Sullair DBP Series Troubleshooting guide

Failure to follow the instructions
and procedures in this manual or,
misuse of this equipment will
VOID its warranty!
WARRANTY NOTICE
USER/SERVICE MANUAL
DESICCANT BLOWER PURGE
REGENERATIVE DRYER
DBP SERIES (800-10,000 CFM)
PART NUMBER:
KEEP FOR
FUTURE
REFERENCE
©SULLAIR CORPORATION
02250195-405 R00
The information in this manual is current
as of its publication date, and applies to
compressor serial number:
and all subsequent serial numbers.
SBPIABIABA-0001

AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.
For detailed course outlines, schedule, and cost information contact:
SULLAIR TRAINING DEPARTMENT
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
[email protected]
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.

TABLE OF CONTENTS
SECTION 1—INTRODUCTION
SECTION 2—SAFETY
9 2.1 SAFETY INFORMATION
10 2.2 DEFINITION OF THE SAFETY SYMBOLS USED
12 2.3 WARNINGS
12 2.4 PROPER USE OF THE DRYER
13 2.5 INSTRUCTIONS FOR THE USE OF PRESSURE EQUIPMENT
SECTION 3—SPECIFICATIONS
16 3.1 TYPE OF CONSTRUCTION
16 3.2 AMBIENT CONDITIONS
16 3.3 OPERATIONAL DATA
16 3.4 PRESSURE VESSEL DESIGN AND CONSTRUCTION DATA
16 3.5 PIPE MANIFOLD DETAILS
17 3.6 ELECTRICAL DATA
17 3.7 TIME, PRESSURE, TEMPERATURE, AND DEWPOINT SETTINGS
17 3.8 DIMENSIONS AND WEIGHT
17 3.9 FILTER MODELS
SECTION 4—INSTALLATION
SECTION 5—OPERATION
21 5.1 ADSORPTION
21 5.2 REGENERATION
21 5.3 COOLING
21 5.4 TIME CONTROLLED VESSEL CHANGE OVER
22 5.5 DEWPOINT CONTROLLED VESSEL CHANGE OVER (OPTION)
22 5.6 PANEL MOUNTED DATA DISPLAY
22 5.7 EQUIPMENT START UP
23 5.8 EQUIPMENT SHUT DOWN
24 5.9 ID—DBP 500

TABLE OF CONTENTS
26 5.10 ID—DBP 650
28 5.11 ID—DBP 800-1000
30 5.12 ID—DBP 1250-1500
32 5.13 ID—DBP 2000
34 5.14 ID—DBP 2500-3000
36 5.15 P&I
38 5.16 WD—DBP 500
40 5.17 WD—DBP 650
42 5.18 WD—DBP 800
44 5.19 WD—DBP 1000
46 5.20 WD—DBP 1250
48 5.21 WD—DBP 1500
50 5.22 WD—DBP 2000
52 5.23 WD—DBP 2500
54 5.24 WD—DBP 3000
56 5.25 WD—DBP 3500
58 5.26 WD—DBP 4000
60 5.27 WD—DBP 5000
62 5.28 WD—DBP 6000
64 5.29 WD—DBP 7000
66 5.30 WD—DBP 8000
68 5.31 WD—DBP 9000
70 5.32 WD—DBP 10000
SECTION 6—TROUBLESHOOTING
SECTION 7—SYSTEM MAINTENANCE
75 7.1 WITH YOUR DRYER ONLINE
75 7.2 MONTHLY INSPECTIONS
75 7.3 QUARTERLY INSPECTIONS
75 7.4 YEARLY INSPECTIONS
75 7.5 DESICCANT CHANGE OUT
75 7.6 FILTER ELEMENT CHANGE OUT
SECTION 8—TECHNICAL DESCRIPTION OF COMPONENTS
77 8.1 ADSORBER
77 8.2 DESICCANT
77 8.3 HEATER
77 8.4 VALVES
77 8.5 ACTUATORS
77 8.6 REGENERATION BLOWER
77 8.7 PRESSURE GAUGE

TABLE OF CONTENTS
SECTION 9—SPARE PARTS LIST
80 9.1 SPARE PARTS LIST

TABLE OF CONTENTS

Section 1
7
DBP BLOWER PURGE HEATED DRYER
INTRODUCTION
This manual contains instructions for the installation,
operation and maintenance of the DBP—(200-
10,000 CFM) adsorption dryer.
This manual is intended to familiarize operators
quickly with the equipment provided, its construction
and operation, and how to carry out any maintenance
when required.
Read it through carefully before commissioning the
dryer.
Record operating hours, maintenance work and
repairs etc in a logbook.
Follow all instructions carefully to ensure a trouble
free life.
Our guarantee is affected if you fail to observe the
instructions and recommendations for the operation
and maintenance of the equipment as given in this
instruction manual. Also we cannot guarantee the
equipment if it has been modified, operated with
parts other than those originally supplied or specified
in the spare parts list or if the equipment is operated
at conditions other than which it was intended and
designed for. Consult Sullair before making any
changes that may void the equipment warranty.
Our after sales service department will be happy to
provide advice, service or any spare parts that you
need.
Quote the model number, serial number and date of
manufacture on all correspondence with Sullair This
is very important, particularly when ordering spare
parts.
Sullair reserves the right to make changes or
modifications to the equipment designs without
notice.

8
NOTES

Section 2
9
SAFETY—REGENERATIVE DRYERS
SAFETY
The dryer has been designed and constructed in
accordance with the generally recognized rules
pertaining to adsorption technology as well as
industrial safety and accident prevention regulations.
The equipment design, development, production,
assembly and customer service fall under the Sullair
quality control system.
The dryer is state of the art. There are, however,
hazards to the body, equipment and life
accompanying this type of product if it is not operated
for the purpose which it is intended by trained and
specialized personnel.
The equipment supplied is intended exclusively for
drying compressed air. Any other use or one
exceeding this is considered unauthorized. Sullair
cannot be held liable for damages resulting from
incorrect or unauthorized use of the equipment. Any
such risk is carried solely by the end user.
Authorized use means complete compliance with all
of the conditions of operation, servicing and
maintenance prescribed by Sullair in this Instruction
and Operation Manual.
The dryer is only to be operated, serviced and
repaired by trained personnel who are familiar with
this type of equipment and understand fully its
operation and any potential dangers.
2.1 SAFETY INFORMATION
The end user and operator must observe all National,
State, and Local industrial and safety regulations
dealing with the operation of pressure vessels under
compressed air service. Also all “end user” safety
rules for the same type of service must be adhered
to. The following points list some of the important
factors dealing with this type of equipment.
• Never make any structural changes to the
equipment
• Use only original spare parts and accesso-
ries
• Never weld on any pressure vessel or mod-
ify it in any way
• All maintenance on “pressure parts” must
be carried out with the equipment shut-
down, depressurized and locked out. Any
in plant procedures or work permits regard-
ing pressure vessels are to be adhered to.
• Do not operate the equipment with the con-
trol panel door open, the electrical system
energized and live parts exposed.
• Disconnect the dryer from the electrical
supply when any electrical work is per-
formed. Lock out the safety disconnect and
obtain any required work permits.
The desiccants used in this equipment are not
considered hazardous. However all contact with or
disposal of the desiccant should be in accordance
with the relevant MSDS. The following lists the more
common safety measures normally observed during
filling operations.
• In the case of accidental contact of the des-
iccant with the eyes, rinse immediately with
an abundance of clean water. Refer to the
MSDS.
• Accidental spillage of desiccant on the floor
should be cleaned up avoiding the creation
of excess dust during this procedure.
• Use a contoured face mask during any fill-
ing or draining operations. Refer to the
MSDS.

10
NOTES
2.2 DEFINITION OF THE SAFETY SYMBOLS USED
Before attempting any intervention on the dryer, read carefully the instructions reported
in this use and maintenance manual.
General warning sign. Risk of danger or possibility of damage to the machine. Read
carefully the text related to this sign.
Electrical hazard. The relevant text outlines conditions which could result fatal. The
related instructions must be strictly respected.
Danger hazard. Part or system under pressure.
Danger hazard. Component or system which during the operation can reach high
temperature.
Danger hazard. It’s absolutely forbidden to breathe the air treated with this apparatus.
Danger hazard: It’s absolutely forbidden to use water to extinguish fire on the dryer or in
the surrounding area.
Danger hazard; It’s absolutely forbidden to operate the machine when the parts (under
pressure or electric panels) are not in place or have been tampered with and changed.
Danger hazard: machine level noise could be higher than 85 dBA. It is mandatory to
install the machine in dedicated area where people are not normally present. The
installator and/or the user is responsible for correct installation of the dryer, in order to
prevent noise propagation to the near work environment. The installator and/or the user
is also responsible for the safety signs affixing into installation site.
Attention: the User or Operator must wear hearing protection before performing any
procedure on the dryer. All personnel must select the proper PPD (Personal Protection
Device) hearing protector (earmuffs, ear canal caps or ear plugs) in order to prevent
damage to the person's hearing.

SECTION 2 SAFETY—REGENERATIVE DRYERS
11
Maintenance and/or control operation to be very carefully performed by qualified
personnel 1.
Compressed air inlet connection point.
Compressed air outlet connection point.
Condensate drain connection point.
Operations which can be worked out by the operator of the machine, if qualified 1.
In designing this unit a lot of care has been devoted to the protection of the
environment:
• Dryer and relevant packaging composed of recyclable materials.
• Energy saving design.
Not to spoil our commitment, the user should follow the few ecological suggestions
marked with this sign.
NOTE
Text to be taken into account, but not
involving safety precautions.

SAFETY—REGENERATIVE DRYERS SECTION 2
12
2.3 WARNINGS
2.4 PROPER USE OF THE
DRYER
This dryer has been designed, manufactured and
tested only to be used to separate the humidity
normally contained in compressed air. Any other use
has to be considered improper. The Manufacturer
will not be responsible for any problem arising from
improper use; the user will be in any case
responsible for any resulting damage.
Moreover, the correct use requires the compliance
with the installation conditions, in particular:
• Voltage and frequency of the primary elec-
trical supply.
• Pressure, temperature and flow-rate of the
incoming air.
• Ambient temperature.
This dryer is supplied tested and fully assembled.
The only operation left to the user is the installation of
the desiccant into the dryer towers and the
connection to the plant in compliance with the
instructions given in the following chapters.
The purpose of the machine is the
separation of water present in
compressed air. The dried air cannot be
used for respiration purposes or for
operations leading to direct contact with foodstuff,
unless subject to further treatments.
Compressed air is a highly hazardous energy source. Never work on the dryer with
parts under pressure. Never point the compressed air or the condensate drain jet
towards anybody.
The user is responsible for the installation of the dryer, which has to be executed on the
basis of the instructions given in the “Installation” chapter. Otherwise, the warranty will
be voided and dangerous situations for the personnel and/or damages to the machine
could occur.
Only qualified personnel can use and service electrically powered devices. Before
attempting any maintenance action, the following conditions must be satisfied :
• Ensure that any part of the machine is under voltage and that it can-
not be connected to the mains.
• Ensure that any part of the dryer is under pressure and that it cannot
be connected to the compressed air system.
Any change to the machine or to the relevant operating parameters, if not previously
verified and authorised by the Manufacturer, in addition to create the possibility of
dangerous conditions it will void the warranty.
Don’t use water to extinguish fire on the dryer or in the surrounding area.

SECTION 2 SAFETY—REGENERATIVE DRYERS
13
2.5 INSTRUCTIONS FOR THE
USE OF PRESSURE
EQUIPMENT
To ensure the safe operation of pressure
equipments, the user must conform strictly to the
following:
1. The equipment must only be operated within
the temperature and pressure limits stated
on the manufacturers name/data plate.
2. No welding is allowed on the shell and end
caps.
3. The equipment must not be stored in badly
ventilated spaces, near a heat source or
inflammable substances.
4. Vibration must be eliminated from the equip-
ment to prevent fatigue failure.
5. An internal inspection must be carried out at
12 month intervals to check for pressure
equipment corrosion. The actual wall thick-
ness of the tower after corrosion should not
be less than the data indicated on the chart
located on the side on the tower.
6. Condensate drains should be checked for
operation every day to prevent a build up of
condensate in the pressure equipment.
7. The maximum working pressure stated on
the manufacturers data plate must not be
exceeded.
8. All documentation supplied with the equip-
ment (manual, declaration of conformity etc.)
must be kept for future reference.

14
NOTES

Section 3
15
DBP BLOWER PURGE HEATED DRYER
SPECIFICATIONS
Model #
Inlet
Flow
Capacity
@100 PSIG
CFM
Voltage
Inlet/Outlet
Connections
(inches)
Dimensions
L x W x H
(inches)
Weight
(Lbs)
500-DBP 500 230/460/3/60 2” NPT 90x42x90 2890
650-DBP 650 230/460/3-60 2” NPT 90x42x90 3500
800-DBP 800 230/460/3-60 3” FLG 95x55x105 4500
1000-DBP 1000 230/460/3/60 3” FLG 95x55x105 5600
1250-DBP 1250 230/460/3/60 3” FLG 110x70x109 6400
1500-DBP 1500 230/460/3/60 3” FLG 110x70x109 8200
2000-DBP 2000 230/460/3/60 3” FLG 140x75x110 9800
2500-DBP 2500 230/460/3/60 4” FLG 140x75x110 12500
3000-DBP 3000 230/460/3/60 4” FLG 140x89x120 15000
4000-DBP 4000 230/460/3/60 6” FLG 160x94x122 21000
5000-DBP 5000 230/460/3/60 6” FLG 180x94x140 27000
6000-DBP 6000 230/460/3/60 6” FLG CF CF
7500-DBP 7500 230/460/3/60 8” FLG CF CF
9000-DBP 9000 230/460/3/60 8” FLG CF CF

DBP BLOWER PURGE HEATED DRYER SECTION 3
16
3.1 TYPE OF CONSTRUCTION
• Designed for operation indoors in a Non-
hazardous location. The electrical equip-
ment is constructed to Nema 12 standards.
• Fully automatic, external heat regenerated
twin tower blower purge dryer.
3.2 AMBIENT CONDITIONS
3.3 OPERATIONAL DATA
3.3.1 ADSORPTION
3.3.2 REGENERATION
3.3.1 COOLING
3.4 PRESSURE VESSEL DESIGN
AND CONSTRUCTION DATA
The desiccant chamber pressure vessels are
constructed to the latest edition of the ASME Code,
Section VIII, Division 1.
3.4.1 DESICCANT CHAMBERS
3.4.2 PREFILTERS AND AFTERFILTER
3.5 PIPE MANIFOLD DETAILS
Atmospheric Pressure 14.7 PSIA
Ambient Temperature Minimum 40 Deg. F.
Ambient Temerature Maximum 105. Deg. F.
Medium Compressed Air
Condition
Free from dirt, oil,
condensation and aggressive
contaminants
Inlet Flow _____scfm
Inlet Pressure 100 psig (minimum)
Inlet Temperature 100°F (maximum)
Adsorption capacity Saturated inlet air at
100°F
Outlet pressure
dewpoint
-40°F
(with dry air cooling)
Desiccant type Activated Alumina (F-200)
Amount per vessel _____lbs
Medium Heated Atmospheric air
Nominal flow rate _____scfm
Regeneration
temperature 400 Deg. F.
Regeneration time 180 minutes maximum
Medium Compressed air or ambient air
Nominal flow rate _____scfm
Cooling air
temperature 100°F maximum
Cooling time 60 minutes
Design pressure 200 psig
Design temperature 400°F
MDMT -20°F at 150 psig
Materials of
construction
SA516 Gr.70, SA53 Gr.B,
SA105
Design Pressure 232 psig
Design temperature -20 to 250°F
Materials of
Construcion
Cast aluminum, up to 1500
CFM (Carbon Steel
ASME Coded)
Wet air inlet _____inch sch. 40 pipe
Dry air outlet _____inch sch. 40 pipe
Regeneration outlet _____inch sch. 40 pipe

SECTION 3 DEX HEATED REGENERATIVE DRYER
17
3.6 ELECTRICAL DATA
3.7 TIME, PRESSURE,
TEMPERATURE, AND
DEWPOINT SETTINGS
3.8 DIMENSIONS AND WEIGHT
3.9 FILTER MODELS
Power Supply 480 volt, 3 phase, 60 Hz
Installed power _____KW
Electrical Encolsure NEMA 12
Control voltage 120 Volts A.C.
Solenoid coil voltage 120 Volts A.C.
Adsorption time 240 minutes
Regeneration time 240 minutes
Heating time 140 minutes
Cooling time 100 minutes
Heater outlet
temperature 350°F
Regen. heater
sheath over temp. 650°F
Adsorption pressure 100 Psig (minimum)
Dewpoint controlled
changeover -40°F
High Dewpoint
alarm setting +32°F
Width _____”inches
Height _____”inches
Depth _____”inches
Weight Approx. _____lbs
Pre-Filter Model _____
Pre-Filter Element _____
After Filter Model _____
After Filter Element _____
Control Air Filter _____
Control Air Element _____

18
NOTES

Section 4
19
DBP BLOWER PURGE HEATED DRYER
INSTALLATION
The dryer should be installed on a level location that
is selected to provide easy access to all parts of the
system to ensure future ease of service.
Care should be taken during the location selection to
ensure that there is enough space provided so that
all future maintenance and service can be performed
efficiently.
Ensure that the inlet and outlet connections to the
dryer are made with flanges the correct size and
pressure rating.
Ensure that the electrical service to the dryer is
suitable for the equipment requirements as listed in
Section 3.6 of this manual.
It is recommended that the dryer “regeneration air
outlet connection” or “purge exhaust connection” be
piped to the outside of the building. This ensures that
the moisture adsorbed in each drying period is not
released into the building as the equipment operates.
Since the regeneration blower is a very “low”
pressure device it is critical that the regeneration air
outlet piping is adequately sized. This will prevent
“back pressure” that reduces the blower delivery
volume and consequently the regeneration
efficiency. A good rule of thumb that governs the pipe
size used is as follows:
• Up to 10 feet long use the same size pipe
as the regeneration air outlet connection.
• Up to 20 feet long use one size bigger pipe.
• Up to 50 feet long use two sizes bigger
pipe.
DO NOT use plastic pipe as the exhaust
temperatures may reach 300 degrees F. or hotter.
It is important that the operating conditions listed in
the “Specifications” are observed. Failure to do so
may result in premature failure of the desiccant due
to low operating pressure or high inlet temperatures.
Do not place the dryer into process service until they
has been fully regenerated on both vessels, the
operating cycle in the PLC has been verified and the
system is at the correct operating pressure.
If the system pressure cannot be maintained in the
adsorption vessel during drying a system pressure
holding valve is required to protect the dryer from
high velocities which are the result of low service
pressure. The pressure holding valve must be
installed downstream of the dryer system. Failure to
maintain the correct operating pressure may lead to
dewpoint failure.
If there are any changes in the operating conditions
of the system from those listed in the
“Specifications” section please contact customer
service department for advice on any necessary
system adjustments.

20
NOTES