This document describes a Gardner Denver DPB Series Blower Purge Desiccant Compressed Air Dryer, a device designed to remove moisture from compressed air. The dryer operates on a pressure swing principle, utilizing two towers filled with desiccant material. While one tower dries the compressed air, the other regenerates, allowing for continuous operation.
Function Description
The DPB Series dryer functions by passing wet compressed air through a bed of desiccant material, which adsorbs moisture. Once the desiccant in one tower becomes saturated, the air flow is switched to the second tower, and the saturated desiccant is regenerated. Regeneration is achieved by depressurizing the saturated tower and purging it with a small portion of the dry air from the active tower, which has been heated to enhance moisture removal. This process effectively drives off the adsorbed moisture, preparing the desiccant for the next drying cycle. The heated purge air is then cooled before being exhausted to the atmosphere.
The dryer is equipped with a control system that manages the switching of towers, regeneration cycles, and heater operation. This ensures optimal performance and energy efficiency. The system can be configured for various operating modes, including Program Mode, Setup Mode, Alarm & Service Mode, and Test Mode.
Important Technical Specifications
The DPB Series dryers are available in various models, each with specific rated flow capacities and corresponding model references.
- DPB500: Rated Flow 500 SCFM, Model Reference 500
- DPB600: Rated Flow 600 SCFM, Model Reference 600
- DPB750: Rated Flow 750 SCFM, Model Reference 750
- DPB800: Rated Flow 800 SCFM, Model Reference 800
- DPB900: Rated Flow 900 SCFM, Model Reference 900
- DPB1050: Rated Flow 1050 SCFM, Model Reference 1050
- DPB1300: Rated Flow 1300 SCFM, Model Reference 1300
- DPB1500: Rated Flow 1500 SCFM, Model Reference 1500
- DPB1800: Rated Flow 1800 SCFM, Model Reference 1800
- DPB2200: Rated Flow 2200 SCFM, Model Reference 2200
- DPB2600: Rated Flow 2600 SCFM, Model Reference 2600
- DPB3200: Rated Flow 3200 SCFM, Model Reference 3200
- DPB3600: Rated Flow 3600 SCFM, Model Reference 3600
- DPB4300: Rated Flow 4300 SCFM, Model Reference 4300
The electrical service for these dryers can be either 460VAC, 3 phase or 575VAC, 3 phase, with specific fusing and wire sizing requirements for each model and component (heater, motor). For instance, a DPB500 with a 10 kW heater and 3 HP motor operating on 460VAC would require a 20 AMP suggested fuse.
The dryer is designed to operate within specific ambient temperature ranges (2°C to 50°C or 35°F to 120°F) and inlet air temperatures (4°C to 49°C or 40°F to 120°F).
Usage Features
The DPB Series dryer is designed for continuous operation, providing a reliable source of dry compressed air. Key usage features include:
- Automatic Operation: The dryer automatically cycles between towers, regenerates desiccant, and controls heater operation based on programmed settings.
- Control Interface: A 2-line LCD display and user interface provide access to operating status, temperature, pressure, and energy management information. The interface allows for configuration of various operating modes and settings.
- Energy Management System (EMS): This optional feature optimizes energy consumption by adjusting the drying cycle based on actual demand and ambient conditions. It monitors temperature, relative humidity, and dew point to minimize energy usage while maintaining desired air quality.
- Dew Point Transmitter (Optional): This option monitors and displays the outlet dew point, providing an alarm signal if the dew point exceeds a user-specified set point.
- Safety Features: The dryer incorporates various safety features, including pressure relief valves, over-temperature RTDs, and interlocks to prevent operation under unsafe conditions.
- Alarm Messages: The system provides detailed alarm messages for various conditions such as low pressure, high pressure, over-temperature, low temperature, high humidity, and dew point issues, aiding in quick troubleshooting.
- Service Due Messages: The display provides reminders for filter, desiccant, and valve service based on programmed intervals (e.g., 4000 hours for filters, 8000 hours for desiccant, 8000 hours for valves).
Maintenance Features
Regular maintenance is crucial for the optimal performance and longevity of the DPB Series dryer. The manual outlines a comprehensive maintenance schedule and procedures:
- General Safety Information: Emphasizes the importance of following safety guidelines, including depressurizing the dryer before any maintenance and ensuring electrical power is disconnected.
- Desiccant Replacement: The desiccant material needs to be replaced periodically, typically every 8000 hours of operation. The procedure involves depressurizing the tower, removing the old desiccant, and filling with new material.
- Filter Service: The pre-filters and after-filters require regular replacement, usually every 4000 hours, to protect the desiccant and downstream equipment.
- Valve Maintenance: The various valves in the system (inlet, purge exhaust, check, repress/sweep, depress) should be inspected and serviced as per the maintenance schedule, typically every 8000 hours.
- Dew Point Analyzer Filter Replacement (Optional): If equipped, the dew point analyzer filter needs to be replaced yearly.
- Troubleshooting Guide: A detailed troubleshooting section helps identify symptoms, possible causes, and corrective actions for common issues such as indicator lights not illuminated, excessive pressure drop, low/high pressure alarms, temperature issues, and blower motor overload.
- Replacement Parts: The manual includes comprehensive lists of replacement parts for various models, categorized by component, along with their part numbers and recommended stock quantities. This facilitates easy ordering and replacement of worn or damaged components.
- Preventive Maintenance Kits: Gardner Denver offers preventive maintenance kits for different years of operation, which include necessary parts for routine maintenance tasks.
The DPB Series dryer is designed for ease of maintenance, with clear instructions and diagrams to guide technicians through various procedures. Regular adherence to the maintenance schedule ensures the dryer continues to provide high-quality dry compressed air efficiently and reliably.
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