Sullair DHL-80 User manual

USER MANUAL
DESICCANT HEATLESS REGENERATIVE
COMPRESSED AIR DRYERS
SHDC-2300 CONTROLLER WITH TOUCH SCREEN
DHL-80 to DHL-5000
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual
or, misuse of this equipment will
VOID its warranty!
SAFETY WARNING
Users are required to read the
entire User Manual before
handling or using the product.
Keep the User Manual in a safe
place for future reference.
MANUAL PART NUMBER:
1000-4544 R01
©SULLAIR LLC

DHL Regenerative Dryer w/SHDC-2300 touch screen controller User Manual US-EN
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Subject to EAR. ECCN EAR99 and related export control restrictions.
TABLE OF CONTENTS
1. DRYER DATA LABEL...................................................................PG 4.
2. SAFETY & INSTRUCTION...........................................................PG (5-10.)
2.1. SAFETY SYMBOL DEFINITIONS........................................................PG 5-6.
2.2. WARNINGS .........................................................................................PG 6.
2.3. USE OF DRYER ..................................................................................PG 7.
2.4. PRESSURE EQUIPMENT INSTRUCTION .........................................PG 7.
2.5. TRANSPORTATION.............................................................................PG 8.
2.6. INSTALLATION ...................................................................................PG 8.
2.7. CORRECTION FACTORS................................................................PG 10.
2.8. PRE-OPERATING PROCEDURES .....................................................PG 10
3. OPERATING CONDITIONS........................................................PG (11-13)
3.1 CONNECTION TO THE COMPRESSED AIR SYSTEM......................PG 11.
3.2 PRIMARY ELECTRICAL CONNECTION.............................................PG 11.
3.3 INLET CONDENSATE DRAIN..............................................................PG 12.
3.4 QUALIFIED SERVICE PERSONNEL.....................................................PG 12.
3.5 MAINTENANCE BY THE USER ............................................................PG 13.
4. PRELIMINARY OPERATION WORKING DETAILS......................PG (13-17.)
A. PRELIMINARY DETAILS .......................................................................... PG 13.
B. PRELIMINARY START UP.........................................................................PG 14.
4.1 SEQUENCE OF OPERATIONS START UP: REFERENCE GUIDE........PG 14-15.
4.2 OPERATION AND SHUTDOWN.............................................................PG 15.
4.3 FIRST START UP ...................................................................................PG 16-17.
5. CONTROLLER SCREEN’S & PROGRAMING ......................PG (18-28.)
5.1 HOME SCREEN.....................................................................................PG 18.
5.2 MENU SCREEN.....................................................................................PG 19.
5.3 SERVICE MAIN MENU- LOGIN ............................................................PG 19-20.
5.4 SERVICE MAIN MENU SCREEN..........................................................PG 20-23.
5.5 ALARM LOG SCREEN .........................................................................PG 23.
5.6 CYCLE TIME SET..................................................................................PG 24.
5.7 OE SETUP SCREEN .............................................................................PG 25.
5.8 DEW POINT SENSOR SET UP SCREEN .............................................PG 26.
5.9 DEW POINT TREND SCREEN.............................................................. PG 27-28.
6. IP INFO SCREEN ...................................................................................PG 29.
6.1 MODBUS ALARM MAP........................................................................PG 30.

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TABLE OF CONTENTS CONT.
7. OPERATING PRINCIPLE.......................................PG (31-35.)
7.1 OPERATION .................................................................PG 32.
7.2 CYCLE DESCRIPTION ................................................ PG 32-33.
7.3 SEQUENCE OF OPERATION ..................................... PG 34-35.
8. MAINTENANCE...........................................................PG 36.
8.1 CONTROLS AND MAINTENANCE.................................. PG 36.
8.2 DISMANTLING OF DRYER .............................................PG 36.
8.3 TROUBLESHOOTING .................................................... PG 37-38.
9. DEW-POINT SENSOR ............................................. PG 39.
9.1 INTENDED USE & DESCRIPTION..................................PG 39.
9.2 SAFETY NOTES..............................................................PG 40.
A TECHINICAL DATA..........................................................PG 40.
9.3 INSTRUMENT DIAGRAM................................................PG 41.
9.4 MODBUS..........................................................................PG 42.
10. SPARE PARTS...............................................................PG 44.
11. WARRANTY....................................................................PG 48.
12. NOTES............................................................................PG 49.
13. ELECTRICAL DRAWINGS.............................................PG 50-51.

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1.1 DRYER DATA LABEL
The following data label is located on the back of the center plate of the compressed air
dryer. The dryer identification plate shows all the primary data values of the dryer. Upon
installation, fill the below data label tag (shown in Figure 1A) with any information located
on the dryer. This data label tag will be useful for the reference of the manufacturer should
you require spare parts, service, or use of the general warranty period.
●Please Note: Removal or alteration of the data label will void warranty rights.
(Figure 1A) Data Label

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2.SAFETY & INSTRUCTION
IMPORTANT SAFETY NOTES PLEASE READ
Before attempting any intervention on the dryer, carefully
read the instructions in this maintenance manual. When operating the air
dryer, the operator must apply safe working methods and observe any
relevant regulations.
2.1 SAFETY SYMBOL DEFINITIONS
🢥Before attempting any intervention on the dryer, read carefully the instructions reported
in this manual.
🢥General warning sign--risk of danger or possibility of damage to the machine. Read
any text related to this sign carefully.
🢥Electrical hazard--the relevant text outlines extreme danger to the operator or
machine, which could be fatal. The related instructions must be strictly respected.
🢥Danger hazard--part or system under pressure.
🢥Danger hazard--notifies components or systems that can reach high temperature.
🢥Danger hazard--it is absolutely forbidden to breathe the air treated with this apparatus.
🢥Danger hazard--it is absolutely forbidden to use water to extinguish fire on the dryer or
in the surrounding area.
🢥Danger hazard--it is 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—dryer noise level could be higher than 85 Dba. It is mandatory to
install the machine in a dedicated area where people are not normally present. The
user is responsible for correct installation of the dryer, to prevent noise propagation to
the nearby work environment. The installer is also responsible for posting safety signs
around the machine site.
🢥Attention--the technician working on the machine must wear hearing protection before
operating the dryer. Each employee must wear proper PPD (Personal Protection
Device) and ear protection (earmuffs, ear canal caps and/or earplugs) to prevent any
danger.
🢥Maintenance should be performed only by qualified personnel.
🢥Compressed air inlet connection point.
🢥Compressed air outlet connection point.
🢥Condensates drain connection point.
●Operations which can be worked out by the operator of the machine, if qualified.

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NOTE : Below are some concerns to be taken into account, but they do not directly involve
safety precautions.
●In designing this unit, a lot of care has been devoted to the protection of the
environment.
oFor example:
●Our dryer and relevant packaging is composed of recyclable
materials.
●We employ an energy saving design.
oTo keep our commitment to this goal, the user should
follow the ecological suggestions marked with this sign.
2.2 WARNINGS
●Compressed air is a highly hazardous energy source. Do not work on the dryer with parts
under pressure. Do not point the compressed air or the condensate drain jet towards
anyone. The user is responsible for the installation of the dryer, which must be executed
based on 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, the following conditions must be satisfied:
●Ensure that the dryer is completely isolated from the power source(s)and that the
electrical panel is de-energized and verified. Perform a proper lockout/tag out.
●Ensure that the dryer is isolated from the compressed air system, fully depressurized and
a proper lockout/ tag out is performed.
●Any change to the dryer or to the relevant operating parameters, if not previously verified
and authorized by the Manufacturer, will void the warranty.
●Do not use water to extinguish fire on the dryer or in the surrounding area.

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2.3 USE OF DRYER
This dryer has been designed, manufactured, and tested only to be used to separate the
moisture normally found in compressed air. Any other use must be considered
unacceptable. The Manufacturer will not be responsible for any issues concerning improper
use of the dryer. If these guidelines are ignored, the user will be responsible for any
resulting damage. Furthermore, the correct use requires compliance with the following
parameters found below:
A) Voltage and frequency of the main power supply.
B) Pressure, temperature, and flowrate of the incoming air.
C) Ambient temperature.
The dryer has been fully assembled and tested prior to delivery. The only operation the
user must complete is to provide a sufficient connection to a compressed air and power
source, in compliance with the instructions given in the following sections. Some models
will have the desiccant shipped separately from the dryer and will require the installation of
the desiccant into the towers prior to start up.
The purpose of the compressed air dryer is to separate H2O molecules and oil particles
from the compressed air. In addition, this dryer cannot be used for applications that include
breathing air or food grade requirements without further treatments.
2.4 PRESSURE EQUIPMENT INSTRUCTION
To ensure the safe operation of pressurized equipment, the user must strictly abide to the
above directives and the following procedures below:
1. Equipment must only be operated within the temperature and pressure limits stated on the
manufacturers name/data plate.
2. Welding is prohibited on the shell or end caps.
3. The equipment must not be stored in poorly ventilated spaces, near a heat source, or near
flammable substances.
4. Vibrations must be eliminated from the equipment to prevent fatigue or failure.
5. An internal inspection must be carried out at 12-month intervals to check for pressure
equipment corrosion. The actual wall thickness of the towers after corrosion should not
be less than the data indicated on the vessel’s certification tag.
6. Automatic 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 manufacturer’s data plate must not be
exceeded.
●All documentation supplied with the equipment (manual, declaration of
conformity etc.) must be kept for future reference.

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2.5 TRANSPORTATION
A) Once the integrity of the packaging is verified, place the unit near the installation location
and unpack its contents.
B) The packaging materials are recyclable.The material must beproperlydisposed in a manner
complying with the regulations of the destination country.
C) Use care when transporting the dryer. Avoid dropping and other physical abuse as some
components, if damaged, can affect the machine’s working capacity.
D) A forklift can be used to transport the dryers, provided the forks are long enough to support
its full width and caution is used throughout the move.
E) If the dryer is set outdoors or indoors, avoid areas where weather or sunlight
can damage the dryer. (The dryer can be damaged by any weather not just
severe weather.)
F) The dryer must be installed vertically. A minimum of a 1 meter clearance
around the dryer is recommended to allow easy access for servicing.
2.6 INSTALLATION
In addition to the general mechanical construction procedures and
local regulations, the following instructions need to be emphasized:
1)Only authorized, trained and skilled engineers should install the compressed air dryer.
2)Safety devices, protecting covers, or insulation on the dryers are never to
be dismantled or modified. Each pressure vessel installed outside the
dryer with air above atmospheric pressure must be fitted with the required
pressure relief safety valves.
INSTALLATION SITE
●Care is required in selecting the installation site, as an improper location could
jeopardise the proper operation of the dryer.
●This unit is not suitable to be used in an explosive atmosphere, where risk of fire
could exist, or in the presence of gaseous or solid polluting material.
●Do not use water to extinguish fire on the dryer or in the surrounding area.
●Dryer’s noise level can be higher than 85 dBA. It is mandatory to install the
machine in a dedicated area where people are not normally present. The installer is
responsible for correct installation of the dryer, in order to prevent noise propagation
to the nearby work environment. The installer and the user is also responsible for
posting signs near the site.
●The machine operator must wear protective equipment. Each additional operator
must select the proper PPD (Personal Protection Device), ear protection (earmuffs,
ear canal caps or earplugs), and observe caution to prevent any danger.

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Minimal installation requirements:
●Select a room which is dry, free from dust, and protected from atmospheric disturbances.
●The supporting area must be smooth, level, and able to hold the weight of the dryer.
●Minimum ambient temperature +1 ºC.
●Maximum ambient temperature +50 ºC.
●Allow at least a clearance of 1 m on each side of the dryer to facilitate possible maintenance
operations.
●Installation of the dryer does not require the dryer being anchored to the mounting surface but
may be by local codes for safety reasons.
INSTALLATION LAYOUT
1
Air Compressor
2
Final After Cooler
3
Condensate separator
4
Filter 5 micron
5
Air Receiver
6
Filter 1 micron
7
Adsorption Dryer
8
Dried Air Outlet
9
Condensates drain
Dryer is supplied with 0.01-micron filter on the inlet and a 1-micron filter on the
outlet. It is recommended to install both 5 micron and 1-micron filter before the
dryer, to protect the life of the inlet filter.
●Type A installation is suggested when the compressed air treated from the dryer is only a
part of the total flow rate of the compressor; or when the compressor operates at reduced
intermittence and the total consumption equals the compressor flow rate.

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2.7 CORRECTION FACTORS
CORRECTION FACTOR TABLE A
CORRECTION FACTOR FOR INLET PRESSURE
PSIG
50
60
70
80
90
10
0
110
120
130
140
150
175
200
225
250
BAR
3.5
4.1
4.8
5.5
6.2
6.9
7.6
8.3
9.0
9.7
10.
3
12.
1
13.
8
15.
5
17.
3
F1
Factor
0.56
0.65
0.74
0.83
0.91
1.0
1.06
1.08
1.12
1.16
1.2
1.29
1.37
1.45
1.52
CORRECTION FACTOR TABLE B
CORRECTION FACTOR FOR INLET TEMPERATURE
0F
70
80
90
100
105
110
115
120
0C
21
27
32
38
40
43
46
49
F2
Factor
1.12
1.09
1.06
1.0
0.93
0.86
0.80
0.75
2.8 BEFORE FIRST START PROCEDURES
🢥The following points must be observed before operating the air dryer:
A) Review all safety precautions.
B) The dryer connection piping measurements must be selected correctly.
C) The dryer connection piping must be adapted to the operating pressure.
D) Never operate the dryer at a pressure above the maximum specified
on the dryer label.
E) The drains should be opened to the atmosphere. If the drains are connected
to a pipe / hose, the diameter of the hose / pipe should be large enough to
create no back pressure during drain. It is not recommended to reduce the
diameter of the hose / pipe less than the port that is given at the drain outlet
of the unit.
The hose / pipe should be at atmospheric pressure at all times. Back
pressure in relevant pipes will result in permanent damage to the drain
system and the affect function of the filters and / or dryers.

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3. OPERATING CONDITIONS
oMaximum working pressure 175 PSIG (10 Bar) for higher pressure contact factory.
oMinimum working pressure 90 PSIG (4 bar)
oMaximum inlet temperature 120 0F (49 0C)
oMinimum ambient temperature: 34 0F (1.6 0C) for lower ambient temperature contact
factory.
3.1 CONNECTION TO THE COMPRESSED AIR SYSTEM
2
●Qualified personnel are required to perform all machine operations that are
suggested in this manual. Never operate under conditions where the factory air is
under pressure.
●The user is responsible to ensure that the dryer will never be operated with
pressure exceeding the nominal values. Eventual over-pressure could be
dangerous both for the operator and the machine.
●The air temperature and the amount of air entering the dryer must comply with the limits
reported on the data label. If the air is not drying at temperatures exceeding 140 F, the
installation of a refrigerated dryer could result as a necessity. The cross section of the
connecting piping must be free from dust, rust, and other impurities. In addition, the flowrate
of the dryer must be consistent. Protective measures must be considered while the dryer
depresses, as vibration could occur during operation. To reduce the vibration during
operation, the use of connecting pipes is recommended to insulate the dryer from possible
vibrations originating from the line (flexible hoses, vibration damping fittings, etc.).
3.2 PRIMARY ELECTRICAL CONNECTION
●The connection to the main switch, which is to be carried out by qualified personnel, must
comply with local rules and laws.
●Before connecting the unit to the electric power, Verify that the voltage and frequency of the
supplied power corresponds to the data plate of the dryer.
●In terms of voltage, a 5% tolerance is allowed. The dryer comes with a power source
connecting cable already installed (6 ft).

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3.3 INLET CONDENSATE DRAIN
●The condensate is discharged at the same pressure of the air entering the dryer.
●Never point the condensate drain jet towards anybody.
Connect and properly fasten the condensate drain to a collecting plant or container.
●The drain cannot be connected to pressurised systems.
●Do not dispose of condensate in the environment.
●The condensate collected in the dryer contains oil particles released in the air by the
compressor. Dispose the condensate in compliance with local rules.
●We suggest installing a water-oil separator which can be used to convey all the condensate
drain coming from compressors, dryers, tanks, filters, etc.
3.4 QUALIFIED SERVICE PERSONNEL
A) Maintenance and repairs should only be performed by DHL when the air
dryer is shut down and depressurized and when the main power switch is
turned off.
B) Use only the appropriate tools for maintenance and repair.
C) Before dismantling a part under pressure, disconnect the pressure sources
and depressurize the system.
D)Proceed carefully during maintenance and repair. Prevent dirt from
entering by covering parts and orifices with a clean cloth, paper or tape.
A receiver should never be welded or modified in any way.
E) Never leave tools, loose parts or cleaning rags in or on the air dryer.
F) Before returning the dryer into service, check the setting of the control and
safety devices as well as the pressure and the temperature of the
compressed air circuit.

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3.5 MAINTENANCE BY THE USER
•Keep the dryer clean.
•Regularly check the correct operation of the condensate drain trap.
•Minimally every six months remove and clean the strainer element installed
before the condensate drain. This may need to be performed more often in some
applications.
•For aircooled dryers, clean the air condenser as soon as it’s dirty or clogged.
•For optional water-cooled condensers, use only clean water and
install a water filter if needed. Use water counterflow to clean the
condenser if needed.
•Check the trouble-shooting list in case of maintenance troubles.
•Check operating pressures, temperatures and time settings after
maintenance. If operating and safety devices function properly, the
air dryer may be used.
4. PRELIMINARY OPERATION WORKING DETAILS
A. PRELIMINARY DETAILS
●This heatless compressed air dryer has been designed to remove water vapor from
industrial compressed air.
●In addition this dryer has been designed for indoor & outdoor conditions of operation.
●Verify that the operating parameters match with the nominal values reported on the
data plate of the dryer (voltage, frequency, air pressure, air temperature, ambient
temperature, etc.).
●Before delivery, each dryer is submitted to accurate tests simulating real operating
conditions. Nevertheless, the unit could be damaged during transportation. We
suggest checking the integrity of the dryer upon arrival and managing the dryer
during its operation.
●Start up procedures are necessary and must be performed with all Sullair Desiccant
dryers.

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B.PRELIMINARY START UP
●At the first start-up, or in case of start-up after a long inactivity period, refer to
the following maintenance operations and comply with the instructions given
below.
●The user that operates the machine must wear hearing protection before
operating the dryer. Each employee must select the proper PPD (Personal
Protection Device) and a hearing protector (earmuffs, ear canal caps and
earplugs) to prevent any discomfort or danger.
●The Minimum and Maximum values found in this operational manual must be
observed and recorded, as well as the safety precautions adhered to.
●Once installation of the dryer has been completed (with the inlet and outlet
connections properly connected), slightly open your air inlet valve in order to
pressurize the dryer slowly. Rapid pressurization can damage filter elements and
instrumentation. As the dryer continues to pressurize, inspect all control and
manifold piping for leaks. If a leak is present, proceed to depressurization of the
dryer and correct any possible air leaks.
●PLEASE NOTE: All pre-setpoint parameters for cycle times configured by the factory
should remain at the (10-minute NEMA CYCLE). UNDER NO CIRCUMSTANCES
should adjustments or changes to the controller set-points occur unless there is prior
communication with SULLAIR’s technical support service team.
4.1 SEQUENCE OF OPERATIONS START UP: REFERENCE GUIDE
●Verify that all the steps of the “Installation” chapter have been observed.
●Verify that the connection to the compressed air system is correct and that the
piping is suitably fixed.
●Verify that the condensate drain piping is properly secured to a collection
system or container.
●Remove any packaging and other material which could obstruct the area
around the dryer.
●Pressurize the dryer slowly.
●Check the piping for air leakage.
●After both towers are equalized switch the on/off switch to the on position.
●Verify that the dryer controller instrument is on.
●Test the drain of the inlet filter.

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●One minute after the start button on the touch screen is pressed, the right
tower will depressurize beginning the regeneration of that tower.
●Wait for the dryer to make some cycles (there is an alternation of
depressurization from tower A to tower B)
PLEASE NOTE: During the first days of working, the Dewpoint is not ensured because the
adsorption material can contain humidity. At the first start-up, or in case of start-up after a
long inactivity period or following maintenance operations, we recommend using the dryer
at a reduced nominal flow of 50% during the first two days.
4.2 OPERATION AND SHUTDOWN: REFERENCE GUIDE
Operation:
●Pause at this point to allow both towers to reach the same pressure.
●Activate the off / on switch.
●Verify that the interactive touch screen display is on.
●Watch for proper operation of the condensate drain connected to the pre-filter. Adjust the time
settings if included. The technician may manually activate a zero loss drain to check operation.
●Press the start button on the touch screen. The tower will remain equalized for 1 minute. The
dryer will then depressurize the right tower. The technician should watch the dryer operation for
two to three full cycles to assure proper operation.
Switching off:
●Press the stop button on the interactive touch screen display.
●Stop the air flow to the dryer.
●Depressurize the dryer.
●Turn the off / on switch to the off position.
●PLEASE NOTE: During the working of the dryer, both towers are cyclic and are
depressurized to be regenerated. The depressurized tower is crossed from part of the
compressed air already dried, which will be expelled outside. The noise of compressed
air during the draining is muffled by silencers.

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4.3 FIRST START UP
●The electrical supply voltage for Sullairs DHL dryers come standard at 110-115-120 Volts /1
Phase / 50-60 HZ . The standard electrical supply voltage will indicate 115 volts as
standard from the factory.
●PLEASE NOTE: that other electrical supply voltages can be optioned to the dryer.
The optioned electrical supplies consist of 208-220-230 Volts / 1 Phase / 50-60 HZ
and 24 volt DC. Prior to powering up the dryer, Verify the spec options of the dryer
and assure that correct voltage is applied.
●Prior to connecting to power, check all electrical connections for tightness and ensure there
are no loose or stray wires present. Once the electrical checks are completed,a qualified
electrical technician may proceed to power up the dryer. Proceed to the following
instructions,
●Turn the dryer OFF/ON switch to the ON position. Once the OFF/ON switch is in the ON
position the Sullair ID screen shown in (Figure.4.1) this will appear during the boot up
process of the program.
●Once the boot screen is present- Touch the
interactive display in order to pull up the home screen,
shown in (Fig 4.1 & 4.2)
INITIAL BOOT UP SCREEN
(Figure 4.1)
HOME SCREEN DİSPLAY MENU
(Figure 4.2)

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HOME SCREEN DISPLAY MENU
(Figure 4.3)
As shown above in (Fig 4.3) the home screen will appear. During this stage, the dryer is ready to
start operations.
●Pressing the start button on the home screen will initiate the program to start pressurizing.
The pressurization screen will pop up and display for a 60 second period.
●When 60 seconds expires, the Controller home screen will be displayed.
PLEASE NOTE: This Pressurizing screen will only appear during start and not during normal
operation.
The pressurizing screen can be seen below in (Fig 4.4)
Pressurizing Screen
(Figure 4.4)

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5. CONTROLLER SCREENS & PROGRAMING
5.1 HOME SCREEN
●The Controller's Home screen will indicate the position of the inlet and purge valves by color coding
the valves, red for closed and blue for open. Dew point will be displayed at the bottom of the screen
next to the Stop button.
(FIGURE 5.1)
HOME SCREEN
●A timer is located at the bottom of the screen to the left of center. This is the time spent in
the NEMA cycle.
●The cycle timer is displayed in seconds and hundredths of seconds (0.00). The Graph on
the left edge of the screen is a bar graph indicating the time expired in the current cycle.
INLET VALVE OPEN
PURGE VALVE
CLOSED
DEW POINT
PROGRAMED
NEMA CYCLE

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5.2 Menu screen
●The Menu button in the top right corner of the Home screen provides access to the Menu
screen.
(Figure 5.2) Menu screen
5.3 Service Main Menu- Login
●Press the Service-Main button to display the log in screen. (Shown below in Fig 5.3)
(Figure 5.3)

DHL Regenerative Dryer w/SHDC-2300 touch screen controller User Manual US-EN
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●Once the Service Main button is pressed the login dialog box will appear. The Login is
"sullair" and will auto fill. Input "1234" as the password. Then press the enter button
(Figure 5.3A) Login screen
5.4 Service Main Menu Screen
●The "Servıce Maın" screen will appear after the correct
password is entered.
(Figure 5.4) Service main screen
sullair
login
password