Refrigerated & Desiccant Compressed Air Dryer Product Selector ASD and HTD Series Refrigerated Dryer Units DD Series Desiccant Dryer Units Service Parts For faster service and to avoid errors, please use the fax as noted below or email us at sales@dvcompressors.com Website: www.dvcompressors.com DV Systems - Canada 490 Welham Road Barrie, ON, Canada L4N 8Z4 Ph: (705) 728-5657 Fax: (705) 728-4974 DV Systems US 128 Talbert Road, Suite B Mooresville, NC 28117 Ph: (704) 799-0046 Fax: (704) 799-0355
Table of Contents. The Purpose for Using a Dryer Unit A Brief Physics Lesson 3 The Purpose of a Dryer 3 DV Systems Compressed Air Dryer Line Refrigerated Dryer and Desiccant Dryer Chart 3 Refrigerated Dryer Units Compressed Air and Refrigeration Circuit 4 Comparison of DV Systems ASD and HTD Dryers 5 Cycling versus Non Cycling Dryers 5 Refrigerated Dryer Basic Information 6 Typical Installation 7 Typical Dryer Operation 8 Most Common Fault Codes 8 Standard Replacement Parts 9 Page Desiccant Dryer Units Dryer Overview 10 Desiccant Dryer Operation 11 Desiccant Dryer Basic Information 11 Standard Maintenance Kits / Parts 12-2 -
The Purpose for Using a Dryer Unit. A Brief Physics Lesson. Though not readily visible, water vapour is present in the atmosphere that we live in. When an Air Compressor is used to increase the pressure of air from atmospheric to something higher, the increase in pressure tends to force the water vapour to condense into water droplets. As there is a great deal of heat present in the compressing of the air, and the warmer the air temperature the more moisture it can hold, the hotter compressed air leaves the Compressor Unit with all the moisture present in a vapour state. In other words, the air has all the moisture in it still in vapour form, none of it has changed to a liquid state. As the compressed air travels through the compressed air system, and cools down to ambient (room) temperature, the water vapour held in the air begins to condense into liquid droplets inside the air lines. The temperature at which the water vapour begins to form into liquid droplets is known as the dew point. The purpose of a Dryer. Air containing moisture may not be harmful to some industries, but it may be very harmful to others. Applications such as the autobody refinish industry and HVAC installations are areas where moisture content (or lack there-of) is very critical, resulting in inferior finishes or damaged controls and componentry. With a Compressed Air Dryer, the compressed air is cooled down to a temperature at which the moisture content is condensed into a liquid state. The key to the Dryer Unit is the ability to dry the air at a dew point temperature below the lowest temperature to which the compressed air will be exposed. With a properly sized and maintained Air Dryer, and coupled with suitable filtration, moisture at your point of use will be non-existent. With a Compressed Air Dryer: Tool life will increase while tool maintenance will be reduced. Air consumption will be reduced. More air is used when it contains water, oil, etc in order to blow out sludge. Production will be increased. Workers can use their tools immediately, as there is no need to purge water or contaminants from the air lines. Piping life is extended indefinitely as internal water corrosion is eliminated. Production quality is improved and maintained there. Poor air quality may cause poor product quality, increased rejects, and production shut-downs because of malfunctioning controls and tools. Trap maintenance down-stream of your Air Dryer is almost eliminated. New installations will not require pitched air lines, drop legs, traps, or drains. DV Systems Compressed Air Dryer Product Line. DV Systems offers (2) types of Compressed Air Dryers, namely the Refrigerated Dryers and the Desiccant Dryer lines. Though the Units achieve the same goal and are thus similar in that way, there are also notable differences in how that goal is attained. Refrigerated Air Dryer Desiccant Air Dryer Minimum Dew Point Achieved: Approx. 1 C (33 F) Approx -40 C (-40 F) Type of Medium Used: Freon Refrigerant Desiccant Beads Refrigerant Compressor Twin Desiccant Towers Power Requirement: To 100 CFM: 115-60-1 115-60-1 150 CFM to 400 CFM: 230-60-1 500 CFM+: 460-60-3 Central Processor: Programmable Control Board Programmable Logic Relay - 3 -
Refrigerated Dryer Units. Compressed Air and Refrigeration Circuits. As indicated on the chart on the previous page, the Refrigerated Air Dryers use Freon to cool the compressed air down to approximately 1 C. Noted below is the process in which the air is cooled and the moisture removed. As shown below, the compressed air: enters the Dryer Unit and passes through the Heat Exchanger. as the air is cooled, water vapour is condensed into water droplets. the water droplets collect in the Condensate Separator and Tubing, and are evacuated from the Dryer by means of the Electronic Autodrain. In the Refrigeration Circuit: the Low Pressure/Low Temperature Liquid Refrigerant ❶ enters the Air to Refrigerant Heat Exchanger where a) it cools the compressed air and b) heat from the compressed air causes the Refrigerant to boil, vapourizing into a liquid the Low Pressure/High Temperature Gas ❷ flows to the Compressor in the Compressor, the Freon Refrigerant is converted to a High Pressure/High Temperature Gas ❸. It then enters the Condenser where it is cooled to a High Pressure/Low Temperature Liquid ❹. The Refrigerant then travels through the Capillary Tube (or Expansion Valve) which decreases the pressure of the Refrigerant making it a Low Pressure/Low Temperature Liquid Heat Exchanger 1 Air to Air 2 Air to Refrigerant Compressed Air Out ❶ 2 1 Capillary Tube or Expansion Valve Compressed Air In Condensate Separator ❷ Moisture Outlet Refrigerant Compressor ❹ ❸ Condensate Tubing Electronic Autodrain Refrigerant States Condenser And Fan ❶: LP/LT Liquid ❷: LP/HT Gas ❸: HP/HT Gas ❹: HP/LT Liquid - 4 -
Refrigerated Dryer Units (cont d). Comparison of DV Systems ASD and HTD Dryers. Within the DV Systems Refrigerated Dryer Unit category, there are two types of Dryers as indicated below. The chart differentiates between the two Dryer types. ASD Refrigerated Dryer HTD Refrigerated Dryer Refrigerant Dew Point 1 C 4 C (33 F 39 F) 3 C (37 F) Maximum Inlet Temperature 49 C (120 F) 83 C (180 F) Suggested Length of Pipe to Dryer Approx. 20 feet Minimum 3 to 4 feet Maximum Inlet Pressure Controls Available 232 psig (16 Bar) up to ASD100 203 psig (14 Bar) ASD150 to 320 174 psig (12 Bar) ASD400 & 500 Controlled by Microprocessor Digital Dew Point Indicator Some Unit parameters adjustable 232 psig (16 Bar) Controlled by Microprocessor Digital Dew Point Indicator Some Unit parameters adjustable Initial In-Line Air Strainer 3 Micron Suggested 3 Micron Suggested Internal Filter High Efficiency Stainless Steel High Efficiency Stainless Steel Internal Autodrain Yes, Electronic Yes, Electronic Internal Aftercooler No Yes 1. Maximum Inlet Temperature is the maximum allowable temperature of the compressed air to enter the Dryer Inlet. 2. Suggested Length of Pipe to Dryer is simply the suggested amount of piping required between the Compressor Outlet and Dryer Inlet to ensure the temperature of the compressed air does not exceed the Maximum Inlet Temperature. 3. Maximum Inlet Pressure is the maximum allowable air pressure entering the Dryer Unit. 4. Initial In-Line Strainer is a pre-filter to the Dryer Inlet, and would remove large contaminants from the compressed air before entering the Dryer. The Strainer must be purchased separately. 5. Internal Filter separates the water from the compressed air after the compressed air has been cooled. 6. Internal Autodrain drains the moisture from the Dryer. 7. Internal Aftercooler is a means of pre-cooling the compressed air immediately after it enters the Dryer Unit. It allows the Unit to be located closer to the Compressor Unit. Cycling versus Non Cycling Dryer Units. There are two basis designs for Refrigerated Air Dryers. Though DV Systems Units are considered Non Cycling Dryers, it is useful to know both designs and how they differ. Non Cycling Dryers: Continually circulate refrigerant through the system When there is a steady flow of compressed air through the Unit, the Refrigerant Compressor will operate constantly. A period of reduced load will either: o Cause a change in the regulation of the refrigerant in the Unit or o Put the Unit into a sleep mode. Cycling Dryers: Uses Refrigerant to cool an internal thermal mass (commonly liquid glycol). The Refrigerant Compressor works intermittently, starting only when the mass temperature has increased. Though there may be some energy savings, the purchase price of these Units is somewhat more expensive. - 5 -
Refrigerated Dryer Units (cont d). Refrigerated Dryer Basic Information. Noted in the charts below is basic information concerning both the ASD and HTD Series of DV Systems Refrigerated Air Dryers. This information is helpful for both ordering a Unit and ensuring the installer is aware of the requirements. ASD Series of Refrigerant Dryer. Model: SCFM Air Compressor HP Electrics Full Load Current Inlet/Outlet Ports Weight ASD10 10 <5 HP 2.21 A 3/8 18 kg/40 lb ASD15 15 5 HP ASD30 30 5, 7½ HP 2.91 A 27 kg/60 lb 115-60-1 ½ ASD40 40 10 HP 5.24 A 28 kg/62 lb ASD60 60 15 HP 6.96 A 35 kg/77 lb ¾ ASD100 100 20, 25, 30 HP 9.82 A 47 kg/104 lb ASD150 150 40 HP 7.35 A 87 kg/192 lb ASD200 200 50 HP 1½ NPT 230-60-1 ASD320 320 75 HP 13.5 A 110 kg/243 lb ASD400 400 11.4 A 120 kg/264 lb ASD500 500 100 HP 2 130 kg/286 lb 460-60-3 5.46 A ASD600 600 150 kg/330 lb HTD Series of Refrigerant Dryer. Model: SCFM Air Compressor HP Electrics Full Load Current Inlet/Outlet Ports Weight HTD18 18 5 HP 5.24 A 28 kg/62 lb HTD26 26 7½ HP 2.95 A 38 kg/ 84 lb 115-60-1 ½ HTD37 37 10 HP 5.24 A 39 kg/86 lb HTD52 52 15 HP 5.24 A 39 kg/86 lb - 6 -
Refrigerated Dryer Units (cont d). Typical Installation. Shown below are minimal clearances (in red) that should be maintained around a Refrigerated Dryer. It is critical that there be sufficient room around and above the Unit to ensure that there is good air flow through and around the Unit. Many issues are caused by the Unit over-heating, this caused by it being installed too closely to any adjacent wall, etc. Also: Place the Dryer in a cooler part of the shop. The refrigeration system requires relatively cool air to function at its optimum. When placed in a warmer environment, the refrigeration system must work much harder to cool the compressed air, thus becoming less efficient. The Unit should not be located in a dusty environment. The interior of the Dryer contains items that must be kept clean to work efficiently. Any build-up of dust and debris will limit the operation of the Unit, and may cause failure. Locating the Unit on a suitable pedestal will ensure that floor dust is not drawn into the Unit. As noted previously, the compressed air lines should have a 3 Micron Separator Filter (as indicated below) installed between the Air Compressor and the Refrigerated Dryer Unit. The Separator Filter will act as a pre-filter to the Dryer collecting any bulk liquids and solids 10 micron and larger. The Separator Filters are sold as the Canister and Filter Element separately, and are available in a variety of sizes to suit the Unit CFM. Bypasses c/w Ball Valves Clean, Dry Air 36 Min 18 Min 18 Min 6 Min Compressed Air From Compressor SAF-C Canister + SAF-S 3 Micron Element Compressed Air Dryer - 7 -
Refrigerated Dryer Units (cont d). Typical Dryer Operation. The typical Refrigerated Air Dryer will operate as follows: Pressing the On/Off Button for 3 seconds will start the Unit There is a delay of up to 2 minutes before the Refrigerant Compressor starts. The Condenser Fan will start approx. 30 seconds there-after. The Fan will not normally run at full speed, this indicated by a flashing LED The readout will initially show ambient temperature indicated by 3 horizontal bars on the readout Once the Fan and Compressor start, the dew point of the Unit will decrease to approx. 1 C, this indicated by 1 or no horizontal bars. Once at approx. 1 C, the Fan will stop, only to be called to run again once the temperature increases to approx. 5 C Pressing the On/Off Button (when the Unit is operating) will run the Fan at full speed for several seconds, after which the Unit will stop. (The LED will be on continually while the Fan runs at full speed.) O N The Unit is ON with a normal load and is operating correctly. As well as showing the dew point, the readout may indicate several fault codes as suggested below. Most Common Dryer Faults. The readout will indicate a variety of fault codes, the most common being as follows: E S A Energy Saving Mode. The Dew Point has been running at below -1 C for over 6 minutes. The Unit will automatically restart operation at 6 C. P F I Temperature Probe Alarm. The Temperature Probe is not working properly. It may not be connected to the Board, or the Probe may be defective. Replace the Probe if necessary. H t A High Temperature Alarm. The Dew Point has been running at above 12.5 C for over 6 minutes. The Unit must be manually turned off and on. The fault could be caused by a dirty radiator, high ambient temperature, a faulty Fan, or a faulty refrigerant Compressor, to name only a few. The manual which accompanies the Unit has a complete listing of the faults. - 8 -
Refrigerated Dryer Units (cont d). Standard Replacement Parts for Current Models. Part Number: Description: ASD Series Dryers HTD Series Dryers 10 15 30 40 60 100 150 200 18 26 37 52 RD-210.0053.00 Fan Motor RD-210.0113.00 Fan Motor RD-210.0146.00 Fan Motor RD-210.1958.00 Fan Motor & Blade * * RD-240.0106.00 Drain Valve Assy RD-240.0108.00 Drain Valve Assy RD-243.0034.02 Temperature Probe RD-305.0055.01 Control Board RD-305.0063.01 Control Board * Note: For ASD150 and ASD200 Units having R407C Refrigerant, use Fan Motor RD-210.1960.00 Current Models have serial numbers equal to or greater than the following: Model Number: Serial Number: Model Number: Serial Number: ASD10 07M-013988 HTD18 07M-008405 ASD15 07M-008319 HTD26 07M-008112 ASD30 07M-007142 HTD37 07M-008109 ASD40 07M-008427 HTD52 07M-003557 ASD60 07M-008417 ASD100 07M-007173 ASD150 07M-003068 ASD200 07M-016998 Standard Replacement Parts for Older Models. Part Number: Description: ASD Series Dryers HTD Series Dryers 15 30 40 60 100 150 200 18 26 37 52 RD-210.0053.00 Fan Motor RD-210.0146.00 Fan Motor RD-210.1958.00 Fan Motor & Blade RD-240.0106.00 Drain Valve Assy RD-240.0108.00 Drain Valve Assy RD-243.0034.02 Temperature Probe RD-305.0050.02 Control Board RD-906.0217.03 Control Board RD-305.0063.01 Control Board - 9 -
Desiccant Dryer Units. Dryer Overview. As indicated on the chart on page 3, the Desiccant Dryers use Desiccant Beads (also termed as Activated Alumina ) to trap the moisture while bringing the dew point down to approximately -40 C (-40 F). Shown below are front and rear views of a typical Desiccant Dryer Unit. Moisture Indicator Pressure Gauges (for LH & RH Towers) Controls include LED s and Start/Stop Switch Outlet Filter Desiccant Towers containing Beads Purge Valves and Silencers Inlet Valves Inlet Filter - 10 -
Desiccant Dryer Units (cont d). Desiccant Dryer Operation. The Desiccant Dryer operation consist of four stages as follows: Drying Stage. The compressed air enters the Inlet Filter containing a High Efficiency Coalescing Filter Element which removes dirt particles 0.01 micron and larger, and 99+% of oil aerosols. The air then enters and flows upwards in the Desiccant Tower. As it flows upwards, it comes in contact with the Desiccant Beads, at which time the moisture in the compressed air is attracted to and adsorbed onto the surface of the Beads. The adsorbing is a heat releasing process that later contributes to the cleaning process. The cool, dry air exits the Tower and flows through the Outlet Filter containing a Coalescing Filter which removes dirt particles 1.0 micron and larger, and 99+% of water condensate. Regeneration Stage. As the one Tower is in the Drying Stage as indicated above, the second Tower is in the Regeneration Stage. A small percentage (approximately 15%) of the air travelling through the Drying Stage is redirected to the second Tower where it is used to release the moisture from the Desiccant Beads. The compressed air is allowed to escape from the Tower by way of a Purge Valve and Silencer. Repressurization Stage. Once the Regeneration Stage has taken place in the second Tower, the Purge Valve is closed, and the second Tower becomes pressurized. Changeover / Depressurization Stage. After the second Tower has been completely repressurized, the Controller signals the Valves to switch operation. The Tower that had been in the Drying Stage enters the Regeneration Stage. The Tower that was in the Repressurization Stage enters the Dryer Stage. Approximate Dryer Cycle Times are as follows: Complete Cycle: 10 minutes Drying Stage: 5 minutes Regeneration Stage: 4 minutes 15 seconds Repressurization Stage: 45 seconds Desiccant Dryer Basic Information. Noted in the chart below is basic information for the DV Systems Desiccant Air Dryers. Model: CFM @ 100 psig Air Compressor HP Electrics Power Consump. Inlet/Outlet Ports Weight DD-28-00 28 <10 HP ½ NPT 66 kg/145 lb DD-37-00 37 10 HP DD-60-00 60 15 HP ¾ NPT 109 kg/240 lb 115-60-1 40 Watt DD-80-00 80 20 HP 112 kg/245 lb DD-100-00 100 25 HP 1 NPT 142 kg/311 lb DD-115-00 115 30 HP - 11 -
Desiccant Dryer Units (cont d). Standard Maintenance Kits / Parts. Item: Description: DD-28 DD-37 DD-60 DD-80 DD-100 DD-115 DD-00105 Maintenance Kit DD-00106 Maintenance Kit DD-00107 Maintenance Kit DD-00100 DD-00101 DD-00102 DD-00103 DD-00104 Maintenance Kit for Inlet Switch Valve Maintenance Kit for Repress. Valve Maintenance Kit for Inlet Switch Valve Maintenance Kit for Inlet Switch Valve Maintenance Kit for Repress. Valve DD-00033 Desiccant (50 lb Bag) (1) Req d (1) Req d (1) Req d (1) Req d (2) Req d (2) Req d Maintenance Kits DD-00105 and DD-00106 include: (1) SAF-A 1.0 Micron Filter Element (1) SAF-E 0.01 Micron Filter Element (2) DD-00009 Filter Silencer (100) DD-00033 Desiccant Beads (in lbs) Maintenance Kit DD-00107 includes: (1) SAF-A 1.0 Micron Filter Element (1) SAF-E 0.01 Micron Filter Element (2) DD-00009 Filter Silencer (150) DD-00033 Desiccant Beads (in lbs) - 12 -