013-004K1

V013-004K1

V013-004K1

CONTROL RELAYS 3PDT, 120 VAC

E002-014

E002-014

E002-014

E002-014

POWER LINE FILTER

E009-024

E009-024

E009-024

E009-024

5 AMP FUSE

E009-021

E009-021

E009-021

E009-021

PRESSURE SWITCH

C002-011

C002-011

C002-011

C002-011

HYGROMETER PROBE

J006-032

J006-032

J006-032

J006-032

PURGE VALVE KIT


OUTLET CHECK VALVE SEAT O-RING
DEPRESS VALVE KIT

ACTIVATED ALUMINA
M001-009

P/N

PURGE PRESSURE GAUGE


OPTIONAL
PURGE CONTROL & REPRESS VALVE KIT
(PCR)
DDS I AND II

SPARE PARTS REV01- sept00

10

DDS
10.1

Description of DDS
Classic type DTX DOWNFLOW and DTX UPFLOW Heaterless Air dryers are
designed and selected to provide a specific pressure dew point performance
(generally -40F PDP (-40C PDP)) at the most severe operating conditions
specified. (Maximum flow at lowest pressure and highest inlet temperature). The
purge flow rate required for the regeneration of the dryer is calculated and
adjusted to achieve this dew point and is based on these conditions. For example,
for dryers operating at 100 PSIG (690 kPa) and 100F (38C) the purge flow rate
is approximately 15% of the specified maximum inlet flow.
Substantial savings of purge air can be realized if the inlet conditions to the dryer
are less severe or if the dew point required is higher (wetter) than specified.
Under the following conditions valuable compressed air normally used during
regeneration will be saved. These savings may be substantial if:
The inlet flow to the dryer is lower than specified or intermittent. (For
example lower air demand during night shifts or on weekends).
The inlet pressure is higher than the minimum inlet pressure specified,
consequently the resulting actual inlet flow (ACFM) to the dryer will be
lower.
The inlet temperature is lower than the maximum inlet temperature
specified. The resulting water load to the dryer will be lower.
The dew point required at certain times of operation might be higher
(wetter) than specified. The DDS system provides a field adjustable dew
point setting over the full range of the meter scale thus savings in purge air
can be realized.

10.2

How DDS works


The normal cycle of a heaterless dryer is 10 minutes, i.e. each desiccant tower is
in service for 5 minutes, followed by a 5 minute regeneration cycle. This dew
point can be observed on a direct reading digital display, calibrated in degrees
Fahrenheit or Celsius.
Prior to the start of each regeneration cycle, (that is before depressurization of the
desiccant tower to be regenerated takes place), the DDS electronic controls
diagnose the condition of the outlet of the dryer. Should the dew point reading be
better than the set point, the purge exhaust valve will not open and the purge cycle
will not take place. This results in saving of the air normally dumped to
atmosphere and saving of the purge air normally consumed during regeneration.
The inlet valve will continue to change positions based upon the dryers cycle
time.

10.3

Simplified maintenance
Maintenance of the humidity sensor can be carried out without interrupting dryer
operation or removing desiccant. The DDS sensor is after the after-filter and can
be isolated by a service valve.

10.4

Sensor maintenance
Any hygrometer probe, no matter what type, is subject to contamination by the
gas being monitored. Probe contamination is minimized by locating the sensor
after domnick hunter s high efficiency after-filter. domnick hunter s DDS sensor
can be removed, and returned to the factory for service once a year.
Field calibration of the sensor can be completed by following instruction in the
hygrometer manual.

10.5

Extended warranty
domnick hunter will replace or repair FOB Charlotte, NC any defective DDS
hygrometer board or probe for a period of two years.

10.6

Start-up

10.6.1. Remove the hygrometer probe from the protective desiccant chamber and
immediately install into the flow cell. Do not allow the sensor to be
exposed to atmospheric air longer than necessary. This will increase the
length of time required for the probe to read at the correct dewpoint.

10.6.2. Turn the selector switch to the DRYER ON position. It is recommended


to cycle the dryer for several hours in the "DRYER ON" mode.
10.6.3. Slowly open the air bleed line by opening the sensor isolation valve
downstream of the after-filter. This valve should be opened fully.
10.6.4. Slightly crack open the adjusting valve. This valve is located downstream
of the sensor. This valve should not be opened fully. Only open until a
flow of gas is exiting the flow cell.
10.6.5. Turn the "DRYER" selector switch to "DDS ON position.
The control panel is now considering the dryers outlet dew point prior to
regenerate. Note that the dew point can be read on either DRYER ON
or DDS ON position.
10.6.6. Observe the dryer operation for several cycles.
If the dew point performance of the dryer is better than the dew point
setting, the dryer will not regenerate.
10.7

Maintenance
The DDS electronic controls are free of regular maintenance and should
give years of trouble free operation. Refer to the separate section on the
hygrometer board and probe for maintenance procedures.
Should any trouble be indicated, it is recommended to send the DDS P.C.
board to domnick hunter for trouble shooting.
In this case follow these simple steps.
A)

Switch dryer to "POWER OFF. *

B)

Disconnect all wires from the DDS P.C. board terminal strip (all
wires and terminals are numbered for reconnection). **

C)

Remove the nuts holding the DDS P.C. board in place and remove
the entire assembly.

The dryer will continue to operate on the DRYER ON mode.

CAUTION
While working inside the control panel disconnect electrical power from the dryer.
Put Marrette connectors on all loose wires.

11

PURGE FLOW ADJUSTMENT


REFER TO THE PURGE MANIFOLD DRAWING ENCLOSED ( # 5P102959).
11.1

PURGE FLOW CALCULATION


To determine the required amount of purge flow use the following equations:

Qp = (Q1 X 14.7 X 1.15)


(P1 + 14.7)

WHERE: Q1 = INLET FLOW IN SCFM


P1 = INLET PRESSURE IN PSIG

Qp= QUANTITY OF PURGE FLOW IN SCFM


11.2

PURGE PRESSURE CALCULATION


11.2.1. Choose the purge flow setting chart for the dryer that is being serviced.
Page 24 or 25 of this manual.
11.2.2. Using the flow rate that was calculated in step 11.1 above and the orifice
curve determine the pressure setting required. This will be the pressure
required at the Purge Pressure Adjustment Gauge ( Item 4 on Drawing
5P102959, Page 26 of this manual).

11.3

SETTING THE PURGE PRESSURE


11.3.1. Remove the sealing nut on the purge adjusting valve and prepare a flat
head screwdriver adequate in size to fit the slot of the adjusting screw.
11.3.2. On dryers equipped with the DDS OPTION, ensure that the selector
switch is in DRYER ON POSITION.
11.3.3. The test gauge has been installed on the right hand side of the purge
manifold when facing the control panel. So purge adjustment must be
performed when the right tower is depressurized and in the regeneration
cycle.
11.3.4. By turning the adjusting screw ( Item 6 on drawing 5P102959) on the
manual purge control valve the purge pressure reading on the purge
pressure gauge will increase or decrease. Adjust the screw until the purge
pressure gauge is reading the pressure that was determined in step 11.2.
11.3.5. When the correct purge rate been achieved, re-install the sealing nut on the
adjusting valve and snug the nut to prevent loss of adjustment.

PURGE FLOW SETTING


DTX 0850/DTX1040
7/16" ORIFICE - DTX0850
15/32" ORIFICE - DTX1040

190.0

PURGE FLOW - SCFM

170.0

150.0

130.0

110.0

90.0
40

50

60
PRESSURE - PSIG

70

80

PURGE FLOW SETTING


DTX 1240/DTX1530
9/16" ORIFICE - DTX1530
17/32" ORIFICE - DTX1240
300.0

280.0

PURGE FLOW - SCFM

260.0

240.0

220.0

200.0

180.0

160.0

140.0
40

50

60
PRESSURE - PSIG

70

80

12

Warranty
This warranty applies to dryers and associated pre-filters (the Equipment) manufactured
and supplied by domnick hunter.
Use of the dryer without the recommended genuine domnick hunter manufactured
filtration or genuine parts, will expressly invalidate the warranty.
Should the Equipment by defective as to materials or workmanship, domnick hunter
warrants that it will remedy such defect for a period of 12 months from the date of
dispatch. Where the Equipment is a desiccant dryer, the warranty period will be 12
months from the date of commissioning or 18 months from date of dispatch, whichever is
the earlier, provided such commissioning is carried out by Domnick hunter or its
authorized agent. In the case of Equipment other than a desiccant dryer, the warranty
period shall commence from the date of dispatch. Should any defect occur during the
warranty period and by notified in writing to domnick hunter or its authorized agent
within the said period, domnick hunter will, at its sole option, remedy such defects by
repair or by provision of a replacement part, provided that the Equipment has been used
strictly in accordance with the instructions provided with each item of the Equipment and
has been stored, installed, commissioned, operated and maintained in accordance with
such instruction and good practice. domnick hunter shall not be under any liability
whatsoever under the warranty if, before giving notification in writing to domnick hunter
as aforesaid, the Customer or any third party meddles, interferes, tampers with or carries
out any work whatsoever (apart from normal maintenance as specified in the said
instructions) in relation to the Equipment or any part thereof.
Any accessories, parts and equipment supplied by domnick hunter but not manufactured
by domnick hunter , shall carry whatever warranty the manufacturer has given domnick
hunter provided it is possible for domnick hunter to pass on such warranty to the
Customer.
To claim under the warranty, the goods must have been installed and continuously
maintained in the manner specified in the User Guide. Our Product Support Engineers
are qualified and equipped to assist you in this respect. They are also available to make
repairs that may become necessary in which event they will require an official order
before carrying out the work. If such work is to be the subject of warranty claim, the
order should be endorsed for consideration under warranty.
Any substitution of parts not manufactured or approved by domnick hunter will expressly
invalidate the warranty.

domnick hunter inc


5900-B Northwoods Parkway,
Charlotte, North Carolina,
28269, USA
Tel: (704) 921-9303
Telefax: (704) 921-1960
Toll Free: 1-800-345-8462

domnick hunter Canada inc


4090 Ridgeway Dr. Unit 1
Mississauga, Ontario
L5L 5X5, Canada
Tel: (905) 820-7146
Telefax: (905) 820-5463
Toll Free: 1-888-342-2623

dh and domnick hunter, are registered trademarks


of domnick hunter limited.

domnick hunter limited has a continuous policy of product


development and although the Company reserves the right to change
specifications, it attempts to keep customers informed of any alterations.
This publication is for general information only and customers are
requested to contact our Industrial Division Sales Department for
detailed information and advice on a products suitability for specific
applications. All products are sold subject to the Companys standard
conditions of sale.

a member of the domnick hunter group plc

For the latest information visit the domnick hunter


website on www.domnickhunter.com

Copyright domnick hunter limited 2000