Trident DRYSPELL PLUS 10 User manual
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Name of purchaser :
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Product :Dryspell Plus desiccant compressed air dryer
Model (refer to name plate) :
Serial number :
Date of manufacture:
Date of delivery :
Date of installation :
Dealer's name/code :
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Note: The warranty on this dryer is valid only if all the details above are filled in and the vendor stamps and signs
this page.
Warranty Statement
Products of Trident Pneumatics Private Limited are guaranteed
to be free from defects in materials and workmanship when
installed and operated in accordance with the instructions
outlined in this user manual.
Trident Pneumatics Private Limited's obligation under this
warranty shall be limited to repair or replacement (at the
discretion of Trident) of defective goods returned to Trident's
plant within one (1) year from the date of commissioning or
18 months from the date of invoicing, whichever is earlier.
Product :
Model :
Serial No.:
Quality Assurance Department
Trident Pneumatics Private Limited
Coimbatore
INSTRUCTION MANUAL - Dryspell Plus
Reference : Manual Version
Statement of conformity
l97/23/EC - Pressurised equipment
l89/392/CEE-Machine safety
l89/336/CEE-Electromagnetic compatibility
l73/23/CEE-Low voltage
lOH6629.5C-CRN
lUL-Listed, RoHs-compliance
INSTRUCTION MANUAL - Dryspell Plus
Reference : Manual Version
Contents
Section Page
1. Intended use 1
2. Unpacking the dryer 2
3. Using this manual 3
4. Functional description 4
4.1 Description of operation 6
4.2 External dewpoint control 7
4.3 Purge economiser 7
5. Technical specifications 11
5.1 Recommended ratings 11
5.2 Physical description 11
5.3 Operating conditions 11
5.4 Power 11
5.5 Capacity 12
5.6 Air inlet conditions 12
5.7 Air outlet conditions 12
6. Installation 13
6.1 General 13
6.2 Location 13
6.3 Layout 13
6.4 Air line 13
6.5 Manpower required 13
6.6 Tools required 13
6.7 Procedure13
7. Operation 14
7.1 Do's and don'ts 14
7.2 Turning the dryer on 14
7.3 Running 15
7.4 Shutting down 15
8. Maintenance 16
8.1 Monthly inspections 16
8.2 Semi-annual inspections 16
8.3 Annual inspections 16
8.4 Replacement of desiccant 17
8.5 Service procedures 17
INSTRUCTION MANUAL - Dryspell Plus
Reference : Manual Version
8.5.1 Dryspell Plus model 10 18
8.5.1.1 Changing the desiccant 19
8.5.1.2 Servicing the bottom shuttle 20
8.5.1.3 Servicing the exhaust valve21
8.5.1.4 Servicing the non-return valve22
8.5.1.5 Changing the inlet tube 23
8.5.2 Dryspell Plus models 20 and 30 24
8.5.2.1 Changing the desiccant 25
8.5.2.2 Servicing the bottom shuttle 26
8.5.2.3 Servicing the exhaust valve27
8.5.2.4 Servicing the top shuttle 28
8.5.2.5 Changing the inlet tube 29
8.5.3 Dryspell Plus models 45 and 60 30
8.5.3.1 Changing the desiccant 32
8.5.3.2 Servicing the bottom shuttle 33
8.5.3.3 Servicing the exhaust valve34
8.5.3.4 Servicing the non-return valve plate 35
8.5.3.5 Changing the inlet tube 36
8.5.4 Dryspell Plus models 100, 125 37
8.5.4.1 Changing the desiccant 39
8.5.4.2 Changing the top shuttle 41
8.5.4.3 Changing the inlet valve assembly 42
8.5.4.4 Servicing the exhaust valve 100 & above 44
8.5.5 Dryspell Plus models 200, 250 45
8.5.5.1 Changing the desiccant 47
8.5.5.2 Changing the top shuttle 200-375 48
8.5.5.3 Changing the inlet valve assembly 50
8.5.6 Dryspell Plus models 300, 375 52
8.5.6.1 Changing the desiccant 54
8.5.6.2 Changing the inlet valve assembly 57
9. Disposal of consumables and replaced parts 59
10. Troubleshooting 60
11. Recommended parts and consumables 61
12. Sales and Services 63
Appendix : Conversion tables 64
Section 1
Intended use
Dryspell Plus dryers are compressed air drying devices manufactured for industrial & other uses.
Water is invariably found in compressed air in the form of vapour and condensed droplets. Dryspell Plus dryers remove this
water.
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Section 2
Unpacking the dryer
Your Dryspell Plus dryer is shipped fully assembled in one or multiple cartons or wooden containers. When you have selected
a suitable location and installed the air line and a suitable system of bypass valves and a pre-filter (refer to Section 6.
Installation), take the dryer out of the carton or container. Remove all protective plastic packaging material.
The shipping carton/container is made of cardboard/wood and is biodegradable.
The polyethylene covers wrapped around the dryers and the bubble wrapping provided around the controllers are recyclable.
They must be disposed of in accordance with prevailing environmental laws.
You will find the following in the shipping carton/container:
1. Dryer assembly
2. User manual (this manual)
3. Connectors and others
4. Cleansweep filter user manual (if pre-filter was obtained from Trident)
If any of the expected items is missing, please contact the vendor with details of your purchase.
INSTRUCTION MANUAL - Dryspell Plus
Reference : Manual Version
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The unpacked dryer must be installed according to the procedure described in this manual (Section 6. Installation).
Section 3
Using this manual
This manual has been specially designed so that you can use your Trident Dryspell Plus dryer optimally and safely. Before
you start using the filter, go through this manual thoroughly. It contains vital information regarding the installation, operation
and maintenance of the dryer.
All the information, illustrations and specifications in this manual are based on the latest product information at the time
of preparation of the manual. Trident reserves the right to make changes in the product at any time without notice.
Ensure that this manual is available at all times to the personnel operating your compressed air system.
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Section 4
Functional description
Figure 1. View of Dryspell Plus dryer with canopy and Trident Cleansweep pre-filter. The control panel may be seen in the
front, at the top. The pre-filter is fitted on the side.
The following are among the major components of your Dryspell Plus:
lTwo desiccant towers
lTop and bottom blocks, including air seals and check valves
lTwo solenoid valves
lTwo inbuilt after-filters
lOne electronic control unit and control panel
lOne pressure gauge (optional)
lTwo silencers
INSTRUCTION MANUAL - Dryspell Plus
Reference : Manual Version
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Your Dryspell Plus dryer may have an optional canopy. There may be an optional pre-filter also. If present, the pre-filter
is fitted outside the dryer assembly.
Figure 2. View of Dryspell Plus dryer without canopy
The function of each of the major components is outlined in the following description of the operation of the dryer.
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4.1 Description of operation
Figure 3. Schematic of Dryspell Plus dryer
Compressed air containing moisture and oil droplets enters the pre-filter. Bulk liquids are removed from the air by the pre-
filter. The air then flows through the inlet shuttle valve, which diverts it to tower 1. The desiccant in tower 1 dries the
compressed air to -40°F PDP as it flows through. The dried air leaves tower 1 via the after-filter. A small part (15%) of
the compressed air is passed through the purge orifice by means of opening a two-way purge valve and thereby expanded
till its pressure is near-atmospheric. This expansion of the already-dry gas (purge air) to near-atmospheric pressure increases
its capacity to strip adsorbed water vapour from the desiccant bed in tower 2. The purge-air stream passes through tower
2, removing water vapour from the desiccant. This purge operation is carried out for 1 minute and 30 seconds. Then the
purge valve is closed, and the pressure in tower 2 begins to rise again. The repressurisation is carried out for 30 seconds.
The purge valve is opened, and purge air passes through tower 1.
During the first 2 minutes of each 4-minute cycle of operation, the following processes take place:
lThe online tower (tower 1) dries compressed air for 2 minutes.
lThe offline tower (tower 2) regenerates (adsorbed moisture is removed from the desiccant in it) for 1 minute and 30
seconds.
lThe offline tower is re-pressurised for 30 seconds.
During the next half of the cycle, these processes are repeated with tower 2 being the online tower and tower 1 the offline
tower.
INSTRUCTION MANUAL - Dryspell Plus
Reference : Manual Version
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4.2 External dewpoint control
The dryer can be optionally operated under external dewpoint control. In this optional system, a dewpoint meter is fitted
at the outlet of the dryer. The dewpoint meter (1) provides an indication of the dewpoint of the dried air and (2) when
the dewpoint of the dried air increases (this happens when the water vapour content of the dried air increases because
the desiccant is saturated and water vapour cannot be adsorbed any more), it provides a signal to end the cycle. The air
is then diverted to the other tower, which contains dry desiccant. Thus the dewpoint meter allows the moisture loading time
of each desiccant bed to stretch as long as the desiccant absorbs moisture. In general, there is no fixed cycle time of 4
minutes' duration when external dew point control is used. The operating cycle with external dew point control is referred
to as a stretch cycle.
4.3 Purge economiser
In practical situations, the airflow through the dryer is not maintained at the maximum flow value that the equipment is
designed for. The moisture load may also vary. At such times, less purge-air may be required to remove the moisture from
the desiccant in a tower. The amount of purge-air used can be reduced by reducing the regeneration time.
Dryspell dryers feature a purge economising feature that can reduce the amount of purge air used by changing the
regeneration time from the maximum value of 90 seconds. The purge is stopped by the purge economiser after a
preprogrammed duration. However, the cycle time is maintained at 4 minutes.
The regeneration flow can be reduced in steps of 20% from 100% to 40% according to the flow through the dryer or the
moisture load. The purge optimisation option may be selected from the control panel.
Control panel. The control panel is used to adjust the purge optimiser and external dewpoint control settings. The control
panel in models 10, 20, 30, 45 and 60 is different from the panel in models 100, 125, 200, 250, 300 and 375.
Figure 4. Control panel of Dryspell Plus (models 10, 20, 30, 45 and 60)
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Figure 5. Control panel of Dryspell Plus (models 100, 125, 200, 250, 300 and 375)
INSTRUCTION MANUAL - Dryspell Plus
Reference : Manual Version
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The following are found on the control panel:
lA schematic of the dryer
lTwo LED indicators for each drying tower-these indicate whether the tower is drying (D) or regenerating/re-pressurising
(R).
lOne LED indicating the operation of the pre-filter drain (only in models 10, 20, 30, 45 and 60)
To adjust the purge flow, press the button marked 'PURGE OPTIMIZER' continuously for 8 seconds, and then set the purge
flow to the required value (40%, 60%, 80% or 100%).
Setting the Purge economizer
Through front panel - Steady conditions
To set the purge economizer please refer the tables below:
Inlet Pressure Correction Factor
Temperature Correction Factor
Dewpoint Correction
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Principle
Pressure swing adsorption dryers purge 15% compressed air at 100 PSI pressure and 1000F inlet compressed air tempera-
ture. This is required to regenerate the bed of adsorbent. The requirement of purge is from basic physical laws and cannot
be altered substantially. Purge loss is a function of Dew point required, Inlet air temperature, Operating pressure and rated
flow. These parameters are have certain values as per standards and Dryers are designed for same. The common standards
are ISO 7183 or CAGI which specifies the standard inlet conditions for the dryer as air temperature 38 deg (1000F) C and
pressure of 7 bar (g) (100 PSI). In practice this is very different. Further a dryer will never be used at its rated flow. When
a dryer is not used at its rated capacity the purge still happens at 15% of the rated capacity. For e.g a Dryspell Plus 100
would purge 15 scfm at 7 bar irrespective of the flow through the dryer. Hence the above dryer with a 80% flow ie 60
scfm would still be purging 15 scfm making the actual purge loss to 25%. This is a common problem with all dyers. Dryspell
plus series dryers come with a front panel purge economizer. Select the Purge economiser switch and the purge flow is
correspondingly reduced. This is done changing the purge time. The purge flow requirement is governed by the Flow rate,
Inlet air temperature, Air pressure and dew point.
Purge optimizer setting = Percentage of rated flow/ (Pressure correction factor * temperature correction factor * Dew point
correction factor) e.g In a given system the Pressure is 120 PSI, Temperature is 1000F, Dew point requirement is -400F
and flow is 80% of rated flow.
Purge optimizer setting = 80/(1.18 x 1 x 1.15) = 58.9 =60%. This saves 40% of purge air. When conditions are not known
or stable set purge optimizer at 100% to ensure dew point.
Through Dewpoint controller - Dynamic Conditions The second method of saving purge is to interface the Dryspell controller
with a dew point switch. A potential free contact of the dew point switch is connected to the controller terminals. The
controller purges correct quantity of air and stops purging. It remains at this state till the dew point at the outlet of the
dryer falls below the set value. At this point the controller changes over to the fresh desiccant tower and starts purge to
regenerate the saturated tower. With this interface highly fluctuating load, varying temperature and pressure can also
factored to save purge air. Please refer user manual for terminal details. This interface also guarantees dew point.
INSTRUCTION MANUAL - Dryspell Plus
Reference : Manual Version
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Section 5
Technical specifications
5.1 Recommended ratings
Pre-filter rating :0.01 micron (coalescer)
After-filter rating (built-in) :25 microns (within the diffuser screen or compactor plate)
5.2 Physical description
Model Overall dimensions (mm)
Height Width Depth Weight (kg)
Dryspell Plus 10 1038 330 150 21
Dryspell Plus 20 963 371 213 29
Dryspell Plus 30 1227 371 213 39
Dryspell Plus 45 999 497 313 49
Dryspell Plus 60 1192 523 313 61
Dryspell Plus 100 1603 439 372 106
Dryspell Plus 125 1913 439 372 119
Dryspell Plus 200 1615 449 582 214
Dryspell Plus 250 1925 449 582 238
Dryspell Plus 300 1615 457 764 256
Dryspell Plus 375 1925 457 764 286
5.3 Operating conditions
Maximum pressure:16 bar g (225 psi g)
Rated operating pressure:7 bar g (100 psi g)
Rated operating temperature:38°C (100°F)
Cycle time :4 minutes
Purge loss :15%
5.4 Power
Voltage :100-240 V AC, 50/60 Hz, 1 phase
Maximum power consumption :20 W
Length of power cord:10 feet * (Optional for US suppliers only)
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5.5 Capacity
Model Nominal inlet flow (cfm)
Dryspell Plus 10 10
Dryspell Plus 20 20
Dryspell Plus 30 30
Dryspell Plus 45 45
Dryspell Plus 60 60
Dryspell Plus 100 100
Dryspell Plus 125 125
Dryspell Plus 200 200
Dryspell Plus 250 250
Dryspell Plus 300 300
Dryspell Plus 375 375
5.6 Air inlet conditions
Rated operating temperature:38°C (100°F)
Rated operating pressure:7 bar g (100 psi g)
Oil should be less than 2 ppm
** As per ISO 7183 option B rated condition
5.7 Air outlet conditions
-40°C (-40°F) PDP (ISO 8573-1:2010 (E) Class 2)
INSTRUCTION MANUAL - Dryspell Plus
Reference : Manual Version
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Section 6
Installation
6.1 General
lMake sure that the dryer is not close to any equipment that does not comply with EU directive 2004/108/EC (relating
to electromagnetic compatibility) and that may affect the operation of the dryer.
lDo not drop the dryer or lift it by the piping or control panel. Doing so may damage the dryer.
lEnsure that the dryer is installed in the vertical position.
6.2 Location
lInstall the dryer in a closed, clean, dry room protected from freezing
lAccess to the room should be restricted to personnel qualified in the maintenance and operation of Dryspell Plus dryers
lThe room must be adequately ventilated
lThe dryer must not be directly exposed to sources of heat
lThe temperature of the room must not exceed 43°C (109°F)
6.3 Layout
lThere must be a minimum distance of 3 feet between the dryer and any other equipment around it that uses electricity
6.4 Air line
Figure 6. Bypass arrangement to be provided on air line
lInstall a system of bypass valves between the dryer inlet and outlet as shown in Figure 6 so that the dryer can be
serviced without having to interrupt the compressed air supply from the circuit
lIf the dryer has been bought without a pre-filter, install a suitable filter ahead of the dryer
lThe upstream and downstream valves must be closed during installation
6.5 Manpower required
lOne skilled technician
6.6 Tools required
lStandard tool set
6.7 Procedure
lSecure the dryer by bolting it down
lConnect a drain line to the pre-filter
lCheck for leaks after all connections have been made
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This manual suits for next models
10
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