GSA Desiccant User manual

Please read this manual before using this equipment must.
Learn all the safety precautions before using this equipment, please keep.
Desiccant Air Dryer
(Heatless Type)
Operating Manual
http://www.gsadryer.com

Table of Contents
Chapter 1. Important User Information
Preliminary .....……………….…………………………………………………….. 4
Product Information ……....….…………………………………...…………….… 4
General Notes ..……..…….………………………………………..…………….. 4
Safety Regulations ..….…..………………………………….……………………. 4
First Aid ………………....……………….……………………………………….... 5
Safety Mark & Parts Location ..………………………………………………….. 5
Light ……………………….……………………………………………………….. 5
Sound Pressure Level ..…….……………………………………………………. 5
Chapter 2. 2. General Descriptions
Purpose……..…..………………………………………………………………..… 6
Composition ……..….….......…………………………………………………...... 6
Principle of Operation ....…………………………………….………………….... 6
Operation ....……………….…….……………………………………..………….. 7
Repressurizing Solenoid Valve..….…………………………………..…………. 7
Fault Alarm …………….….…….……………………………………..…………. 7
Chapter 3. Installation & Wiring
Receiving and inspection ………………………………………………………... 8
Location …………………………………………………………………………… 8
Connecting services ……………………………………………………………… 8
Filtration …………………………………………………………………………… 9
Back pressure regulator …….…………………………………………………… 9
Purge exhaust piping……………………………………………………………... 9
Chapter 4. Operating
Start-Up ................….…...…...…….…………………………………….…...... 10
Stop…………....………….…………………………………...…..………...…… 10
2

Chapter 5. Maintenance
Pre-Filter …………………….......…….………………………………….......... 11
After Filter ……………………….……………………………………………….. 11
Control Air Filter ……..………….……………………………………………….. 11
Purge Flow Rate Adjustment ………........…………………………………….. 11
Solenoid Valve ……….................…………………………………….………… 12
Desiccant Replacement ….…....…………………………………….………… 12
Maintenance Schedule ……………………………………………….………… 13
Troubleshooting …………….………………………………….……..........…… 14
Chapter 6. Appendix
Control Panel .….......….…..…………………………....……………………… 15
Purge Air Calibration Chart .....….....…………………...……………………… 16
Sequence Chart .....…….…..…………………………....……………………… 16
3
Table of Contents

1. Important User Information
■Preliminary
The usability and the life cycle of the heatless regenerative air-dryer (referred to below as PHL-
dryers) as well as the avoidance of premature repairs depends on proper operation, care and
competent repair under consideration of these operating instructions.
■Product Information
Due to our position as suppliers of components we do not always know the final usage and
total range of products’ applications. We constantly improve our products to the latest state
of science and technology and therefore, we assume that our products are free from defects
in the sense of product liability. However, it cannot be excluded that during faulty operation
in critical areas of application especially at danger to life and limb of persons involved,
additionally safety measures may be necessary.
Therefore, we request the user of our components / units, to ensure in his own interest, to
inform us about the application of our products in order to initiate additional safety
measures, if necessary.
■General Notes
The Company does not accepts responsibility if these safety measures are not met during
handling, operation, maintenance and repair, even though this is not strictly stated in these
operating instructions.
We recommend receipt and notice of these operating instructions verified by the operating
personnel in writing (personnel file).
We request strict observation of these notes as otherwise we do not accept any liability in
respect of this machine (plant).
■Safety Regulations
• Protective or safety devices must not be removed, modified or readjusted.
• During operation of the dryer none of the protective of safety devices must be removed,
modified or readjusted temporarily or permanently.
• Use proper tools for maintenance and repair work only.
• Use original spare parts only.
• All maintenance works must be performed at stopped machine, disconnected power supply
and pulled mains plug only. Ensure that the dryer cannot be switched on by mistake.
• Prior to dismounting a part under pressure disconnect the dryer from all pressure sources
or depressurize the complete system respectively.
• Never weld the pressure vessel or modify it in any way.
• Ensure that no tools, loose parts or similar are left in the system.
• Wear eye protection and protective gloves during the change of desiccant.
Caution!
The operator has to observe the national working-, operating- and safety
regulations. Also existing internal factory regulations must be met.
Maintenance and repair work must only be carried out by specially trained
personnel and, if necessary, under supervision of a person qualified for this work.
4

■First Aid
• Take victim immediately into the fresh air or into a very well ventilated room.
• If the victim does not breathe, perform a mouth-to-mouth resuscitation or use a respirator until
the doctor’s arrival.
• Never leave the victim unattended.
■Safety Mark & Parts Location
5
■Light
Dryer is not provide with a local lighting since it is designed for indoor use only. The sufficient
illumination of the working area must be fulfilled by the factory in accordance with the appropriate
code of practice and factory regulations.
■Sound Pressure Level
If the sound pressure level is larger, proper safety method is needed to the operator such as ear
protections and warning signs.
Purge Adjust Valve
Control Panel
Safety Valve
Desiccant
Fill Port
Desiccant
Remove Port
Inlet
Orifice
Purge Valve
Purge Press. Gauge
B-Tower Press.
Gauge
Control Air Filter
Outlet
A-tower B-tower Low Pressure
Switch
De-press. Valve
Inlet Valve
A-Tower Press.
Gauge
Silencer
Caution!
If the dryer is not disconnected, the risk of electric shock exists at control box.
1. Important User Information

■Purpose
Compressed air will be dehumidified by the dryer.
■Composition
1.Control box
2. Electronic timing sequence module.
3. Sequence lights display
- Drying Time
- Repressurization Time
4. Tower safety relief valves
5. ASME coded vessels (100 over model : option)
6. Tower pressure gauge
7. Purge pressure gauge
8. Pneumatic valves
9. Tower exhaust mufflers
■Principle of Operation
The Desiccant air dryer is specifically designed to remove moisture in vapor form. The dryer’s
Electronic Sequence Module is fully automatic, alternately cycling gas flow through the dryer’s
twin desiccant towers. Cycling between the two towers accomplishes the adsorption and
regeneration processes and provides a continuous flow of air.
The desiccant air dryer is charged activated alumina, composed of desiccant tower, pneumatic
valve, check valve, solenoid valve, and control panel.
The compressed air with moisture vapor enters a tower and flows upward through the desiccant
bed. The desiccant has great affinity for moisture vapor, therefore it adsorbs or removes moisture
from the air process is am exothermic process meaning heat is produced as moisture is
adsorbed on the desiccant surface.
At the end of the drying cycle, the desiccant in the tower is regenerated the moisture that the
desiccant adsorbed is removed by dry air.
A small portion of the dry gas is expanded to near atmospheric pressure by passing through an
orifice specifically designed for the regeneration(Purge) stream to strip the previously adsorbed
moisture vapor. The exothermic reaction from the previous drying cycle contributes to the
regeneration of the desiccant bed. The heat is picked up by the regeneration stream which in
turn increases the moisture adsorption capacity of the regeneration stream.
6
2. General Descriptions

2. General Descriptions
■Operation
Assume the dryer has completed re-pressurization and the left tower has begun drying. The inlet
compressed air/gas enters the dryer and is diverted to the lift tower to begin the five minute
drying cycle. Approximately five seconds later the right tower purge (regeneration) exhaust valve
will open depressurizing the off-line tower. The purge flow will continue for a period of three
minutes and fifty-five seconds. When regeneration of the off-line tower is complete, the purge
exhaust valve will close, initiating the sixty second re-pressurization phase. After re-
pressurization is complete, the inlet selector valve will switch inlet valves and the inlet air/gas
stream will divert from the left tower to the right tower. After five seconds the left tower purge
exhaust valve will continuously cycle through the sequence described above until power is
removed from the dryer.
(See Appendix Sequence Chart)
The complete standard operating (NEMA) cycle is ten minutes. Under normal conditions and
during normal operation, the dryer should provide on outlet pressure dew point (ADP) of -40℃or
below.
■Repressurizing Solenoid Valve
Repressurizing solenoid valve is installed Large capacity model to prevent break of activated
alumina gel.
■Fault Alarm
Pressure switch will transmit a outlet low pressure signal to DCS or local control panel. Then
Purge solenoid valve is closed by control unit(in local control panel)
7

3. Installation & Wiring
■Receiving & inspection
Carefully inspect the packaging and dryer for external and internal damage. If you suspect
damage has occurred during shipment, notify the transportation agency at once. This is the
customer's responsibility.
Check the name plate for correct power supply requirements.
Inspect all piping and tubing. Vibration during shipment may have loosened the connections.
Desiccant air dryers are tested and operated before leaving the factory. They are ready to
operate after connecting to proper services.
■Location
Locate your Desiccant Air Dryer on a level floor free from vibrations and in clean surroundings.
Although the dryer is a free standing package, it may be secured by bolting the dryer base to the
floor. Allow approximately three feet on each side of the dryer for ease of connecting and
maintaining the dryer.
The ambient temperature in the dryer's location should range from 2℃to 40℃. The dryer will
function in warmer ambient, but as a result, the degree of dew point suppression will decrease.
Operation of the dryer in ambient approaching freezing could cause freezing of separated liquids
in the pre-filter sump or in the dryer itself. For dryer operation at temperatures below freezing,
Pioneer recommends heat tracing the pre-filter sump, drain trap and inlet manifold. For more
information on heat tracing, contact your distributor or the factory.
Protective barriers are recommended for the prevention of accidental damage that may occur
due to vehicular or personnel traffic, particularly for dryers located in open areas.
■Connecting service
1. Connect inlet piping, including a shut off valve.
2. Connect outlet piping, including a shut off valve.
3. Install pre-filter(s) and after(s) if not factory installed.
4. If desired, install bypass piping using bubble tight valves.
- Bypass piping is recommended for ease of maintenance, troubleshooting and service.
5. Connect electrical supply to the control box. This should be performed by a qualified
electrician according to local and national codes. (See Appendix Control Panel)
6. Install access ports upstream and down-stream of the dryer for dew point and temperature.
8
Caution!
Must install a suitable earth leakage circuit breaker.

■Filtration
All regenerative desiccant dryers are designed to remove water in the vapor phase. The
possibility of liquid carry over to the desiccant dryer must be avoided. A coalescing pre-filter will
eliminate the carry over of droplets and aerosol-sized mists of both liquid water and compressor
lubricant. The use of a coalescing filter will enhance the dew point depression capability of the
dryer. It will also extend the life of the desiccant by preventing compressor lubricant fouling of the
desiccant bed.
After filtration is also a very important step. All regenerative desiccant dryers gradually produce
hard and abrasive desiccant fines. These contaminants should be removed with a particulate
filter. The elimination if desiccant fine carry over will protect your plant air systems and reduce
future system malfunctions.
When installing filters, make connections according to the arrow directions marked on the filter
head.
■Back pressure regulator
In dryer applications where sudden down-stream demand for dry air frequently occurs, a rapid
pressure loss in the compressed air system is possible. To prevent this, it is recommended that a
back pressure regulator be installed down-stream from the dryer.
The back pressure regulator will maintain a constant pressure within the dryer. This will eliminate
any chance of saturating the desiccant bed by sudden flow surges which accompany rapid
pressure loss. By eliminating saturation and desiccant bed “bumping,” the life the desiccant
charge will increase, and the after filter elements will nit become prematurely clogged with
desiccant finer.
■Purge exhaust piping
To eliminate noise created by frequent tower release of purge exhaust, the dryer’s exhaust may
be piped to an outside or more remote location. This will also eliminate any possible problems
caused by indoor accumulation of condensed moisture from the purge exhaust. If extending the
exhaust pipe, install it horizontal or downward to avoid accumulation of condensate at low points.
If the purge exhaust is required to run upward, install a valve at the low point. If extending the
exhaust pipe farther than 5 meter, consult the factory for recommendations.
9
3. Installation & Wiring

4. Operating
■Start-Up
After all installation procedures are performed, drain water from the system prior to dryer start up.
This will prevent saturation of the desiccant bed and improve performance of the dryer.
1. The inlet shutoff valve open, the outlet shutoff valve & bypass valve close.
2. Before to turning the dryer control panel switch ON, pressurize the dryer by slowly opening the
Inlet shutoff of the dryer.
3. When both tower pressure gauges indicate line pressure, open the outlet shutoff valve.
Compressed air now flows through the pre-filter, the dryer and the after filter.
4. Switch the control panel power switch ON. Five seconds after activating the dryer control
circuit, one tower will depressurize to atmospheric pressure. Regenerating purge air will then flow
through the regenerating tower.
5. Set the purge adjustment valve to 45 psig (3.1 barg). The purge pressure can be properly set
only the purge exhaust valve is open and the regenerating tower is at atmospheric pressure.
(See Appendix Purge Air Calibration Chart)
■Stop
To stop the dryer, place the switch in off.
During maintenance of dryer, disconnect main electrical source.
10
Caution!
Sudden pressurization of the dryer will cause a rush of high velocity air into the
desiccant bed. This will hasten the need for after filter element and desiccant
replacement and may cause premature failure of valves due to desiccant fines.
Must keep the purge pressure : 3.0~3.5barg.
Caution!
Do not operate the air dryer before purge air exhaust.
Damage caused by this is not covered by the product warranty.

5. Maintenance
■Pre-Filter
Under normal operating conditions, the pressure drop across the filter indicates when the
element needs changing typically 6 psig or greater. However, inspect the filter element at least
every three months for proper seating and condition of the element. If the element has collapsed
or can not be properly seated, replace the element.
■After Filter
Under normal operating conditions, the pressure drop across the filter indicates when the
element needs changing typically 6 psig or greater. However, inspect the filter element at least
every three months for proper seating and condition of the element. If the element has collapsed
or cat be properly seated, replace the element.
Replacement of the element will enhance system operation and prevent inflow of desiccant
powder to load side.
■Control air filter
The control air filter should be inspected periodically and replaced when dirty. Periodic
replacement of the element will ensure clean control air for operation of the valves.
■Purge flow rate adjustment
The purge flow rate should be checked periodically for proper adjustment. The purge pressure
for full load operation should be set at 45 psig(3.1barg). The purge calibration graph(Appendix)
may be used for purge adjustment when the load is less than capacity.
11
Caution!
Before servicing any component, be certain the component is depressurized
and valves are closed. Otherwise, equipment damage, severe injury or death
could result.
Caution!
The life cycle of filter element depends of the quality of compressed air.
Periodic attention must be paid to proper performance.

■Solenoid valve
Inspect solenoid valves periodically for proper operation. The inspection should include
monitoring the tower pressure gauge on each tower during the cycle. The back pressure on a
regenerating tower should not be greater than 5 psig. Higher pressure indicates either a
malfunctioning valve or a cogged muffler.
Frequent monitoring of the tower pressure gauges in conjunction with the control will give a good
indication of proper operation and can assist with troubleshooting should a problem occur.
Failure of a solenoid valve may result from:
- Faulty control circuit. Check the electrical system to verify that the solenoid coil is receiving
electrical input.
- A burned out coil. Replace the coil.
- Clogged solenoid valve. Disassemble and clean.
- Damaged valve seat. Disassemble and clean.
■Desiccant replacement
Remove contaminated desiccant from each vessel through the desiccant “drain port” located
near the bottom of each vessel. Pour new desiccant into the indicated “fill port” located near the
top of each vessel. Allow adequate space above the desiccant bed to permit bed motion and
expansion during drying. Change the desiccant periodically for optimum dryer performance.
Store any unused desiccant in an airtight container.
12
Caution!
Do not operate the dryer with no purge flow. It may damage the dryer and will
void the warranty.
Caution!
Use only activated alumina in your Desiccant Air Dryer.
5. Maintenance

13
5. Maintenance
■Maintenance schedule
Maintenance intervals highly depend on the mode of operation and the ambient
conditions on site, the intervals below air only to be understood as general recommendation.
Period Check point Method
Start up
Pressure indication
All pressure gauges
-
Drying tower pressure : same line pressure
-
purge pressure : 3.0~3.5 barg
-
Regeneration tower pressure : below 0.5barg
Solenoid & pneumatic
valve
Operation check
Back pressure on
regeneration
tower
Max. 0.5 bar. If needed clean
the silencer.
Every 3~4
months
Pre
-filters and after-filters
Inspect pre
-filter and after filter for dirt, oil and
other
contaminants. Replace if contaminated.
Control air filter
Inspect filter element
or regulator.
if needed
clean the filter & regulator.
Every 6
months
Calibrate dew point meter
(if
installed)
Refer to dew point meter owner’s manual.
Inspect the silencer
Replace exhaust silencer if back pressure on
regeneration exceed
0.5 barg.
Inspect solenoid valves
While dryer is operating, inspect solenoid valves.
If leak or malfunction persists, replace valves.
Yearly
Replace filter elements
Replace pre
-filters & after-filters.
Inspect
& replace
pneumatic valves
Inspect valve seating and valve internals.
If needed,
clean or replace the valve.
Inspect
pressure gauge
Replace if readings are incorrect.
Every 2~3
year
Replace desiccant
(recommendation)
Replace if contaminated oil moisture and other
contaminants inhibit the performance of the
desiccant.

■Troubleshooting
14
5. Maintenance
Problem Probable Cause Remedy
Excessive backpressure
in regeneration tower
(above 0.5barg)
Silencer is clogged
Clean or replace silencer.
Pressure
gauge
malfunction
Check or replace pressure gauge.
Depressurization fail
De
-press. valve &
purge valve doesn’t
open
Check de
-press. & purge valve.
And check its solenoid valve.
Silencer is clogged
Clean or replace silencer.
Low
pressure
Check control
air pressure(above 5 barg)
Re-press. fail
De
-press & purge
valve doesn’t close
Check de
-press. & purge valve.
And check its solenoid valve.
Excessive press. drop
Excessive flow rate
Check working pressure
.
Low Inlet pressure
Check line pressure.
Tower change failure
No control air
Low control press.
Check control air line & control filter.
Controller failure
Check the PLC
or PCB controller.
Elevated dew point
Insufficient purge air
Check purge
pressure.(nor. 30.~3.5 barg)
Silencer is clogged
Clean or replace silencer.
Low pressure
Check pressure sauce.
High inlet temp.
Reduce
inlet temp.
Check after
-cooler or ref. dryer.
Desiccant
contaminated by oil.
Install suitable pre
-filter.
And replace desiccant.
Water entering
Check after
-cooler or ref. dryer.
If necessary replace desiccant.

6. Appendix
■Control Panel
SV1 –[B-Tower] Right Tower On-Line
SV2 –[B-Tower] Right Tower Purge
SV3 –[A-Tower] Left Tower On-Line
SV4 –[A-Tower] Left Tower Purge
SV5 –Re-Pressure
Tower Select –A or B Tower Select
DPOS –Dew Point Operating System
PRSS. –Repressurize
15

■Purge Air Flow Calibration Chart
60
50
40
30
20
10
10 20 30 40 50 60 70 80 90 100 110 120 130
RATED FLOW OR NORMAL CAPACITY (%)
PURGE PRESSURE (PSIG)
50
60
70
80
90
100
11
0
12
0
13
0
140
15
0
■Sequence chart(5 minutes drying cycle)
16
6. Appendix

2017.05
GSA CO., Ltd
Head office / Factory
679-2, Sinwol-ri, chowol-eup, Gwangju-si,
Gyeonggi-do, KOREA.
TEL [phone] / FAX [phone]
www.gsadryer.com E-mail : [email protected]