Gardner Denver SPX FLOW DHP Series User manual

DHP Series
High Pressure Refrigerated Type Compressed Air Dryer
Models: DHP130, DHP200, DHP300, DHP500, DHP750, DHP1000
FORM NO.: 5003971 REVISION: 07/2016 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
INSTRUCTION MANUAL

CONTENTS
GENERAL SAFETY INFORMATION................................................................................................ 1
RECEIVING, MOVING, AND UNPACKING ...................................................................................... 1
1.0 INSTALLATION .......................................................................................................................... 2
1.1 Location ..................................................................................................................................................... 2
1.2 Mounting ..................................................................................................................................................... 3
1.3 Piping Connections ..................................................................................................................................... 3
1.4 Electrical Connections ................................................................................................................................. 3
1.5 Moisture Separator ..................................................................................................................................... 3
2.0 OPERATION ............................................................................................................................... 4
2.1 Minimum/Maximum Operating Conditions ................................................................................................... 4
2.2 Start-up ........................................................................................................................................................ 4
2.3 Timer Drain .................................................................................................................................................. 4
2.4 Timer Drain Programming Mode.................................................................................................................. 5
2.5 Operating Check Points .............................................................................................................................. 5
3.0 MAINTENANCE.......................................................................................................................... 6
3.1 Daily............................................................................................................................................................. 6
3.2 Weekly ......................................................................................................................................................... 6
3.3 Monthly ........................................................................................................................................................ 6
3.4 Annually ....................................................................................................................................................... 6
4.0 TROUBLESHOOTING GUIDE ................................................................................................... 7
5.0 REFERENCE.............................................................................................................................. 8
5.1 Sizing ........................................................................................................................................................... 8
5.2 Engineering Data ......................................................................................................................................... 9
6.0 DIMENSIONS / WEIGHTS.......................................................................................................... 10
7.0 DRAWINGS ................................................................................................................................ 11
7.1 Process Gas / Refrigeration Flow Diagram: Models DHP130 and DHP200............................................... 11
7.2 Process Gas / Refrigeration Flow Diagram: Models DHP300 through DHP1000....................................... 12
7.3 Wiring Diagram: Models DHP130 and DHP200 (115 or 208-230V/60 Hz, 100 or 240V/50 Hz) ................. 13
7.4 Wiring Diagram: Models DHP300 through DHP750 (230-400-460V/3/50-60 Hz) ...................................... 14, 15
7.5 Wiring Diagram: Model DHP1000 (230-400-460V/3/50-60 Hz).................................................................. 16, 17
7.6 Wiring Diagram: Models DHP300 through DHP1000 (575-460/3/60 Transformer Pack) ........................... 18
8.0 REPLACEMENT PARTS LIST ................................................................................................... 19
8.1 Replacement Parts ...................................................................................................................................... 19
8.2 Maintenance Kits ......................................................................................................................................... 19
WARRANTY...................................................................................................................................... 21

1
GENERAL SAFETY INFORMATION
1. PRESSURIZED DEVICES:
This equipment is a pressure containing
device.
• Donotexceedmaximumoperating
pressure as shown on equipment
serial number tag.
• Makesureequipmentisdepressurizedbeforeworking
on or disassembling it for service.
2. ELECTRICAL:
This equipment requires electricity to
operate.
• Installequipmentincompliancewithall
applicable electrical codes.
• Standardequipmentissuppliedwithelectrical
enclosures not intended for installation in hazardous
environments.
• Disconnectpowersupplytoequipmentwhenperforming
any electrical service work.
3. BREATHING AIR:
• Airtreatedbythisequipmentmaynot
be suitable for breathing without further
purication.
Refertoapplicablestandardsandspecicationsforthe
requirements for breathing quality air.
RECEIVING, MOVING, AND UNPACKING
A. RECEIVING
This shipment has been thoroughly checked, packed and
inspectedbeforeleavingourplant.Itwasreceivedin
good condition by the carrier and was so acknowledged.
CheckforVisibleLossorDamage.Ifthisshipmentshows
evidence of loss or damage at time of delivery to you, in-
sist that a notation of this loss or damage be made on the
delivery receipt by the carrier’s agent.
B. UNPACKING
Check for Concealed Loss or Damage. When a shipment
has been delivered to you in apparent good order, but
concealed damage is found upon unpacking, notify the
carrier immediately and insist on his agent inspecting the
shipment. Concealed damage claims are not our respon-
sibility as our terms are F.O.B. point of shipment.
C. MOVING
Inmovingortransportingdryer,donottipdryerontoits
side.
D. STORAGE/SHUT DOWN
Dryer should not be stored outside (either
packed or unpacked) or exposed to the weather. Damage to
electrical and control components may result.
IMPORTANT: WATER-COOLED UNITS-Iftheunitisshut
down in below freezing temperatures, the water-cooled con-
denser may freeze and cause permanent damage. Condenser
must be drained when the unit is shut down.
IMPORTANT: Do not store dryer in temperatures above 130°F
(54.4°C).

2
IMPORTANT:READPRIORTOSTARTINGTHISEQUIPMENT
1.0 INSTALLATION
1.1 Location
A. For typical placement in a compressed air system, see
drawing.
B. Air compressor intake – Locate air compressor so that
contaminants potentially harmful to the dryer (e.g. ammo-
nia) are not drawn into the air system.
C. Free Air Flow Clearances
Front: 36 inches (914 mm)
Back: 6 inches (152 mm)
Sides: 36 inches (914 mm)
Service - To facilitate maintenance leave 36 inches
(914 mm) of clearance in front of dryer.
D. Standard units are designed to operate in ambients:
Air-cooled: 40 to 110°F (4 to 43°C).
Water-cooled: 40 to 130°F (4 to 54°C).
E. Installationsinaltitudesabove4500feet(1370meters)
– Dryer is adjusted to operate in altitudes up to 4500 feet
(1370meters).Ifdryerisinstalledinanaltitudeabove
this, and has not been preset at the factory for this altitude,
contact manufacturer’s Service Department.
There shall be no external forces or vibrations
transmitted to the dryer inlet/outlet connections from the piping.
External piping must be properly supported. The installation of
aexibleconnectionorvibrationdampener,withintheair/gas
stream, prior to the dryer is recommended to further reduce the
possibility of damage from vibration or pulsations. Failure to do
so may void the warranty.
NOTE: Outdoor installation – Standard units are designed for
indoor installation. Contact manufacturer if installing outdoors.
Aftercooler
Separator
Dryer
Oil Removal
Filter
Compressor
Air Outlet
Air Inlet
Control Panel
Moisture Separator
Electric Timed Drain
w/3-Way Valve
(Standard)
Condenser
230-VAC Electrical Entry
120-VAC Electrical Cord
Drain Outlet
Drain Outlet
Models: DHP300 Through DHP750 Only
Drain Outlet for DHP1000
on rear panel.
Air Outlet
Air Inlet
Control Panel
Moisture Separator
Electric Timed Drain Assembly
w/3-Way Valve
Water Inlet Connection
Models: DHP300 Through DHP1000
(W/C Models Only)
Water Outlet Connection
Models: DHP300 Through DHP1000
(W/C Models Only)
Condenser
Primary Electrical Entry
Secondary Electrical Entry
Models
DHP130 and DHP200
Models
DHP300, DHP500, DHP750, and DHP1000

3
1.2 Mounting
Mount the dryer on a level solid surface. Holes are provided in
thedryerbasetopermanentlymountthedryertotheoor.
1.3 Piping Connections
A. AirInlet-Connectcompressedairlinefromairsource
to air inlet. (Reference markings on dryer or see call out
drawing on page 10 for air inlet/outlet connection loca-
tions.)
NOTE:Useback-upwrenchwhenmakingpipingconnec-
tions.
There shall be no external forces or vibrations
transmitted to the dryer inlet/outlet connections from the piping.
External piping must be properly supported. The installation of
aexibleconnectionorvibrationdampener,withintheair/gas
stream, prior to the dryer is recommended to further reduce the
possibility of damage from vibration or pulsations. Failure to do
so may void the warranty.
RefertoSerialNumberTagformaximum
working pressure. Do not exceed dryer’s Maximum Working
Pressure.
NOTE:Installdryerinairsystemathighestpressurepossible
(e.g. before pressure reducing valves).
NOTE: Installdryeratcoolestcompressedairtemperature
possible. Maximum inlet compressed air temperature: 120°F
(49°C).Ifinletairexceedsthistemperature,precooltheair
with an aftercooler.
B. Air Outlet – Connect air outlet to downstream air lines.
NOTE:Useback-upwrenchwhenmakingpipingconnec-
tions.
There shall be no external forces or vibrations
transmitted to the dryer inlet/outlet connections from the piping.
External piping must be properly supported. The installation of
aexibleconnectionorvibrationdampener,withintheair/gas
stream, prior to the dryer is recommended to further reduce the
possibility of damage from vibration or pulsations. Failure to do
so may void the warranty.
C. Bypasspiping–Ifservicingthedryerwithoutinterrupting
the air supply is desired, piping should include inlet and
outlet valves and an air bypass valve.
D. Water cooled models – cooling water inlet and outlet
1. Connect cooling water supply to cooling water inlet.
2. Connect cooling water return line to cooling water
outlet connection.
NOTE: Strainer and water regulating valve are supplied on
water cooled models.
1.4 Electrical Connections
IMPORTANT:Usecoppersupplywiresonly.
A. Dryer is designed to operate on the volt-
age, phase, and frequency listed on the
serial number tag.
B. Ifdryerissuppliedwithacordandplug,
install in a receptacle of proper voltage.
C. Electrical entry on larger dryers is through a hole in the
cabinet.Itislocatedontherightsidepanelwhenfacing
the front of the unit. Connect power source to terminal
strip in electrical enclosure as shown on the wiring dia-
gram included with the dryer.
NOTE: Refrigeration condensing unit is designed to run con-
tinuously and should NOT be wired to cycle on/off with the air
compressor.
1.5 Moisture Separator
A. Separator has an external drain which auto-
matically discharges collected condensate.
NOTE:Itmaybedesirabletopipethecon-
densate from the Automatic Drain outlet to a
suitable drain.
B. For manual draining, convenient dryer depressurization,
and drain valve maintenance, a three-way valve assembly
is installed between the drain port on the moisture separa-
tor and the drain valve. On all models, the three-way
valve is mounted to the bottom of the separator vessel
using a pipe union. Review the following for proper drain
function:
• AutomaticDraining-Valvehandleshouldbepositioned
parallel to the valve body (as shown), with the arrow
onthehandlepointingtowardthedrainvalve.Inthis
position,condensatewillowfromthebowltothedrain
valve.
• DrainIsolation(Shutdown)-Valvehandleshallbe
turnedperpendiculartothevalvebody(rotate90°).In
thisposition,condensateowisshutoff.
Pipe Union 3-Way Valve
Manual Discharge Line
Solenoid Valve
Automatic Discharge Line
• ManualDraining-Drainvalvehandleshallberotated
slightly past the drain isolation position to allow
throttling through the valve for manual discharge and
depressurization.
• NOTE: The pipe union allows removal of the
entire drain assembly. However, the unit must be
depressurized prior to disassembly or serious injury
may occur.
NOTE: Discharge is at system pressure. Drain line should be
anchored.
NOTE: Condensate may contain oil. Comply with applicable
laws concerning proper disposal.

4
Ifwaterispresentdownstreamofthedryer,
always verify that any condensate drains installed upstream of
the dryer are draining properly before attempting to readjust
the LED setting.
1. For minimum inlet air pressures that fall between column
values, the setting for the lower pressure is recommended.
(i.e. select the 300 psi column values for 324 psi inlet pres-
sure listed in Table 1.)
2. Where the dryer is consistently operating at less than max-
imum capacity, it may be possible to increase the LED set
point to minimize air loss. Discretionary adjustments to the
dryer should only be made on a hot, humid day when the
maximumexpectedairloadisowingthroughthedryer.
Failure to do so may prevent the condensate from draining
completely when operating under peak load conditions.
Table 1 Timed drain illuminated LED Settings
Inlet Pressure
300 400* 500 600 725
Dryer Model
DHP130 3 4 4 4 5
DHP200 3 3 4 4 4
DHP300 3 4 4 4 5
DHP500 3 3 3 4 4
DHP750 2 2 3 3 3
DHP1000 1 2 2 3 3
* Recommended and pre-programmed factory settings for each model dryer.
Assumes inlet conditions with 120°F ambient and 10°F air-cooled aftercooler
approach temperature.
Table 2 Timed drain illuminated LED Settings
LED
Illuminated
Minutes
between
Drain Cycles
1st 1
2nd 3
3rd 5
4th 10
5th 20
6th 30
7th 40
8th 50
9th 60
2.0 OPERATION
2.1 Minimum/Maximum Operating Conditions
A. Maximum inlet air pressure: 725 psig (50 barg)
B. Minimum inlet air pressure: 15 psig (1.0 barg)
C. Maximum inlet air temperature: 120°F (49°C)
D. Maximum ambient temperature:
Air-cooled models: 110°F (43°C)
Water-cooled models: 130°F (54°C)
E. Minimum ambient temperature: 40°F (4°C)
Condensate
Draining
Drain
Push-to-Test
On/Off
Switch
Switch Legend
Power On
Light
Compressor
On Light
Dew Point
Temperature
Indicator
2.2 Start-up
IMPORTANT: Energize dryer disconnect switch (provided by
others,seeNEC)24hoursbeforerefrigerationcompressor
isstarted!Neverusethedisconnectswitchtoshut-downthe
dryer for a extended period of time (except for repair). Failure
to follow these instructions may result in a non-warrantable
compressor failure.
NOTE:Itisrecommendedthatdryerbestarted15minutes
beforecompressedairowbegins.
NOTE: Ifthereisnopowertothecontrolboardforaperiod
of two weeks or more, it may return to the default mode.
1. ConrmOn/OffSwitchisinthe“Off”position.
2. Check for proper electrical voltage.
3. Energizedryerdisconnectswitch(seeIMPORTANTnote
above)
4. For water-cooled models: after 24 hours, begin cooling
waterow.
5. ToggleON/OFFswitchtotheONpositiontoenergize
dryer. Green power-on light will illuminate.
6. Slowly pressurize unit air side by opening inlet isolation
valve. Check for leaks.
7. After 15 minutes, open outlet isolation valve slowly.
8. Close air by-pass valve.
2.3 Timer Drain
NOTE: The Timer Drain LED level has been pre-programmed
atthefactoryforyourspecicdryermodel.Programmingis
based upon a minimum of 400 psig saturated inlet air pressure
andmaximumenergyefciency.Thedrainopentimeisxed
at one second and a small amount of air will be exhausted with
each cycle. Generally, no adjustment to the timer is required.

5
2.4 Timer Drain Programming Mode
1. Pressthe“DrainIntervalProgram”button.The“Conden-
sateDraining”LEDwillstarttoash,andtheilluminated
LEDonthe“DewPointTemperatureIndicator”willidentify
thefactorysettingfor“MinutesBetweenDrainCycles.”
(See Table 1)
2. Pressandreleasethe“DrainIntervalSelector”buttonto
sequencethe“MinutesBetweenDrainCycleLED’s”from
lefttorightuntilreachingyourselection.The“Red”LEDis
notused(ReferenceTable2for“DrainCycleIntervals”)
3. Toinitiatethenewsetting,pressthe“DrainIntervalPro-
gram”button(thiswillstorethenewsettingandexitthe
program).
4. Exiting the Program will cause the Timer Drain to dis-
charge and begin a new cycle.
NOTE: Failure to perform step 3 within 25 seconds of com-
pleting step 2 will cause the unit to revert back to the previous
setting.
NOTE:Intheeventofabrieforextendedperiodofpower
loss, the unit will retain the existing program setting and will
begin a new cycle once power is reapplied. Had drain been
ready to drain before the loss of power, the drain bowl’s capac-
itywouldpreventdownstreamooding.Condensatewilldrain
completely within a couple of cycles. (Manually pressing the
“Push-to-Test”buttonwoulddrainbowlimmediately)
2.5 Operating Check Points
Check the following on a periodic basis:
A. Green power on light is illuminated.
B. Dew point indicator is in green area.
C. Condensate is discharging from drain.
Condensate Draining
(Flashes in
programming mode)
DrainInterval
Program
Dew Point
Temperature
Indicator
DrainInterval
Selector
(LED illuminated
indicates drain
cycle setting)

6
3.0 MAINTENANCE
3.1 Daily
A. Check separator daily to be sure automatic drain is dis-
charging.
3.2 Weekly
A. Blow down separator weekly by pushing test button on
control panel.
3.3 Monthly
A. Condenser coil
1. Air-cooled - clean off accumulated dust and dirt
monthly or as necessary in dirty environments.
2. Water-cooled - clean strainer monthly, more often if
required. Shut off water, remove small plug to relieve
pressure, then remove large plug to remove strainer.
Clean strainer and replace.
3.4 Annually
NOTE: Prepackaged maintenance kits are available that
includeallnecessarylterandtimeddrainvalvecomponents.
MaintainmaximumperformanceandefciencywithGenuine
Parts. See page 19 for ordering information.
A. Rebuild drain mechanism annually.
B. Moisture Separator/Oil Removal Filter
1. Replacelterelementannually,orwhenpressuredrop
across dryer is excessive.
 Whenremovingliquidsatratedowconditions,an
increase in pressure drop will occur as the separator/
lterelementsbecomeloadedwithsolidparticles.
2. Procedure for Separator / Filter Element Replacement
THISFILTERISAPRESSURE
CONTAININGDEVICE.DEPRESSURIZEBEFORE
SERVICING.
a) Isolatedryer(closeinletandoutletvalvesifin-
stalled) or shut off air supply.
b) Removefrontpanelanddepressurizelterby
slowly opening manual drain by-pass valve.
c) Disconnect drain line from bottom of separator.
d) Disassemblelterhousing.
1) Forallmodels-removethelterbowl,
unscrewingitfromthelterheadbyhandor
strap wrench.
e) Cleanlterbowl.
D
D
Separator Bowl Insulation
Drain Assembly
Pipe Union
Separator Element
Replacement Sleeve
Separator Element Nut
Separator Element Bottom Cap
Air Inlet Air Outlet
Separator Bowl O-Ring
Separator Element O-Rings
Separator Head
Separator Bowl
f) Remove and replace complete element.
1) Unscrewtheoldlterelementanddiscard.
Also,discardthesmallo-ringthatsealsthelter
tothelterassemblyhead.
g) Installnewlterelementandbowlwithnewo-rings
properly seated to head or bowl (dependent upon
dryer size).
h) Connect drain line and replace panel.
i) Repressurize dryer and resume operation.

7
4.0 TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
A) Water downstream of dryer 1. Residual free moisture remaining in
downstream pipelines
2. Air bypass system is open
3. InletandOutletconnectionsarereversed
4. Air lines downstream of dryer are exposed
to temperatures below the dew point.
5. Excessive free moisture (bulk liquid) at
dryer inlet.
6. Condensate not being drained
Drain mechanism is clogged or
inoperative.
Drain line is restricted or frozen.
Electric drains-timer not set to allow for
sufcientcondensateremoval.
7. Dryer overloaded resulting in elevated dew
point.
8. Refrigeration system not functioning
Blow out system with dry air
Check valve positions
Check for correct connection
Insulateorheattraceairlinesexposedtolow
ambients or dry air to lower dew point
Installseparatoraheadofdryer
Replace drain mechanism if inoperative.
Open drain line.
Electric drains-reset time so that all liquid is
discharged
Checkinletairtemperatureandpressure,ow
rate (compressor capacity) and ambient air or
water temperature.
See D below
B) High pressure drop across dryer 1. Excessiveairow
2. Freezing of moisture in evaporator
because of refrigeration system fault
3. Separatorlterelementclogged
Checkowrate
See D below
Replacelterelement
C) Dew point indicator in red area 1. Dryer overloaded resulting in high air
outlet temperature
2. Refrigeration system not functioning
properly resulting in high air outlet
temperature
See A 7
See D below
D) Refrigeration system not functioning
properly
1. Power on light off
2. Compressor on light off
3. Refrigeration compressor cycles on
and off
a. Power failure
b. Line disconnect switch open
c. Blown fuses, open breaker
d. Faulty wiring, loose terminals
a. ON/OFFswitchis“OFF”
b. Line disconnect switch open
c. Blown fuses, open breaker
d. Faulty wiring, loose terminals
a. High or low ambient conditions
b. Air-cooled-Dirty,cloggedcondenserns,
obstructedowacrosscondenser,faulty
fan motor or fan control switch.
Check for power to unit
Close disconnect switch
Check for continuity
Have electrician check electrical connections.
Turnswitch“ON”
Close disconnect switch
Check for continuity
Have electrician check electrical connections
Check min./max. temperature ranges
Cleancondenserandcheckforfreeairow,if
problempersistscontactqualiedrefrigeration
repairman or manufacturer’s service
department.

8
5.0 REFERENCE
5.1 Sizing
Determining dryer capacity at actual operating conditions
Todeterminethemaximuminletowcapacityofadryeratvari-
ous operating conditions, multiply the rated capacity from Table
1 by the multipliers shown in Table 2.
Example: How many scfm can an air-cooled model DHP300
handle when compressed air to be dried is at 350 psig and
90°F; ambient air temperature is 80°F?
Answer: 300 x 1.19 x 1.12 = 400 scfm.
Table 1. Rated Capacity
Rated capacity (scfm) @ 725 psig inlet pressure, 100°F inlet
temperature, and 100°F ambient temperature and 60 Hertz
operation.
MODEL RATED FLOW
(scfm) m3/hr
DHP130
DHP200
DHP300
DHP500
DHP750
DHP1000
130
200
300
500
750
1000
221
340
510
850
1275
1700
Table 2. Capacity Adjustment Factors for Air Inlet
Temperature and Pressure
INLET PRESSURES INLET TEMPERATURES
(psig) (barg) 80°F
27°C
90°F
32°C
100°F
38°C
110°F
43°C
120°F
49°C
300 to 725 21 to 50 1.49 1.19 1.00 0.83 0.72
Table 3. Capacity Adjustment Factors for Ambient Air
Temperature
AMBIENT
TEMPERATURE
°F (°C)
CAPACITY
ADJUSTMENT
FACTOR
80°F (27°C) 1.12
90°F (32°C) 1.06
100°F (38°C) 1.00
110°F (43°C) 0.94
Water-cooled
(85°F, 29.4°C
cooling water)
1.15
Table 4. Capacity Adjustment Factors for Electrical
Frequency
50 Hertz 60 Hertz
0.83 1.00