DHA Series

Installation, Operation and
Maintenance Manual
DHA SERIES
Heatless Desiccant Compressed Air & Gas Purification Systems
With Modular Electronic Controls (MEC)
Models 60DHA-EM1 Through 760DHA-EM1
This instruction manual must be read by everyone

who installs or works with this equipment
Form No: 3201784 (12/2007)

Revision: B
A WORD TO PNEUMATIC PRODUCTS
AIR/GAS PURIFICATION SYSTEM OWNERS
This manual has been prepared to acquaint you with the installation, operation and mainte-
nance of your Pneumatic Products Air or Gas Dryer, and to provide important safety informa-
tion. We urge you to read this data carefully. Follow the recommendations to help insure the
highest performance, safe and trouble free operation of your Air Purification System.
When it comes to Service, remember that your Local Pneumatic Products Sales Represen-
tative knows your equipment and is interested in your complete satisfaction. To help handle
your needs, most of these Sales Companies have become Authorized Pneumatic Products
Service Centers. Please contact the office listed inside your dryer control box when you
need parts or service assistance. If you have a problem that has not been handled to your
satisfaction, follow the steps outlined in Field Service Information and Assistance Section of
this manual.
We thank you for choosing a Pneumatic Products product and want to assure you of our
continuing dedication to provide the highest air purification equipment reliability and perform-
ance available anywhere in the world.
Table of Contents
SPECIFICATIONS
Chapter 1 General Information

1.1 Foreword ................................................................................................................ 1-1
1.2 Warranty Policy ...................................................................................................... 1-1
1.2.1 Warranty ................................................................................................................ 1-1
1.2.2 Warranty Replacement Parts Process ................................................................... 1-2
1.2.3 Warranty Field Service Labor ................................................................................. 1-2
1.2.4 Start-Up Process .................................................................................................... 1-2
1.3 Field Service Information and Assistance ............................................................... 1-2
1.4 Short Shipment or Incorrect Material Claims .......................................................... 1-2
1.5 Shipping Damage Claims ....................................................................................... 1-2
1.6 Return Goods Authorization ................................................................................... 1-3
1.7 General System Information ................................................................................... 1-3
1.7.1 Dryer ...................................................................................................................... 1-3
1.7.2 Prefilter Assembly .................................................................................................. 1-3
1.7.3 Automatic Drain Valves .......................................................................................... 1-3
1.7.4 Afterfilter Assembly ................................................................................................ 1-3
Chapter 2 Installation
2.1 Equipment Handling ............................................................................................... 2-1
2.2 Mechanical Set-Up ................................................................................................. 2-1
2.3 Equipment Check ................................................................................................... 2-1
2.4 Piping and Component Installation Notes ............................................................... 2-2
2.5 General Piping Information ..................................................................................... 2-3
2.6 Purge Exhaust Restrictor ........................................................................................ 2-3
2.7 Purge Exhaust Muffler ............................................................................................ 2-3
2.8 Electrical Connection .............................................................................................. 2-3
2.9 Remote Alarm Connection ..................................................................................... 2-4
2.10 Instrumentation ....................................................................................................... 2-5
Chapter 3 Operation
3.1 How It Works .......................................................................................................... 3-1
3.2 Automatic Drain Valve ............................................................................................ 3-1
3.3 Start-Up .................................................................................................................. 3-2
Initial Start-Up ......................................................................................................... 3-2
Normal Start-Up or Restart ..................................................................................... 3-3
3.4 Normal Operational Checks ................................................................................... 3-3
3.5 Dryer Shutdown ...................................................................................................... 3-4
Table Of Contents
Chapter 4 Maintenance and Repair

4.1 Preventative Maintenance Schedule ...................................................................... 4-1
Daily ....................................................................................................................... 4-1
Weekly ................................................................................................................... 4-1
Quarterly ................................................................................................................ 4-1
Semi-Annually ........................................................................................................ 4-1
Annually .................................................................................................................. 4-2
4.2 Desiccant Charging Procedures ............................................................................. 4-2
4.3 Filter Element Replacement ................................................................................... 4-4
4.4 Automatic Drain Valve Disassembly and Servicing ................................................ 4-4
4.5 1" Switching Valve Maintenance (Inlet and Purge Exhaust) ................................... 4-6
4.6 1-1/2" Switching Valve Maintenance (Inlet and Purge Exhaust) ............................. 4-8
4.7 2" Switching Valve Maintenance (Inlet and Purge Exhaust) ................................... 4 - 10
4.8 1" Purge and Outlet Check Valve Maintenance ...................................................... 4 - 12
4.9 1-1/2" Purge and Outlet Check Valve Maintenance ................................................ 4 - 14
4.10 2" Purge and Outlet Check Valve Maintenance ...................................................... 4 - 16
4.11 Repressurization Valve Maintenance ..................................................................... 4 - 18
4.12 Single Orifice Remote Flow Restrictor Maintenance ............................................... 4 - 19
4.13 Moisture Indicator Recharging Procedure .............................................................. 4 - 20
4.14 Remote Sensor Assembly Maintenance ................................................................. 4 - 21
4.15 Microcomputer-Based Dryer Control System ......................................................... 4 - 22
4.16 AMLOC® Control Board ......................................................................................... 4 - 23
Chapter 5 Troubleshooting Guide
Appendix A Purge Curves

SPECIFICATIONS
STANDARD DESIGN OPERATING CONDITIONS
MODEL FLOW CAPACITY¹

(scfm)
60 DHA 60 Operating Pressure 60 psig minimum
110 DHA 110 150 psig maximum
130 DHA 130

Operating Temperature 40° F minimum
185 DHA 185 120°F maximum
240 DHA 240
Inlet Moisture Content Saturated (at specified inlet pressure)
270 DHA 270
360 DHA 360
Outlet Moisture Content -40 °F Dew Point @ line pressure
505 DHA 505
630 DHA 630
760 DHA 760
¹ Based on standard inlet conditions of 100 psig, 100°F and 100% RH.
Maximum recommended inlet temperature, 120°F. For capacity at inlet
temperature higher than 100°F, consult your local distributor.
DETAIL SPECIFICATIONS:
Dryer Cycle: NEMA Cycle 6 minutes

Drying 3 minutes
Regeneration 3 minutes
Dryer Adsorbent: Type DE-4 Activated Alumina
Pressure Vessels: ASME Section VIII, DIV. 1 Stamped

Design Pressure 150 psig
Design Temperature 450° F
Dryer: Operation Automatic

Pressure Drop .5 TO 5 psid @ 100 psig and 100° F
Purge Source Dryer Outlet
UTILITIES:
Electrical: NEMA Type NEMA 4

Input 120V, 60 HZ, 1 PH
Power Consumption 40 WATTS
SPECIFICATIONS
MODEL PREFILTER AFTERFILTER

60 DHA P2001-100SU1-G16 P2001-100AF1-G16
110 DHA P2001-150SU1-G16 P2001-150AF1-G16
130 DHA P2001-150SU1-G16 P2001-150AF1-G16
185 DHA P2001-275SU1-G24 P2001-275AF1-G24
240 DHA P2001-275SU1-G24 P2001-275AF1-G24
270 DHA P2001-275SU1-G24 P2001-275AF1-G24
360 DHA P2001-400SU1-G32 P2001-400AF1-G32
505 DHA P2001-600SU1-G40 P2001-600AF1-G40
630 DHA P2001-800SU1-G40 P2001-800AF1-G40
760 DHA P2001-800SU1-G40 P2001-800AF1-G40
1
General
Information
1.1 Foreword 1.2.1 Warranty
This manual is designed to serve as the installation, op- DHA-EM1 Series dryers are warranted for a period of five
eration, and maintenance guide for your dryer. The con- years from date of shipment, with the exception of con-
tents of this manual should be carefully read BEFORE at- sumable items, against defective materials when:
tempting any phase of installation, operation or mainte- (1) properly installed, (2) operated within design condi-
nance. Failure to follow the operating and maintenance tions, (3) maintained according to the maintenance and
procedures of the instruction manual could result in per- repair schedule in section 4 of this manual and (4) genu-
sonal injury or property damage. ine Pneumatic Products replacement parts are used.
Consumable items are those which are expected to wear
To facilitate maintenance, a “Spare Parts List” for your under normal operating conditions, including filter car-
specific dryer model has been prepared and attached. tridges, gaskets, seals, desiccant, gauges, dew point sen-
Failure to maintain spare parts and filter cartridges may sors and valve software items. Consumable items are
result in EXPENSIVE and unnecessary downtime, for warranted for a period of one year from the date of ship-
which Pneumatic Products cannot be responsible. To ment against defective materials when properly installed
request a quotation, or place an order for spare parts, and operated within design conditions. All parts proven to
please contact your local Pneumatic Products Sales Rep- be defective within the warranty period will be replaced
resentative. free-of-charge, with all shipment and labor charges paid
A Dryer Specification Plate has been permanently at- by the customer. Claims for damage or lost labor will not
tached to the front of the dryer. When requesting infor- be allowed, nor can we guarantee our equipment against
mation, service, ordering of spare parts, etc., please refer- corrosion or similar sources of failure where the operating
ence all information supplied on the Specification Plate. conditions are beyond our control.
Refer to the Field Service Information and Assistance This warranty applies to the air dryer only. Accessories,
Section of this manual for contact procedures. consumable items, and other ancillary components are
All information, specifications and illustrations within this not covered under this warranty, however, they may be
manual are those in effect at the time of printing. Pneu- covered under their own express warranties, i.e., drain
matic Products reserves the right to change or make im- valves, gauges, desiccant, etc.
provements without incurring any obligation to make THE WARRANTY DESCRIBED ABOVE IS IN LIEU OF
changes or add improvements to products previously ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUD-
sold. ING THE IMPLIED WARRANTY OF MERCHANTABIL-
ITY AND THE IMPLIED WARRANTY OF FITNESS FOR
1.2 Warranty Policy A PARTICULAR PURPOSE, WHICH IMPLIED WAR-
RANTIES ARE EXPRESSLY DISCLAIMED. THE MANU-
FACTURER EXPRESSLY DISCLAIMS AND EXCLUDES
The following clearly defines the Pneumatic Products ANY LIABILITY FOR CONSEQUENTIAL, INCIDENTAL,
Warranty Policy. Pneumatic Products management is INDIRECT, OR PUNITIVE DAMAGES FOR BREACH
solely responsible for establishing service rates and deter- OF ANY WARRANTY. THIS LIMITED WARRANTY
mining the disposition of warranty claims. Approval for SHALL CONSTITUTE THE COMPLETE AND FINAL
deviation from this policy must have prior approval of AGREEMENT BETWEEN THE MANUFACTURER AND
Pneumatic Products management. PURCHASER WITH RESPECT TO ALL WARRANTY
OBLIGATIONS OF THE MANUFACTURER AND PROD-
UCTS SOLD.
General Information 1-1

1.2.2 Warranty Replacement Parts 1.3 Field Service Information and
Process Assistance
It should be noted that the Pneumatic Products warranty For information or inquiries concerning dryer installation,
responsibility is limited to furnishing the customer replace- operation, maintenance problems or service, contact your
ment parts at no cost. The customer is responsible for local Pneumatic Products Sales Representative. If your
the outward shipping costs. problem is not handled to your satisfaction then contact:
A customer Purchase Order is required prior to shipment PNEUMATIC PRODUCTS
of warranty replacement parts. Replacement parts will be 4647 S.W. 40th Avenue
shipped immediately at no charge. The customer is re- Ocala, Florida 34474
quired to return the reportedly defective parts to Ocala,
Florida at Pneumatic Products expense. When the parts ATTENTION: FIELD SERVICE
are received, inspected, and the defect is confirmed; the PHONE: (352) 237-5793
customer’s P.O. is considered closed. If no defect is FAX NO: (352) 873-5770
found, the original part will be returned to the customer, When making inquiries by phone or correspondence,
freight collect and an invoice against the customer’s P.O. please provide the following information:
will be issued for the replacement part already sent. Re-
turns must be made through Pneumatic Products Return 1. Dryer Model Number
Goods Authorization System. Contact the Pneumatic 2. Dryer Serial Number
Products Field Service Department for return authoriza- 3. Actual Dryer Inlet Pressure
tion. 4. Actual Dryer Inlet Temperature
5. Actual Flow Rate (if known)
6. Approximate Time In Service
1.2.3 Warranty Field Service Labor 7. Nature Of Problem
While the Pneumatic Products warranty does not cover 1.4 Short Shipment or Incorrect
replacement parts installation; Pneumatic Products may
elect to provide this service at the discretion of Pneumatic Material Claims
Products management. Prior authorization is required
before a service call will be made. A customer Purchase All claims for shortage or incorrect material must be made
Order is required before a Pneumatic Products Autho- within ten (10) days after its receipt. A shipment often
rized Service Engineer will make a service call (warranty consists of several containers, skids, etc. that include
or paid). After the service call, Pneumatic Products will loose accessories such as pipe, filter elements, relief
determine what charges will be covered by the warranty valves, drain valves, and desiccant. Please review all in-
and what charges will be invoiced to the customer’s Pur- voices and shipping documents carefully for possible
chase Order. shortages.
1.2.4 Start-Up Process 1.5 Shipping Damage Claims
Dryer start-up is the responsibility of the local Pneumatic Equipment must be carefully inspected immediately upon
Products Sales Representative. receipt for possible damage incurred during shipment.
Pneumatic Products requires two (2) weeks notification Ownership of equipment shipped F.O.B. factory, is trans-
from the customer or local representative in order to ferred to the purchaser upon departure from our factory.
schedule a factory service engineer for a paid start-up Therefore, all shipping claims must be owner-processed
call. The local Pneumatic Products Authorized Service with the shipping carrier, and cannot be handled by Pneu-
Center may also be contacted to provide paid start-up in matic Products. We, the manufacturer, will attempt to
order to gain the Extended Warranty Coverage. assist you in every way possible, however, the initial claim
In any case, the local Pneumatic Products Sales Repre- and all future proceedings are the responsibility of the
sentative is required to be present at all start-ups. owner.
1-2 General Information

In the event that the equipment has sustained visible ex- 1.7.1 Dryer
ternal damage or it is suspected that internal damage may
have occurred, immediately enter a claim with the ship-
ping carrier and notify Pneumatic Products. Any indica- This fully automatic, heaterless-type dryer alternately
tion of damage or careless handling by the carrier should cycles the compressed, process gas flow through two
be noted on the delivery receipt. Obtaining the delivery desiccant-filled, vertical chambers where the gas's en-
man’s signed agreement to any noted damages will facili- trained, vaporous moisture content is adsorbed. One
tate any future insurance claims. desiccant chamber is always on-line in a timed Drying
Cycle throughout normal dryer operation. The opposite,
In all cases of damage, visible or suspected, contact your off-line chamber is in a timed Regeneration Cycle for re-
local representative or the factory before attempting to moval of the desiccant's previously adsorbed moisture
install subject equipment. content or in a static state pressurized condition. The
dryer's 'fail-safe' design feature provides continued pro-
cess gas flow though both desiccant chambers if the con-
1.6 Return Goods Authorization trol system's power supply is lost or interrupted.
To ensure that material or equipment being returned for

repair or credit is being handled properly, please adhere 1.7.2 Prefilter Assembly
to the following procedure:
1. Contact the Pneumatic Products Field Service De- As the first line of defense against oil/water contaminants
partment to discuss potential returns. Valid returns a Coalescing Prefilter with an automatic drain is required.
will be assigned an authorization number. The Coalescing Prefilter Assembly removes oil and water
2. Mark the outside of each shipping container with the aerosols, as well as dirt and pipe scale from the gas
assigned authorization number. If more than one stream BEFORE the gas enters the dryer. Oil and liquids
container is returned, please mark each additional collected by the assembly's filter cartridges fall to the
container with the assigned authorization number. housing sump which must be periodically drained.
3. Return subject equipment or material to Pneumatic

Products unless otherwise directed. 1.7.3 Automatic Drain Valves
4. Material or equipment shipped to Pneumatic Prod-
ucts without proper authorization cannot be ac- As previously stated, the accumulated water and oil mix-
cepted and will be immediately returned at the ture collected by a prefilter must be periodically drained
customer’s expense. from the prefilter housing sump. An Automatic Drain
Valve is a recommended and reliable means of removing
Note: Return goods authorization does not in itself collected moisture, oil and sludge from coalescing filter
constitute a guarantee that credit will be issued. Fi- housings and other components requiring periodic drain-
nal disposition of credit allowance rests solely with ing.
Pneumatic Products and will be made after receipt
and inspection of subject material or equipment.
1.7.4 Afterfilter Assembly
1.7 General System Information A Particulate Afterfilter Assembly is another feature of-
fered. Even under the most ideal conditions, all regenera-
CAUTION: The DHA-EM1 Series Heatless Desiccant tive type desiccant dryers tend to generate small quanti-
Dryer System is designed to sequentially remove con- ties of micron-sized desiccant dust particles. This highly
taminants. The Prefilter removes liquid and particulate abrasive contaminant can erode instruments, valve seats,
contaminants, the Dryer removes vaporous contaminants air cylinders and pneumatic tools. A Particulate Afterfilter
and the Afterfilter removes any remaining particulates. Assembly installed downstream of your desiccant dryer
Bypass of any component in the system compromises the will remove desiccant dust, pipe scale and other harmful
whole system. particulate before the gas stream continues to points-of-
use.
CAUTION: Each component of the dryer system has
been selected to compliment the performance of the other
components of the system. Therefore, use of unautho-
rized parts or supplies or improper operation will degrade
system performance.
General Information 1-3

2
Installation
2.1 Equipment Handling 3. Utilizing the baseplate mounting holes provided, an-
chor the dryer to a solid, level foundation designed to
support the dryer’s dead weight loading, plus any
Note: Should question arise concerning site selection, earthquake or wind loadings, as required.
installation, operation, etc., please contact your local
Pneumatic Products Sales Representative for assistance. 4. Suitable protective barriers are recommended to re-
duce the possibility of accidental damage if the unit
WARNING! is located in an open area, or in close proximity to
Use appropriate, load-rated lifting equipment, and vehicular and pedestrian traffic.
observe safe lifting procedures during all moves.
The unit should be carefully unloaded as close as is
possible to final installation site to minimize chances 2.3 Equipment Check
of equipment damage. Refer to the General Arrange-
ment Drawing for equipment shipping weight. 1. Vibration during shipment can cause loosening of fit-
Forklift slotting at the base of the dryer’s protective ship- tings and fasteners. Therefore, inspect the dryer for
ping framework and lifting straps installed on the dryer are alignment, connection and tightness of all subas-
provided. semblies, etc. Do not tighten AMLOC® Probes .
CAUTION: Never attempt to remove, loosen or
2.2 Mechanical Set-Up tighten an AMLOC® Probe which is installed in a
desiccant filled chamber. Desiccant must first be
drained to prevent AMLOC® Probe damage.
IMPORTANT: When selecting an installation site, con-
sideration must be given to the need for adequate clear- 2. Desiccant is normally installed prior to shipment un-
ances around and above the dryer for ease of mainte- less otherwise specified by the customer. Tapping
nance and accessibility. Site selection should also take on each chamber with a soft-face mallet will yield a
into account possible momentary sound levels in excess deadened sound if desiccant has been installed. If a
of 85 decibels during each desiccant chamber depressur- hollow sound is noted, the chambers are empty and
ization period. require installation of desiccant prior to operation.
Refer to the Desiccant Charging Procedure in the
1. Locate the dryer in an area with adequate clearance Maintenance and Repair section of this manual, if
for servicing of all components. The recommended charging is necessary.
clearance around the dryer should be a minimum of
four (4) feet. An overhead clearance of not less than CAUTION: Dryer models covered within the scope
two (2) feet above each desiccant chamber fill port of this manual are designed to use a specific desic-
plug is required for desiccant installation. Refer to cant. Use of any other size or type may reduce effi-
the general arrangement drawing for dimensions, ciency or damage the dryer.
connections and weight specifications applicable to CAUTION: Do not hydrostatically test the dryer
your specific dryer model. with desiccant installed. All pressure vessels
2. Remove all protective shipping framework, covers, which fall under the scope of ASME Section VIII, are
pipe plugs, shipping blocks, etc. hydrostatically tested in accordance with the latest
addenda. Hydrostatic testing will damage the dryer's
desiccant charge.
Installation 2-1
3. While exercising caution for Static Sensitive De- Table 2.1 — Connections
vices, open the Dryer Control System enclosure
cover and check all terminal block wiring connec-
tions. Do not overtighten terminal block lug Connections
screws. Close the dryer control system enclosure Model (Inches)
cover and tighten all cover latches. Inlet Outlet
CAUTION: Do not remove the factory programmed 60 1" NPT 1" NPT
microcomputer chip or any I.C. chip from the logic
control circuit board. Improper removal will cause 110 1" NPT 1" NPT
irreparable damage to these highly static-sensitive 130 1" NPT 1" NPT
components. Damage to these components will
render the Dryer Control System inoperative until 185 1½" NPT 1½" NPT
replacement is accomplished by a Field Service En-
240 1½" NPT 1½" NPT
gineer. Do not remove the program identification
sticker from the microcomputer chip. 270 1½" NPT 1½" NPT
WARNING! 360 2" NPT 2" NPT
DIP switches within the control box have been
preset at the factory to conform to customer op- 505 2½" NPT 2½" NPT
erating conditions. Any tampering with DIP 630 2½" NPT 2½" NPT
switches will void warranty and may reduce the
quality of the product gas. Any adjustments of 760 2½" NPT 2½" NPT
DIP switches should only be made by a qualified
Pneumatic Products Field Service Engineer.
PREFILTER
BLOCK
2.4 Piping and Component AIR
VALVE
INLET
Installation Notes
Note 1: Use the proper pressure rated piping, fittings

and valves as approved by ASME, ANSI, CSA,
DRAIN
UL, etc. Separate or special requirements im- VALVE
posed by local and/or municipal codes may also

apply.
DRYER
BYPASS
Note 2: Pneumatic Products is not liable for code viola- VALVE
tions, downtime, component failure or conse-

quential damages to customer supplied compo-
nents and/or equipment.
Note 3: Where it is undesirable to interrupt process flow,
an Adsorber Bypass System with block valves AFTERFILTER
should be installed to permit servicing and main-
BLOCK
tenance of the dryer and associated filter as- AIR
VALVE
semblies. The recommended block valve OUTLET
MUST be of a type which will provide bubble- SERVICE

VALVE
tight shut-off. Ball, globe, or butterfly valves with
soft seats are suitable for this purpose. Do not
use plug or gate valves.
Note 4: All inlet and outlet connections, valve and inter-
Figure 2.1 — Recommended Piping Layout
connecting piping MUST be of the same size as
the dryer’s gas inlet connection or larger. Pneu-
matic Products and its affiliates are not liable for
excessive pressure drops and loss of capacity
caused by undersized or incorrectly installed
piping and/or piping components. Refer to
Table 2.1 for inlet and outlet connection sizes for
your dryer system.
2-2 Installation
Note 5: Carefully inspect all piping lengths and compo- The Equivalent Length (based on Purge Exhaust Size) of a
nents BEFORE installation. Remove any inter- pipe which will have the same resistance to air flow as the
nal oil, water, dirt, or debris which may have ac- actual pipe run, including all its pipe fittings and valves. A
cumulated during shipment and/or storage. list of fittings and applicable L/D factors for each are shown
below:
Note 6: Leakage from piping connections and/or associ-
ated components installed upstream of the dryer FITTINGS L/D
will cause a loss of gas pressure and unneces- Standard 45 Elbow (Threaded) 16
sary compressor cycling. The slightest leakage Standard 90 Elbow (Threaded) 30
from piping connections and/or associated com- Long Radius 45° Welded Elbow 8
ponents installed downstream of the dryer’s out- Short Radius 90° Welded Elbow 20
let connection can easily cause a degradation of Long Radius 90° Welded Elbow 14
the dried gas dew point. The use of TFE tape
on all male pipe threads and the application of To obtain the equivalent length of pipe for each of the fit-
sufficient torque at assembly will greatly reduce tings shown, multiply the L/D factor by D (the inside diam-
chances of leakage and subsequent rework. eter of the pipe in feet).
1. All external piping must be supplied by the customer Example: What size should be used in an exhaust line
unless otherwise specified. Refer to Table 2.1 for which combines 25.0 feet of pipe; (3) 90° threaded elbows?
connection sizes. Inlet and outlet manual shut-off The dryer purge connection size is 1.5 inch pipe.
valves and a vent valve are recommended so the
dryer and filters can be isolated and depressurized (3) ells @ 30 each= L/D = 90
for servicing. Refer to Figure 2.1 for recommended Equivalent Length= 90 X D
piping layout. L = 90 X (1.5 in./12 in.) = 11.25 ft.
11.25 ft. + 25 ft. of pipe run = 36.25 ft. total.
Use 2.5 in. Exhaust pipe and fittings.
2.5 General Piping Information
1. Refer to the following sources of information as nec-

2.6 Purge Exhaust Restrictor
essary while conducting piping and component in-
stallation procedures: The dryer’s proprietary Purge Exhaust Restrictor quiets
the gas flow and prevents desiccant bed fluidization by
a) Piping and Installation Notes section of this controlling (slowing) the rate of depressurization. To op-
manual. erate properly, the Purge Exhaust Restrictor MUST re-
b) Dryer General Arrangement Print for dryer di- main attached to the Purge Exhaust Switching Valve
mensions and connection sizes, component body.
identification and location.
c) Purge Exhaust Piping is not required, however, 2.7 Purge Exhaust Muffler
if it is necessary to have a remote mounted si-
lencer, consult with your local Pneumatic Prod- The dryer’s proprietary Purge Exhaust Muffler quiets the
ucts Sales Representative or the Pneumatic gas flow to atmosphere during depressurization and re-
Products Customer Service Department for a generation (purge) cycles.
special purge exhaust restrictor and muffler.
Piping will be as follows: 2.8 Electrical Connection

PURGE EXHAUST PIPE SIZE DIMENSIONS
ARE INCHES Note 1: Use proper, load-rated components as ap-
PURGE CONNECTION 1 1.5 2 proved by NEC, NEMA, CSA, UL, etc., as re-
quired. Local and municipal codes may also
EQUIVALENT 10 FT. or LESS 1 1.5 2 apply. All installations and connections must be
LENGTH OF 11 FT. to 25 FT. 1.5 2 2.5 in accordance with recognized electrical codes,
PIPE IN FT. 26 FT. to 50 FT. 2 2.5 3 in effect.
51 FT. to 100 FT. 2.5 3 3.5 Note 2: It is mandatory that each dryer be individually
GROUNDED. Do not use your plant’s frame as
Never use more than 100 equivalent feet of pipe. a ground. Use an adequate ground with the
conductor sized to NEC. The electrical supply
must be a three wire, grounded service.
Installation 2-3
Note 3: A disconnect switch is not provided as standard these terminals should be routed as far as possible
equipment and therefore, must be supplied by from any other wiring or components within the en-
the customer. The dryer’s electrical load is indi- closure.
cated on the dryer-mounted Specification Plate
or on the Dryer Specification Sheet located in NOTE: For hazardous locations, the Power Input
the front of this manual. and Remote Alarm Terminal Block are located in the
NEMA 7 enclosure.
Note 4: Pneumatic Products is not liable for code viola-
tions, component damage, downtime or conse- CAUTION: Do not make any additional wiring con-
quential damages related to customer supplied nections to terminals H, N, or GND on the POWER
and installed electrical components and connec- INPUT.
tions. CAUTION: Do not remove the factory programmed
Note 5: Exercise CAUTION for Static Sensitive Devices microcomputer chip or any I.C. chip from the logic
before making electrical connections. control circuit board. Improper removal will cause
irreparable damage to these highly static-sensitive
Note 6: DRYER CONTROLS FOR HAZARDOUS LO- components. Damage to these components will
CATIONS. Optima dryer controls for hazardous render the Dryer Control System inoperative until
locations comply with the National Electrical replacement is accomplished by a Field Service En-
Code (NEC) for application in Class I, Division 2, gineer. Do not remove the program identification
Group B through D hazardous locations. Per sticker from the microcomputer chip.
NEC 501-3 (b), all incendive devices (power
supply, common alarm relay, fuse) that may re- WARNING!
lease enough energy to ignite B through D DIP switches within the control box have been
gases and vapors are located in a NEMA 7 en- preset at the factory to conform to customer op-
closure. Also, all non-incendive devices (sole- erating conditions. Any tampering with DIP
noid valves, DIP switch and pressure switch switches will void warranty and may reduce the
contacts) that do not normally release enough quality of the product gas. Any adjustments of
energy to ignite B through D gases and vapors, DIP switches should only be made by a qualified
are located in a NEMA 4 enclosure. Pneumatic Products Field Service Engineer.
1. Refer to the dryer-mounted Specification Plate, (or

the Dryer Specification Sheet in the front of this 2.9 Remote Alarm Connection
manual) for your specific dryer model’s electrical in-
put requirements. Ensure that the intended power WARNING!
source conforms to these requirements. Most standard air and gas dryers are furnished with
CAUTION: Surges, spikes and input voltage of less contacts for remote alarms. These contacts should
than eighty-five (85) VAC or greater than one-hun- be wired to an audible alarm and/or to an area where
dred and thirty-two (132) VAC, may cause the Dryer they are continuously monitored. When these con-
Control System to operate erratically, or malfunction. tacts are not used, the dryer must be visually
This malfunction may or may not be accompanied checked every two (2) hours for existence of any pos-
by an alarm. Adequate surge, spike, brownout and sible malfunction. Failure to do so may result in an
blackout protection must be provided to protect your upset condition that could damage the equipment.
equipment and allow safe shutdown time. (An unin- Failure to protect the dryer from aerosols and liquid
terrupted power supply is recommended.) Failure to condensate will void warranties.
do so may result in Wet Pilot Gas entering the con- 1. Remote alarm terminals (A1, A2, A3) are provided
trol enclosure and damage to the equipment. Fail- for connection of a customer-supplied remote alarm
ure to provide adequate protection to the Input volt- circuit (if desired). Should an alarm situation or loss
age will void warranties. of the dryer’s power supply occur, the remote alarm
2. Using the conduit connection ports provided, con- relay will de-energize to transfer contact from A3 to
nect the electrical input and ground leads to the A2 for remote alarm actuation.
Power Input and Remote Alarm Terminal Block. Note: A customer supplied separate power source
Make connections in accordance with the lead con- of sufficient voltage, (not to exceed 120 VAC) must
nection inscriptions (FG, H, N). CONNECT be connected to terminal A1 for remote alarm actua-
GROUND LEAD (FG) FIRST. tion.
Note: All customer connection terminals will accept CAUTION: The total current rating of all customer
24 through 10 AWG wire. In order to minimize elec- supplied remote alarm equipment MUST NOT ex-
trical noise related problems, all wiring connected to ceed 6 amperes inductive, and 10 amperes resis-
2-4 Installation
tive. Do Not make any additional wiring connections High Humidity Alarm
to terminals A1, A2, and A3. If the on-line AMLOC® frequency falls below 6000 Hz prior
to switchover, meaning that the on-line chamber has be-
come moisture loaded, the 'HIGH HUMIDITY' alarm is
2.10 Instrumentation activated and the cycle continues. The 'HIGH HUMIDITY'
alarm condition automatically clears as soon as the
The DHA-EM1 Series Heatless Desiccant Dryer System AMLOC® frequency rises above 6000 Hz.
is equipped with a microprocessor system that controls
the operation of all dryer functions. The controller is Chamber Pressure Gauges
programmed to operate on a six (6) minute cycle. The A gauge mounted on the inlet piping manifold indicates
controller keeps the drying chamber on-line for three (3) which chamber is on-stream and which is regenerating.
minutes while simultaneously regenerating the off-line The gauge for the on-stream chamber indicates operating
chamber. Indicators on the controller help in monitoring pressure; the gauge for the regenerating chamber indi-
dryer operation and performance. cates 0 psig.
AMLOC® Energy Management Purge Flow Indicator

The AMLOC® energy management system automatically A gauge mounted on the outlet piping manifold of the
adjusts dryer operation to compensate for changes in dryer indicates purge air pressure as an approximate
operating conditions. AMLOC® (Automatic Moisture Load measure of purge airflow when used with the appropriate
Control) reduces expensive purge gas consumption by calibration curve found in Appendix A.
reducing the number of desiccant chamber regeneration
cycles (depressurization, regeneration, and repressuriza- AQUADEX® Moisture Indicator
tion). Basically, an off-line chamber will not depressurize A color-change moisture indicator mounted on the outlet
and regenerate unless its previously-adsorbed "moisture piping manifold that provides a constant visual indication
front" has reached the system's moisture sensing that dry gas is being supplied to the dryer outlet connec-
AMLOC® probe. This elimination of unnecessary regen- tion. A sampling line installed at the dryer's outlet, sup-
eration extends dryer desiccant and component life. plies a small, continuous gas sample to the moisture indi-
cator for circulation.
Power ON Light As illustrated is Figure 2.2, the gas sample supplied from
The power ON light on the control panel indicates when the dryer outlet enters the moisture indicator's inlet con-
the dryer is turned on and operating. nection (1), and circulates through a desiccant-filled site
dome (2). The granular indicator (3), is a specially
Left Chamber DRYING Light treated "silica gel" which gradually changes from blue to
The Left Chamber DRYING light on the control panel indi- pink in color whenever a "wet" gas sample is received.
cates when the left chamber is drying. The color will return to blue when dry gas is once again
supplied to the dryer outlet. The indicator's change from
Right Chamber DRYING Light blue (dry) to pink (wet), alerts personnel of a dryer-associ-
The Right Chamber DRYING light on the control panel in- ated moisture problem which requires investigation. The
dicates when the right chamber is drying. gas exits the indicator through a porous disc (4) and then
vents to atmosphere through an adjustable bleed valve
Valve Malfunction Alarm (5).
This alarm is implemented by means of pressure sensors
located on each chamber. The alarm is triggered when
2
the drying chambers are not in the correct pressure state.
The chamber pressure switch should be open on the on-
5
line chamber and closed on the regenerating chamber. If
triggered, the dryer control system will energize the red
LED on the control panel labeled VALVE MALFUNCTION 1
and de-energize the common alarm relay. The alarm au-
tomatically clears once the alarm conditions are cor-
rected.
Check AMLOC® Alarm

If at any time, the on-line AMLOC® frequency falls below
2000 Hz or rises above 30000 Hz, the 'CHECK AMLOC' 4
alarm is activated and the dryer cycle continues to oper- 3
ate in Fixed Cycle control until the on-line AMLOC® fre-
quency returns to the valid range of 2000 to 30000 Hz. Figure 2.2 — AQUADEX® Moisture Indicator
Installation 2-5
CAUTION
STATIC SENSITIVE DEVICES
STATIC SENSITIVE DEVICES CAN BE DAMAGED BY ELECTROSTATIC DISCHARGE.

YOU CAN MINIMIZE THE CHANCES OF DESTROYING SUCH DEVICES BY:
1. KNOWING THAT THERE IS A POTENTIAL STATIC SENSITIVE PROBLEM.
2. ADHERING TO THE GUIDELINES LISTED BELOW FOR HANDLING THEM.
3. USING RECOMMENDED PACKAGING AND BENCH TECHNIQUES.
FOLLOW THESE PRACTICES TO MINIMIZE DAMAGE TO STATIC SENSITIVE DE-

VICES.
1. DO NOT WELD ON THIS EQUIPMENT AND/OR ASSOCIATED PIPING. THE CON-

TROL IS SENSITIVE TO ELECTRICAL GROUND LOOP VOLTAGES.
2. DISCHARGE PERSONAL STATIC BEFORE HANDLING DEVICE. (USE GROUND-

ING WRIST STRAP.)
3. MINIMIZE HANDLING.
4. HANDLE STATIC SENSITIVE DEVICES BY THE BODY ONLY. DO NOT TOUCH

ANY CONNECTORS. (USE MICROCHIP EXTRACTION AND INSERTION TOOLS.)
5. KEEP PARTS IN ORIGINAL CONTAINERS UNTIL READY FOR USE.
6. DO NOT SLIDE STATIC SENSITIVE DEVICE OVER ANY SURFACE.
7. USE ANTI-STATIC CONTAINERS FOR HANDLING AND TRANSPORT.
8. KEEP PLASTIC, VINYL AND POLYSTYRENE FOAM OUT OF THE WORK AREA.
9. WHEN REMOVING ASSEMBLIES HANDLE ONLY BY NON-CONDUCTIVE EDGES

AND NEVER TOUCH OPEN CONNECTORS EXCEPT AT A STATIC FREE WORK
STATION. PLACING SHORTING STRIPS ON CONNECTOR USUALLY PROVIDES
COMPLETE PROTECTION TO INSTALLED STATIC SENSITIVE DEVICES.
10. HANDLE STATIC SENSITIVE DEVICES ONLY AT A STATIC-FREE WORK STATION.
11. USE ONLY ANTI-STATIC TYPE SOLDER-SUCKERS.
12. USE ONLY GROUNDED TIP SOLDERING IRONS.
STATIC SENSITIVE SYMBOL ©

2-6 Installation
3
Operation
3.1 How It Works The dryer cycle is initiated through programming of the
microcomputer based dryer control system. The dryer
control system utilizes its pilot gas supply to position the
The DHA Series Heatless Desiccant Dryer System is spe- dryer's inlet and purge switching valves as required for the
cifically designed to remove vaporous moisture from com- cycle at hand. The timed sequencing of your specific
pressed air or specific compressed gas systems. The dryer model has been factory programmed to operate on
dryer's fully automatic control system alternately cycles a minimum cycle.
the compressed gas flow through the unit's twin, desic-
cant filled chambers to accomplish this moisture adsorp-
tion process. 3.2 Automatic Drain Valve
As the vapor-laden gas supply enters and flows down-
ward through a desiccant chamber, the entrained mois- All DHA-EM1 Series Dryer Systems are equipped with an
ture is attracted to and adsorbed on the surface of the electronic drain valve that automatically discharges con-
desiccant. This adsorption is an exothermic (heat releas- densate from the prefilter.
ing) process which later contributes to regeneration. The The automatic drain valve has two LED indicators and a
dry gas than exits the dryer and proceeds downstream to test button to help verify operation. Pushing the test but-
intended points-of-use. ton causes the drain port to click open. One LED indi-
While one desiccant chamber is in the Drying Cycle previ- cates that power is supplied to the drain valve; the other
ously described, the opposite, off-line chamber will be in LED indicates that the drain port is open. The power indi-
one of two possible conditions. During normal dryer op- cator turns off when the drain port opens. If either LED
eration, the condition selected is totally dependent upon fails to turn on at the proper time, refer to the mainte-
the previously adsorbed moisture content held by the off- nance section of this manual. If the dryer is under war-
line desiccant chamber, as sensed by the chamber in- ranty, call your local representative for authorization be-
stalled AMLOC® probe. fore servicing.
CONDITION 1 Operation of the automatic drain valve is controlled by an

electronic timer. The drain opening can be set from 0.5 to
The off-line chamber will depressurize and proceed 10 seconds. The drain cycle can be set from 0.5 to 45
through a fixed time Regeneration Cycle to purge (re- minutes.
move) previously adsorbed moisture from its desiccant
bed. During normal operation, a Regeneration Cycle will To minimize air losses, the timer should be adjusted to
take place only when the desiccant bed's progressively open the port just long enough to discharge accumulated
advancing moisture front has reached an AMLOC® probe. condensate. The timer is properly set if nothing but air
Upon completion of a Regeneration Cycle, the desiccant vents at the end of the open period. If air vents for more
chamber will repressurize and once again be placed on- than a few seconds, set the timer for a longer cycle or
line for another fixed time Drying Cycle. shorter drain opening. If liquid is still discharging when
the port closes, set the timer for a shorter cycle or longer
CONDITION 2 drain opening.
If the off-line chamber's progressively advancing moisture
front has not reached the AMLOC® probe, a Regeneration
Cycle is not required. In this situation the chamber will
remain pressurized while awaiting completion of the on-
line chamber's Drying Cycle.
Operation 3-1
3.3 Start-Up 7. Ensure that all associated pipe and tubing connec-
tions, flanges, unions, plugs, mounting bolts, pipe
hangers, etc., have been checked tight and/or prop-
WARNING! erly secured.
Ensure that the dryer is de-energized, valve isolated
and fully depressurized before attempting to remove IMPORTANT: It is recommended that the dryer’s
or disassemble any dryer component or subassem- process gas output not be consumed or used at the
bly. Failure to do so may result in serious personal intended points-of-use until the start-up and any re-
injury and/or equipment damage. lated adjustments have been completed, and the
system is producing process gas of the required
CAUTION: Each component of the dryer system has quality. The quality of the process gas should be
been selected to compliment the performance of the other verified through test and analysis when a specific
components of the system. Therefore, use of unautho- quality process gas is required.
rized parts or supplies or improper operation will degrade
system performance. 8. Supply pressure to dryer by slowly opening the Dryer
Inlet Isolation Valve (customer supplied). Both des-
Once the DHA-EM1 Series Dryer System has been in- iccant chamber Inlet Switching Valves will open and
stalled according to instructions, it is ready to be operated. both Purge Exhaust Switching Valves will close.
The system is fully automatic and does not require any The desiccant chambers will immediately begin
auxiliary controls. It is designed to run continuously. pressurizing to system pressure as indicated by
chamber pressure gauges.
Initial Start-Up 9. The AQUADEX® Moisture Indicator's Bleed Valve is
installed directly into the back of the indicator's body.
Do not start the dryer with compressed air flow through Close the Indicator's Bleed Valve. FULLY open the
the dryer. Close customer supplied dryer shut-off valves Moisture Indicator Supply Valve.
before beginning start-up procedure.
10. Soap bubble test all external piping, fittings, and con-
1. Refer to the General Arrangement drawing as nec- nections. Locate and repair all noted points of leak-
essary for component identification and location age. Do not soap bubble test components located
while conducting start-up and operational proce- inside dryer control system's enclosure .
dures.
Note: Small leaks noted in inlet piping to the dryer
Note: If your dryer cannot be started, or fails to start will not affect operation, other than a slight loss of
due to special installation or other problems, contact pressure supplied to the dryer. However, any gas
your local Pneumatic Products Sales Representative leaks, (no matter how small), detected at, or down-
for assistance. stream of the dryer outlet MUST BE FIXED to en-
2. Remove the Pilot Gas Filter Bowl. Verify that the sure that the dryer will provide a continuous supply
pilot gas filter cartridge is installed. Replace Filter of process gas at specified dew point, to intended
Bowl ensuring that O-ring is properly seated. Close points-of-use.
the filter bowl bleed valve. IMPORTANT: Water molecules can diffuse through
3. All Prefilter and Afterfilter Assemblies are shipped a pinhole-size leak even though pressure inside the
WITH filter cartridges installed. Verify that prefilter piping is several hundred PSIG. It is not uncommon
and afterfilter cartridges are installed. Prefilter and to have a minute pinhole leak in a gas line cause an
Afterfilter cartridges are NOT interchangeable and increase in dew point from -40°F to -10°F at a dis-
must be installed in their respective assemblies tance of forty or more feet downstream of the leak.
ONLY. The proper filter cartridge part number is 11. SLOWLY open the System Outlet Isolation Valve
listed on each Prefilter and Afterfilter Assembly. (customer supplied), while monitoring the outlet
4. Replace and tighten filter assembly bowls. Ensure pressure gauge. Do not permit the Dryer's Outlet
that O-rings are properly seated. Pressure gauge to exceed a 5% drop in pressure
while pressurizing downstream piping.
5. Close any manual vent or drain valves installed in
prefilter and afterfilter assemblies. 12. Close the System Bypass Valve (if gas system has
been so-equipped).
6. If the prefilter assembly utilized is factory-equipped
with an automatic drain valve, inspect for, and re- 13. Open and adjust the AQUADEX ® Moisture
move pipe plug or cap which may have been in- Indicator's Bleed Valve until a very slight, continuous
stalled in drain port for shipping purposes. Ensure gas bleed is felt exhausting from the bleed valve's
isolation ball valve to automatic drain valve is open. exhaust port. Ensure that the granular indicator
crystals remain motionless after final adjustment.
3-2 Operation
14. Energize the dryer’s electrical power supply. 11. Slowly rotate dryer’s Purge Adjusting Valve until the
Purge Pressure Indicator indicates the calculated
15. Refer to Appendix A and calculate your dryer purge pressure setting. (See following Note).
model's purge pressure setting as instructed.
Note: The purge pressure can only be read and ad-
16. Locate the Purge Adjusting Valve. Slowly rotate justed when an off-line desiccant chamber has de-
dryer’s Purge Adjusting Valve until the Purge Pres- pressurized for regeneration. (When the off-line
sure Indicator indicates the calculated purge pres- chamber is pressurized, the Purge Pressure Indica-
sure setting. (See following Note). tor will read “system pressure”.)
Note: The purge pressure can only be read and ad- 12. The Normal Start-Up or Restart procedure is now
justed when an off-line desiccant chamber has de- complete. Proceed to the Normal Operational
pressurized for regeneration. (When the off-line Checks section of this manual for final operational
chamber is pressurized, the Purge Pressure Indica- checks and adjustments.
tor will read “system pressure”.)
17. The Start-Up procedure is now complete. Proceed
to the Normal Operational Checks section of this
3.4 Normal Operational Checks
manual for final operational checks and adjust-
ments. 1. Ensure that the dryer is being operated within the
standard design operating conditions, as specified
Normal Start-Up or Restart on the Specification Data Sheet located in the front
of this manual.
1. Close the Pilot Gas Filter's Bleed Valve. 2. If the prefilter utilizes any automatic drain device,
ensure that it is draining and functioning properly.
2. Close any manual vent or drain valves installed in
prefilter and afterfilter assemblies. 3. Ensure that the Purge Pressure Indicator (gauge)
indicates the pressure setting calculated during start-
3. Close the System Outlet Isolation Valve (customer up.
supplied).
4. After an off-line desiccant chamber has depressur-
4. Supply pressure to system by slowly opening the ized for regeneration, a flow of purge gas should be
System Inlet Isolation Valve (customer supplied). felt exiting the purge exhaust muffler. The regener-
Both desiccant chamber Inlet Switching Valves will ating chamber’s pressure gauge MUST indicate
open and both Purge Exhaust Switching Valves will zero (0) PSIG throughout the purging period.
close. The desiccant chambers will immediately
begin pressurizing to system pressure as indicated 5. The dryer controller should automatically switch from
by chamber pressure gauges. left to right and right to left chamber drying on a fixed
time cycle. If the system fails to switch drying cham-
5. Fully open the Moisture Indicator Supply Valve. bers twice within its designated NEMA Cycle, refer
6. The AQUADEX® Moisture Indicator's Bleed Valve is to the Troubleshooting Guide.
installed directly into the back of the indicator's body. 6. If the AQUADEX® Moisture Indicator’s granular indi-
Adjust the AQUADEX® Moisture Indicator's Bleed cating gel is pink at the time of dryer start-up, a color
Valve until a very slight, continuous gas bleed is felt change to blue should be noted within twenty-four
exhausting from the bleed valve's exhaust port. En- (24) hours. Ensure that the indicator’s bleed valve
sure that the granular indicator crystals remain mo- has been adjusted as instructed in the start-up pro-
tionless after final adjustment. cedure.
7. SLOWLY open the System Outlet Isolation Valve 7. Ensure that the System Inlet and Outlet Isolation
(customer supplied), while monitoring the outlet valves (customer supplied) have been fully opened.
pressure gauge. Do not permit the Dryer's Outlet
Pressure gauge to exceed a 5% drop in pressure 8. Ensure that the dryer control system’s enclosure
while pressurizing downstream piping. cover is closed with all latches tightened to prevent
entrance of moisture, dust, dirt, etc.
8. Close the System Bypass Valve (if gas system has
been so-equipped). 9. Shutdown and Depressurize Dryer following two
(2) to three (3) weeks of initial operation. Inspect
9. Energize the dryer’s electrical power supply. desiccant beds through fill ports, for settling. If set-
10. Refer to Appendix A and calculate your dryer tling has occurred, refill chambers as necessary to
model's purge pressure setting as instructed. bring desiccant levels to bottom of each desiccant
retaining screen. DO NOT TAMP OR RAM DESIC-
CANT.
Operation 3-3
3.5 Dryer Shutdown
1. De-energize the dryer’s electrical supply. When the

dryer’s power supply is de-energized, both desiccant
chambers will be placed on-line.
2. If customer's gas system must continue supplying
unprocessed gas to point(s)-of-use, open the Sys-
tem Bypass Valve (if gas system has been so
equipped).
3. Close the System Inlet and Outlet Isolation Valves
(customer supplied).
IMPORTANT: Inlet and Outlet Isolation Valves
MUST be closed to prevent moisture overloading of
desiccant beds, due to continuous flow without re-
generation.
4. Close the Moisture Indicator Supply Valve. This
MUST be done to prevent depressurization of the
pilot gas supply, which in turn, will eventually result in
dryer depressurization.
5. Shutdown is now complete. The dryer may be left
pressurized during periods of non-use, if desired.
However, if any servicing or maintenance is to be
performed, ensure that the dryer is depressurized
BEFORE beginning work. Proceed to Step 6 for
depressurization instructions.
WARNING!
Ensure that the dryer is de-energized, valve iso-
lated, and fully depressurized before attempting
to remove or disassemble any component or
subassembly. Failure to do so may result in se-
rious personal injury and/or equipment damage.
6. To depressurize dryer, proceed as follows:
a) Open the Pilot Gas Filter’s Bleed Valve.
b) Open the Moisture Indicator Supply Valve.
Allow pilot gas system to depressurize through
AQUADEX® Moisture Indicator’s Bleed Valve
and the Pilot Gas Filter’s Bleed Valve. When
pilot gas pressure is sufficiently reduced, the
purge exhaust switching valves will automati-
cally open to depressurize dryer through purge
exhaust muffler.
c) Depressurization is complete when all dryer
pressure gauges indicate zero (0) PSIG.
3-4 Operation
4
Maintenance
and Repair
4.1 Preventative Maintenance For optimum dryer operation and performance,

these recorded parameters should correspond as
Schedule close as is possible to the design operating condi-
tions and specifications as noted on the Specifica-
WARNING! tion Data Sheet located in the front of this manual.
Ensure that the Dryer and any associated Prefilters 2. Check the pressure drop (differential pressure)
and Afterfilters are valve isolated and fully depressur- across the Prefilters and Afterfilters. See filter ele-
ized before attempting to remove or disassemble any ment replacement section 4.3.
components or subassemblies. Failure to do so may
result in serious personal injury and/or equipment
damage. Quarterly
CAUTION: Each component of the dryer system has Check the dry gas outlet dew point. A precision Dew
been selected to compliment the performance of the other Point Analyzer is required to read the exact dew point.
components of the system. Therefore, use of unautho- The analyzer should be connected as close to the dryer
rized parts or supplies or improper operation will degrade outlet as is possible. Test piping or tubing used to con-
system performance. nect the analyzer to the gas system must be metallic, as
rubber and certain plastics contain or permit moisture dif-
Daily fusion from the ambient air and can cause a false high
dew point indication. Alnor, Beckman, Shaw and several
1. Check operation of the prefilter's automatic drain other brands of precision dew point instruments are avail-
valve. This component must function properly to able.
maintain filter efficiency and prevent premature des-
iccant failure induced by liquid and oil carry over Semi-Annually
from the prefilter, due to a clogged or inoperative au-
tomatic drain valve. WARNING!
2. Visually inspect the AQUADEX® Moisture Indicator Ensure that the dryer and any associated Prefilters
for a BLUE (dry) indication. If the indicator is PINK and Afterfilters are valve isolated and fully depressur-
(wet) in color, refer to the Troubleshooting Guide ized before attempting to remove or disassemble any
and conduct checks listed for the AQUADEX Mois- components or subassemblies. Failure to do so may
ture Indicator. result in serious personal injury and/or equipment
damage.
3. Check the dryer’s Indicator Panel for the presence of
any illuminated alarm indicators. If an alarm indica- CAUTION: Each component of a Pneumatic Products
tor is illuminated, refer to the Troubleshooting Guide. Air Purification System has been sized and selected to
compliment the performance of the other components in
the system. Therefore, use of unauthorized parts or sup-
Weekly plies or improper operation will degrade system perfor-
mance.
1. Check the following operating conditions:
a) Purge pressure setting (during regeneration) Filter Cartridge Inspection/Replacement
b) Inlet pressure Pneumatic Products filter cartridges are designed for
c) Inlet flow rate maximum separation efficiency and service life.
d) Inlet temperature
Maintenance and Repair 4-1

Coalescer performance is critical to the adsorption capa- 4. Remove the desiccant fill port plugs or drain port
bility and useful life of the desiccant material found in the flanges from the top of each desiccant chamber. Vi-
air dryer. Particulate filter performance is paramount in sually inspect the desiccant through each chamber’s
protecting sensitive downstream instrumentation. Typical fill port. Replace desiccant if it appears badly broken
service life of Pneumatic Products filters is one year or or contaminated with oil.
more. However, any one or more of the following condi-
tions may minimize service life:
4.2 Desiccant Charging
• Excessive Particulate Challenge - Typically when a
lubricated compressor is replaced by a non-lubri-
Procedures
cated compressor.
Note: Periodic desiccant replacement is necessary to
• Overflow conditions maintain dryer performance. The frequency of desiccant
• Corrosive Atmospheric Conditions at Compressor replacement is dependent on the actual operating condi-
Intake tions present, and will vary in all cases. These conditions
can be process related, mechanical or accidental. A ris-
• Inadequate Separation Devices upstream of the ing dew point at the dryer outlet is an indication that new
Coalescer desiccant is required. This is assuming that the dryer is
It is therefore important that the filters be periodically in- functioning properly from a mechanical and control
spected to insure system performance and protection. standpoint; and the dryer is not being overloaded (oper-
ated above its maximum flow capacity).
1. Prefilter – Normal operating differential pressure is
2–3# under saturated conditions. Periodic inspec- Desiccant is normally installed prior to shipment unless
tion to insure that there is some differential pressure otherwise specified by the customer. Tapping on each
(i.e., filter is installed properly, not torn or missing). desiccant chamber with a soft-face mallet will yield a
Changeout is recommended when differential pres- deadened sound if desiccant has been installed. If a hol-
sure gauge shows fully red (approximately 7 psid). low sound is noted, the chambers are empty and require
installation of desiccant before operation.
2. Afterfilter/Pilot Air Filter – Normal operating differen-
tial pressure is 1–2#. Periodic inspection is sug- WARNING!
gested to insure that there is some differential pres- Ensure that the Dryer is de-energized, valve isolated
sure (i.e., filter is installed properly, not torn or miss- and fully depressurized before attempting to remove
ing). Afterfilter element changeout is recommended or disassemble any Dryer component or subassem-
when differential pressure gauge shows fully red bly. Failure to do so may result in serious personal
(approximately 7 psid). Pilot air filter element should injury and/or equipment damage.
be changed on a regular basis (typically annually) to CAUTION: Dryer models covered within the scope of this
insure positive actuation of the systems piloted actu- manual are designed to use a specific desiccant. Use of
ated valves. any other size or type may reduce efficiency or damage
the Dryer.
Annually CAUTION: Prior to installing desiccant, review all appli-
cable Material Safety Data Sheets and container warn-
WARNING! ings. Safety Data Sheets may be obtained from the
Ensure that the Dryer and any associated Prefilters manufacturers Safety Coordinator. Exercise all neces-
and Afterfilters are valve isolated and fully depressur- sary precautions for your health and welfare.
ized before attempting to remove or disassemble any
components or subassemblies. Failure to do so may WARNING!
result in serious personal injury and/or equipment A static electric charge can build up when pouring
damage. desiccants or dry powders. Proper grounding should
be observed when pouring from a container (bag,
1. Disassemble, clean and inspect the Outlet and drum, etc.).
Purge Check Valve Assemblies. Replace all dam-
aged or worn parts. WARNING!
Do not transfer desiccant under pressure. Malfunc-
2. Disassemble, clean and inspect the Inlet Switching tion or improper use of equipment can propel beads
and Purge Exhaust Switching Valves. Replace all with enough velocity to penetrate skin.
damaged or worn parts.
3. Disassemble, clean and inspect the Repressuriza-
tion Valve. Replace all damaged or worn parts.
4-2 Maintenance and Repair

Table 4.1 — Desiccant Requirements been drained. LIGHT tapping on the chamber sides
with a soft-face mallet will remove any desiccant that
may have remained in each chamber.
Activated Alumina
Model (lbs. per chamber) 5. Use a wire brush to clean drain ports and drain port
plug threads.
DE-4
60 28 6. Apply TFE tape to drain port plug threads. Reinstall
drain port plugs into each drain port. Torque drain
110 47 port plugs to a reasonable limit.
130 59
7. Carefully remove the AMLOC® probes from the des-
185 80 iccant chambers. Do not disassemble. Wipe clean
240 102 with a soft clean cloth and inspect for any visible
damage.
270 120
360 155 CAUTION: Handle the AMLOC® Probe with care to
prevent damaging the probe's TFE finish or ceramic
505 219
insulators.
630 272
8. Refer to Table 4.1 for the quantity of desiccant re-
760 333 quired for each desiccant chamber.
WARNING! 9. Utilizing an appropriately sized funnel, fill each desic-

Used desiccant material must be handled with spe- cant chamber as follows:
cial care. Desiccant is an adsorbent material. Used a) Fill each chamber with DE-4 (4mm bead) desic-
desiccant may contain chemicals and/or gases that cant until the desiccant is level with the lowest
are hazardous, toxic and/or flammable. It is recom- point of the two inch (2") AMLOC® Probe half
mended that all used desiccant be analyzed to deter- coupling.
mine content before disposal. Exercise proper care
and procedures during handling and storage of used b) Apply an appropriate thread sealant to each
materials. All containers must be properly labelled probe's male threads to ensure a leak tight seal.
and disposed of in accordance with Local, State and c) Install AMLOC ® Probe in each desiccant
Federal regulations. chamber's threaded AMLOC® Probe half cou-
WARNING! pling. Apply sufficient torque to ensure a leak
Do not install desiccant with the AMLOC® Probe in tight seal. FURTHER TIGHTENING MUST
place prior to completion of the fill process to the NOT BE ATTEMPTED AFTER COMPLETION
bottom of the AMLOC® Probe half coupling. Failure OF THE DESICCANT FILL PROCEDURE.
to remove the probe may damage it and cause the Note: AMLOC® Probe connections must be
dryer to malfunction. mounted in a horizontal position.
WARNING! d) Finish filling each chamber with desiccant until
Never attempt to remove, loosen or tighten an the specified quantity has been installed. Light
AMLOC® Probe which is installed in a desiccant filled tapping on the chamber sides with a soft-face
chamber. Desiccant must first be drained to prevent mallet should yield additional free space to allow
AMLOC® Probe damage. installation of the specified quantity. Do Not
1. Remove the desiccant fill port plug installed in the Tamp Or Ram Desiccant.
top of each desiccant chamber. Clean and inspect Note: Do not be alarmed if the specified quantity of
the fill port closure. desiccant cannot be installed in each chamber.
Note: If this is an Initial Desiccant Installation Proce- Desiccant levels will settle after approximately two to
dure go to Procedure 8. three weeks of normal operation. Following this
“settling” period, desiccant should be added as nec-
2. Place a container suitable for receiving the spent essary to return levels to BOTTOM of each
desiccant under the desiccant chambers. chamber’s retaining screen (when installed).
3. Remove desiccant drain port plug from the bottom of 10. Clean the fill port and fill port plug threads on each
each desiccant chamber. When the drain port plug desiccant chamber. Apply TFE tape to fill port plug
is removed, the desiccant will begin draining. threads. Re-install the fill port plug in each desiccant
4. Use a flashlight to inspect each chamber through its chamber, and torque drain port plugs or flange bolts
respective fill port to ensure that all desiccant has to a reasonable limit.

4.3 Filter Element Replacement 9. LIGHTLY lubricate the housing O-ring with a petro-
leum-based lubricant that is compatible with your ap-
plication.
Coalescing prefilters and particulate afterfilters are in-
cluded with all DHA Series Dryer Systems. The filter ele- CAUTION: Do not use a pipe wrench to tighten the
ments should be replaced when the differential pressure filter bowl to the head.
gauge on top of the filter reads 7 to 10 psid, or once a 10. Reattach bowl to head and hand tighten. As the
year, whichever comes first. Replace elements in accor- bowl is threaded onto the head, supports in the bot-
dance with the following instructions. tom of the bowl ensure a proper seal between the
WARNING! element and the filter head.
Ensure that the Dryer and any associated Prefilters 11. Reattach drain lines (if applicable).
and Afterfilters are valve isolated and fully depressur-
ized before attempting to remove or disassemble any 12. Close service valve.
components or subassemblies. Failure to do so may
result in serious personal injury and/or equipment 13. Slowly open the inlet isolation valve to prevent a
damage. pressure surge through the filter.
1. Isolate the filter by opening the system bypass valve 14. Once the filter has been pressurized, slowly open
(refer to Figure 2.1, page 2-2), and closing both inlet the outlet isolation valve.
and outlet isolation valves. 15. After both isolation valves have been opened, close
2. Open the service valve to vent the filter to atmo- the system bypass valve. The filter is now in ser-
spheric pressure. vice.
3. Disconnect drain lines at manual and automatic 16. Record the date of the element change in a record
drain valves (if installed). book or on the provided "Element Change" label. A
new element change label with the updated informa-
WARNING! tion should be applied over the previous label each
A "hissing" sound while the bowl is being removed time the element is replaced.
indicates the filter has not been properly depressur-
ized. DO NOT continue to remove the bowl until the
filter has been completely vented to atmospheric 4.4 Automatic Drain Valve
pressure. Disassembly and Servicing
CAUTION: Filter bowls may be heavy. Caution should
be taken when removing the bowl. All DHA Series Dryer Systems are equipped with an elec-
tronic drain valve that automatically discharges conden-
4. Remove the bottom bowl by unscrewing it from the sate from the prefilter.
head. A strap wrench may be needed.
CAUTION: Do not disassemble the drain valve timer or
5. Remove the element from the filter head with a brisk attempt to repair electrical parts. Replace timer if defec-
downward pull, or by working the element back and tive.
forth until it snap frees. Discard the element in ac-
cordance with applicable regulations. Used ele- The automatic drain valve discharges condensate
ments typically hold contaminants such as compres- through a full-port drain opening. The valve body may
sor lubricants and particulate matter. need to be cleaned under conditions of gross particulate
contamination.
Note: The element may be unsnapped by differen-
tial pressure in normal operation. This will not affect To disassemble the automatic drain valve body for clean-
filtration, as the O-ring on the element maintains a ing or other maintenance (refer to Figure 4.1):
positive seal.
1. Disconnect main power supply to dryer.
6. Clean accumulated debris from the bowl with soap
and water, and dry thoroughly. 2. Lock out and tag power supply in accordance with
OSHA requirements.
7. LIGHTLY lubricate the new O-ring with a petroleum-
based lubricant that is compatible with your applica- WARNING!
tion before installing the new element. Ensure that the Dryer is de-energized, valve isolated,
and fully depressurized before attempting to remove
8. Insert new element, snapping it into place with a firm or disassemble any Dryer component or subassem-
push up into the head. The element will hang from bly. Failure to do so may result in serious personal
the head until the bowl is installed. injury and/or equipment damage.

13mm NUT
CORE HOUSING
SPRING WASHER
TIMER ASSEMBLY
O-RING
SOLENOID COIL
HOUSING SOLENOID CORE
SOLENOID COIL
ASSEMBLY
SPRING
GASKET BRASS DIAPHRAGM

CONNECTOR WITH ASSEMBLY
POWER CORD RUBBER
VALVE BODY
GASKET VALVE BODY
WASHER
SCREW
ARROW INDICATES
FLOW DIRECTION
Figure 4.1 — Automatic Drain Valve Components
3. Remove hose that connects the drain valve to the To reassemble the drain valve, reverse the sequence of
filter. the preceding steps. After the drain valve is reas-
sembled, connect the main power supply to the dryer.
4. Remove screw and washer from front of drain valve. When the dryer is returned to service, check the drain
5. Remove the power supply connector and gasket valve for air or condensate leaks; tighten connections as
(with the timer assembly, if attached) from the sole- required to correct leaks. Check the drain cycle; adjust
noid coil housing. Do not damage or lose the gas- the timer according to the procedure in the drain valve
ket. adjustment section.
6. Remove 13 mm nut and spring washer from top of

solenoid coil housing.
7. Lift solenoid coil housing off solenoid core in valve
body.
8. Unscrew solenoid core from valve body.
Once the drain valve is disassembled, the following main-
tenance can be performed:
1. Inspect diaphragm, clean or replace as required.
2. Remove debris from the valve body.
3. Wipe solenoid core components with a clean cloth
or blow out debris with compressed air from an
OSHA approved air nozzle that limits the discharge
pressure to 30 psig.
4. Check the small port in diaphragm assembly is clear
and solenoid coil moves freely in housing. Viton dia-
phragm seals are compatible with commonly used
synthetic lubricants.
5. If timer is attached to valve body, check electrical
continuity across timer assembly.

4.5 1" Switching Valve 1" Switching Valve Components
Maintenance Item Description Total
(Inlet and Purge Exhaust)
1 Valve Body 1
2 Poppet Shaft 4
WARNING! 2A Retaining Disc 4
Ensure that the dryer is de-energized, valve isolated, 2B Gasket Washer 4
and fully depressurized before attempting to remove 2C Seal Retainer 4
or disassemble any dryer component or subassem- 2D Seal Nut 4
bly. Failure to do so may result in serious personal 2E O-Ring (Poppet Shaft) 4
injury and/or equipment damage. 3 Valve Bonnet 4
Note: Removal of valve body [1] from the dryer manifold 3A Rod Scraper 4
is not required unless replacement of square O-rings [16] 3B Valve Piston 4
or valve body is necessary. 3C Piston Seal 4
3D O-Ring (Valve Bonnet) 8
Note: Exploded view illustrates one-half of inlet switching 4 Valve Cover 4
valve only. Disassembly of opposite half of inlet valve and 5 Sockethead Cap Screw 16
each of the purge exhaust valves (not shown exploded), 10 Square O-Ring (Tetraseal) 3
is identical.
1. Clean and inspect all valve hardware upon disassem-
bly. Replace all software and any hardware which
appears damaged or abnormally worn.
2. Clean and inspect valve seat located inside the valve
body [1]. As previously noted, this can be accom-
plished without removing the valve body [1] from the
dryer manifold.
3. Apply an ultra-thin film of O-ring lubricant to items
[2E], [3C], [3D], and [10] before reassembly. Do not
apply lubricant to the gasket washer [2B].
4. The U-cup piston seal [3C] has been fitted with a cut
O-ring. Ensure that the U-cup piston seal is installed
on the valve piston [3B]. The open side of the U-cup
piston seal [3C] must face the valve cover [4] upon
reassembly.
IMPORTANT NOTICE
Due to potential damage of screwed fasteners from over

torquing, fatigue, and corrosion, maintain the following pro-
cedure.
Inspect internal threads for conformity to ensure no dam-

age was caused during previous assembly and/or disas-
sembly, and remove all foreign debris.
Install the new bolts provided in the repair kit and torque as
outlined in the schedule below.
TORQUE TABLE
SIZE TORQUE
1/4 - 20 30 - 40 inch lbs. (3.4 - 4.5 Nm)

5/16 - 18 130 - 135 inch lbs. (14.7 - 15.3 Nm)
3/8 - 16 240 - 245 inch lbs. (27.1 - 27.7 Nm)
1/2 - 13 525 - 550 inch lbs. (59.3 - 62.2 Nm)
Nm = Newton-meters

Notes:
(1) When unit is located in a corrosive environ-
ment, coat item #1 with a corrosion resistant
compound.
(2) Torque per torque table.
INLET VALVES
PURGE EXHAUST
VALVES
ASSEMBLED VIEW
10
1
2D
2B 2A
2C
2E
3A 2
3D
3
3C
3B
3D
4
5
Figure 4.2 — 1" Switching Valve

DHA Models: 60DHA, 110DHA, 130DHA, 185DHA

4.6 1-1/2" Switching Valve 1-1/2" Switching Valve Components
1 Valve Body 1
2 Poppet Shaft 4
is not required unless replacement of square O-rings [10] 3B O-Ring 12
or valve body is necessary. 4 Bonnet Cylinder 4
4A Valve Piston 4
Note: Exploded view illustrates one-half of inlet switching 4B Piston Seal 4
valve only. Disassembly of opposite half of inlet valve and 5 Valve Cover 4
each of the purge exhaust valves (not shown exploded), 6 Sockethead Cap Screw 16
is identical. 10 Square O-Ring (Tetraseal) 3
dryer manifold.
[2E], [3B], [4B], and [10] before reassembly. Do not
apply lubricant to the gasket washer [2B].
4. The U-cup piston seal [4B] has been fitted with a cut
on the valve piston [4A]. The open side of the U-cup
piston seal [4B] must face the valve cover [5] upon re-
assembly. IMPORTANT NOTICE

cedure.

TORQUE TABLE
SIZE TORQUE
1/4 - 20 30 - 40 inch lbs. (3.4 - 4.5 Nm)

5/16 - 18 130 - 135 inch lbs. (14.7 - 15.3 Nm)
3/8 - 16 240 - 245 inch lbs. (27.1 - 27.7 Nm)
1/2 - 13 525 - 550 inch lbs. (59.3 - 62.2 Nm)
Nm = Newton-meters

Notes:
compound.
INLET VALVES
PURGE EXHAUST
VALVES
ASSEMBLED VIEW
10
1
2D
2B 2A
2C
2E
2
3A
3B
3
3B
4
4B
4A
3B
5
6
Figure 4.3 — 1-1/2" Switching Valve

DHA Models: 240DHA, 270DHA, 360DHA

4.7 2" Switching Valve 2" Switching Valve Components
1 Valve Body 1
2 Poppet Shaft 4
is not required unless replacement of square O-rings [10] 3B O-Ring 4
or valve body is necessary. 4 Bonnet Cylinder 4
4A Valve Piston 4
Note: Exploded view illustrates one-half of inlet switching 4B Piston Seal 4
valve only. Disassembly of opposite half of inlet valve and 4C O-Ring 8
each of the purge exhaust valves (not shown exploded), 5 Valve Cover 4
is identical. 6 Sockethead Cap Screw 16
10 Square O-Ring (Tetraseal) 3
dryer manifold.
[2E], [3B], [4B], [4C] and [10] before reassembly. Do
not apply lubricant to the gasket washer [2B].
4. The U-cup piston seal [4B] has been fitted with a cut
on the valve piston [4A]. The open side of the U-cup
piston seal [4B] must face the valve cover [5] upon re-
assembly. IMPORTANT NOTICE

cedure.

TORQUE TABLE
SIZE TORQUE
1/4 - 20 30 - 40 inch lbs. (3.4 - 4.5 Nm)

5/16 - 18 130 - 135 inch lbs. (14.7 - 15.3 Nm)
3/8 - 16 240 - 245 inch lbs. (27.1 - 27.7 Nm)
1/2 - 13 525 - 550 inch lbs. (59.3 - 62.2 Nm)
Nm = Newton-meters
4 - 10 Maintenance and Repair

Notes:
compound.
INLET VALVES
PURGE EXHAUST
VALVES
ASSEMBLED VIEW 10
1
2D
2A
2B
2C
2E
2
3A
3B
3
4C
4
4B
4A
4C
5
6
Figure 4.4 — 2" Switching Valve

DHA Models: 505DHA, 630DHA, 760DHA
Maintenance and Repair 4 - 11

4.8 1" Purge and Outlet Check Purge and Outlet Check Valve
Valve Maintenance Item Description Total
WARNING! 1 Purge Orifice 2

Ensure that the dryer is de-energized, valve isolated, 2 Shoulder Bolt 2
and fully depressurized before attempting to remove 3 Washer 2
or disassemble any dryer component or subassem- 4 Sockethead Cap Screw 4
bly. Failure to do so may result in serious personal 5 Valve Poppet 2
injury and/or equipment damage. 6 O-Ring 3
7 Roll Pin 2
Note: The purge orifice [1] is specifically sized and drilled 8 O-Ring 2
for your dryer. If the purge orifice [1] is lost or damaged, 9 Pipe Plug 2
contact your local Pneumatic Product Sales Representa- 10 Valve Stem 1
tive for the correct replacement. 11 Valve Guide 1
12 O-Ring 1
Note: Do Not remove shoulder bolts [2] from the valve
13 Check Ball 2
body [14] unless wear or damage necessitates replace-
14 Valve Body 1
ment.
15 Pipe Plug 2
1. Clean and inspect all valve hardware upon disassem- 16 Valve Spring 2
bly. Replace all software and any hardware which ap- 17 Tetraseal 1
pears damaged or abnormally worn. Closely inspect
valve poppets [5], check balls [13], valve stem [10]
and associated mating-sealing surfaces for any faults
which could prevent positive sealing.
2. Apply an ultra-thin film of O-ring lubricant to items [6],
[8], [12], and [17]. Do not apply lubricant to check
balls [13] or valve poppets [5].
IMPORTANT NOTICE

cedure.

TORQUE TABLE
SIZE TORQUE
1/4 - 20 30 - 40 inch lbs. (3.4 - 4.5 Nm)

5/16 - 18 130 - 135 inch lbs. (14.7 - 15.3 Nm)
3/8 - 16 240 - 245 inch lbs. (27.1 - 27.7 Nm)
1/2 - 13 525 - 550 inch lbs. (59.3 - 62.2 Nm)
Nm = Newton-meters

Notes:
(1) When unit is located in a corrosive environment, coat
item #2 with a corrosion resistant compound.
6
14
9
13
12
15
16
3
11
5
17
2 10
Figure 4.5 — 1" Purge and Outlet Check Valve Assembly


4.9 1-1/2" Purge and Outlet Check Purge and Outlet Check Valve
WARNING! 1 Pipe Plug 2

Ensure that the dryer is de-energized, valve isolated, 2 Valve Guide 1
and fully depressurized before attempting to remove 3 Purge Orifice 2
or disassemble any dryer component or subassem- 4 Washer 2
bly. Failure to do so may result in serious personal 5 O-Ring 2
injury and/or equipment damage. 6 Valve Stem 1
7 O-Ring 3
Note: The purge orifice [3] is specifically sized and drilled 8 O-Ring 1
for your dryer. If the purge orifice [3] is lost or damaged, 9 O-Ring 2
contact your local Pneumatic Product Sales Representa- 10 Retaining Ring 2
tive for the correct replacement. 11 Pipe Plug 2
12 Check Ball 2
Note: Do Not remove shoulder bolts [16] from the valve
13 Sockethead Cap Screw 4
body [18] unless wear or damage necessitates replace-
14 Valve Poppet 2
ment.
15 Anti-Spin Retainer 2
1. Clean and inspect all valve hardware upon disassem- 16 Shoulder Bolt 2
bly. Replace all software and any hardware which ap- 17 Roll Pin 2
pears damaged or abnormally worn. Closely inspect 18 Valve Body 1
valve poppets [14], check balls [12], valve stem [6] 19 Tetraseal 1
and associated mating-sealing surfaces for any faults
which could prevent positive sealing.
[7], [8], [9], and [19]. Do not apply lubricant to
check balls [12] or valve poppets [14].
IMPORTANT NOTICE

cedure.

TORQUE TABLE
SIZE TORQUE
1/4 - 20 30 - 40 inch lbs. (3.4 - 4.5 Nm)

5/16 - 18 130 - 135 inch lbs. (14.7 - 15.3 Nm)
3/8 - 16 240 - 245 inch lbs. (27.1 - 27.7 Nm)
1/2 - 13 525 - 550 inch lbs. (59.3 - 62.2 Nm)
Nm = Newton-meters

Notes:
17
18
1
12
11
15
2
14
10 8
4
6
7
19
9
3 16
5
13
Figure 4.6 — 1-1/2" Purge and Outlet Check Valve Assembly


4.10 2" Purge and Outlet Check Purge and Outlet Check Valve
WARNING! 1 Pipe Plug 2

Ensure that the dryer is de-energized, valve isolated, 2 O-Ring 1
and fully depressurized before attempting to remove 3 Purge Orifice 2
or disassemble any dryer component or subassem- 4 O-Ring 2
bly. Failure to do so may result in serious personal 5 Sockethead Cap Screw 4
injury and/or equipment damage. 6 O-Ring 1
7 Tetraseal 2
Note: The purge orifice [3] is specifically sized and drilled 8 Roll Pin 2
for your dryer. If the purge orifice [3] is lost or damaged, 9 Machine Screw 2
contact your local Pneumatic Product Sales Representa- 10 Valve Guide 1
tive for the correct replacement. 11 Valve Stem 1
12 Washer 2
Note: Do Not remove spacer [16] from the valve body
13 Valve Body 1
[13] unless wear or damage necessitates replacement.
14 Valve Poppet 2
1. Clean and inspect all valve hardware upon disassem- 15 Anti-Spin Retainer 2
bly. Replace all software and any hardware which ap- 16 Spacer 2
pears damaged or abnormally worn. Closely inspect 17 Pipe Plug 2
valve poppets [14], check balls [19], valve stem [11] 18 Rod Scraper 2
and associated mating-sealing surfaces for any faults 19 Check Ball 2
which could prevent positive sealing. 20 Tetraseal 1

[6], [7], and [10]. Do not apply lubricant to check
balls [19] or valve poppets [14].
IMPORTANT NOTICE

cedure.

TORQUE TABLE
SIZE TORQUE
1/4 - 20 30 - 40 inch lbs. (3.4 - 4.5 Nm)

5/16 - 18 130 - 135 inch lbs. (14.7 - 15.3 Nm)
3/8 - 16 240 - 245 inch lbs. (27.1 - 27.7 Nm)
1/2 - 13 525 - 550 inch lbs. (59.3 - 62.2 Nm)
Nm = Newton-meters

Notes:
5
8
1
13
11
19 2
17
10
15
20
16
3
18
7
14
12
Figure 4.7 — 2" Purge and Outlet Check Valve Assembly


4.11 Repressurization Valve Repressurization Valve
WARNING! 1 Valve Body 1

Ensure that the dryer is de-energized, valve isolated, 2 Valve Cover 1
and fully depressurized before attempting to remove 3 Valve Piston 1
or disassemble any dryer component or subassem- 4 Gasket Washer 1
bly. Failure to do so may result in serious personal 5 Screw 1
injury and/or equipment damage. 6 Spring 1
7 O-ring 1
1. Clean and inspect all valve hardware upon disassem- 8 O-ring (Valve Piston) 1
bly. Replace all software and any hardware which 9 O-ring (supplied separately) 2
appears damaged or abnormally worn. 10 Sockethead Cap Screw 4
11 Lock Washer 4
[8], and [9] before reassembly. Do not apply lubri-
cant to the gasket washer [4].
10
11
Figure 4.8 — Repressurization Valve

4.12 Single Orifice Remote Flow
Restrictor Maintenance
WARNING!
Ensure that the dryer is de-energized, valve isolated,
and fully depressurized before attempting to remove
or disassemble any dryer component or subassem-
bly. Failure to do so may result in serious personal Purge
injury and/or equipment damage.
Exhaust
1. Remove each AMLOC® Probe Remote Sensor As-
sembly to protect from damage.
2. Remove muffler as follows:
a) Unscrew muffler from the Purge Exhaust Switch-
ing valve's threaded muffler port. (see following
CAUTION). Spring Orifice
CAUTION: Exercise caution when lowering muf- Assembly
fler and flow restrictor to prevent damaging con-
trol tubing, AMLOC® Probe pins, and the Purge
Pressure Indicator.
3. Remove, clean and inspect the "spring and orifice-
type" flow restrictor. Install a new flow restrictor if
damage is noted.
IMPORTANT: When installing Flow Restrictor, its
springs must be fully seated in the spring recep-
tacle. This must be accomplished for proper opera-
tion. Flow
4. Reinstall muffler and flow restrictor assembly in the
Restrictor
reverse order of removal. Housing
5. Reinstall each AMLOC® Probe Remote Sensor As-
sembly (if dryer so-equipped). Ensure that each
probe connector cable has been reconnected.
Purge
Exhaust
Piping
Figure 4.9 — Single Orifice Remote Flow Restrictor

4.13 Moisture Indicator Recharging 4. Remove porous disc [4] and clean sight dome. (see
following CAUTION.)
Procedure
CAUTION: Sight Dome [2] is an acrylic plastic. Do
Not clean with any type of solvent.
Note: Dryer shutdown is not necessary to perform the
following procedure and can be accomplished without re- 5. Replace O-ring [9], and re-install screw [6] in sight
moving the entire assembly. dome [2].
1. Close the Moisture Indicator Supply Valve, and en- 6. Carefully pour new granular indicator into sight dome
sure that the Moisture Indicator has fully depressur- [2]. Slide porous disc [4] into place.
ized through bleed valve [5] before proceeding to
step #2 for disassembly. (See following WARN- 7. Replace O-ring [7] and re-install sight dome assem-
ING.) bly (items [2], [4], [6], [7], and [9]) in body [8].
WARNING! 8. Fully open the moisture indicator’s gas supply valve

Ensure that Moisture Indicator is fully depres- (not shown).
surized before attempting disassembly. Failure 9. Adjust bleed valve [5] until only a very slight constant
to do so may result in serious personal injury gas bleed valve is felt exhausting from valve’s bleed
and/or equipment damage. port. Ensure that granular indicator remains motion-
2. Remove sight dome assembly (items [2], [4], [6], [7], less after final adjustment.
and [9]) from body [8] by turning screw [6] counter-
clockwise.
3. Remove screw [6] from sight dome [2] by exerting
pressure on screw’s threaded end. Drain granular
indicator.
5
6
8
9
4
3
7
Figure 4.10 — Moisture Indicator

4.14 Remote Sensor Assembly WARNING!
Ensure that the dryer is de-energized, valve isolated,
Maintenance and fully depressurized before attempting to remove or
disassemble any dryer component or subassembly.
1. To remove the Remote Sensor Assembly [3] proceed Failure to do so may result in serious personal injury
as follows: and/or equipment damage.
Note: The Remote Sensor Assembly [3] is not cus- 2. To remove AMLOC® Probe from desiccant chamber
tomer-serviceable, and must be replaced if found to be proceed as follows:
inoperative, or visibly damaged. a) Remove probe's Remote Sensor Assembly [3], as
a) Disconnect probe connector cable [2] by squeezing instructed in step 1, sub-steps a through c.
pin connector's "ribbed" area and simultaneously b) After dryer has been shutdown and fully depressur-
pulling downward. ized, drain the subject chamber's desiccant charge.
b) Remove screws [1] and nuts [5]. Note: If desiccant appears badly broken, or brown in
c) Pull Remote Sensor Assembly [3] straight away color, replace with a new charge. Remedy cause of oil
from AMLOC® Probe's pin connectors. contamination and/or breakage.
d) Inspect the Remote Sensor Assembly and AM- CAUTION: Never attempt to remove, loosen or tighten
LOC® Probe Pins [4] for damage and/or corrosion. an AMLOC® Probe which is installed in a desiccant
Remove corrosion, or replace Remote Sensor As- filled chamber. Desiccant must first be drained to pre-
sembly and/or AMLOC® Probe if damage is noted. vent AMLOC® Probe damage.
e) Install Remote Sensor Assembly in reverse order c) Unscrew AMLOC® Probe [4] and remove from
of removal if probe removal is not necessary. desiccant chamber. Install new probe if surface
finish or ceramic spacer damage is noted upon in-
spection.
Item Description Total d) Apply TFE tape to AMLOC® Probe threads.
1 Screw (mounting) 4 e) Replace desiccant as instructed in Section 4.2, re-
2 Probe Connector Cable 1 installing the AMLOC® Probe [4] as required. AM-
3 Remote Sensor Assembly 1 LOC® Probe connections must be mounted in a
4 AMLOC® Probe 1 horizontal position.
5 Nut (mounting) 4
Quantities indicated are for one AMLOC® Probe/

Remote Sensor Assembly.
1 AMLOC® Probe Connections

MUST Be Horizontal
2 Figure 4.11— Remote Sensor Assembly

4.15 Microcomputer-Based Dryer
Control System
3 4 7 13 12 15
FG 14
H 5
N
A1
A2 8
A B C D E A3
11
A B C D E
2 1 6 9 10
LEGEND
1. Annunciator Panel
2. Operating Status and Alarm LED Indicators
3. Microcomputer Chip (U6)
4. MEC CPU Circuit Board
5. Power Input and Remote Alarm Terminal Block
6. Remote Alarm Relay (K1)
7. Power Fuse (250V, 1/2 Amp and Fuse Cover)
8. 1/2" Conduit Electrical Input Port (not visible)
9. Pilot Gas Input Connection
10. Pilot Gas Exhaust Port
11. Valve Control Ports (A - E)
12. Power Supply Circuit Board
13. Pressure Switch Terminal Block (J3)
14. 3-Way Solenoid Valves (A, D, E - Normally Open)
(B, C - Normally Closed)
15. Valve Malfunction Alarm Pressure Sensor
Figure 4.12 — Microcomputer-Based Dryer Control System

4.16 AMLOC® Control Board AMLOC® Frequency Set Point Chart
DHA (-40°F) CDA (-100°F)

TB1 1 - Frequency Input From Left AMLOC® Probe
Sensor ↑
High Alarm High Alarm
|
Top Right
Terminal Block
2 - Ground
}
This Is The Voltage Which Feeds
3 - 5 Volts DC The AMLOC® Sensor Board Fixed Cycle Fixed Cycle
4 - Frequency Input From Right AMLOC® Probe ↓
Sensor
2000 Hz 2000 Hz
J3 1 - Input From Left Pressure Switch
2nd From 2 - Ground
Top Right 3 - Input From Right Pressure Switch ↑
Terminal Block 4 - Ground AMLOC® AMLOC®
|
With Regeneration With Regeneration
J2 1 - +24V Buss Common To Solenoid Block ↓
4 - Pin 2 - Ground For Solenoid 'A' When Active
Connector 3 - Ground For Solenoid 'B' When Active
4 - Ground For Solenoid 'C' When Active
10000 Hz 14000 Hz
5 - Ground For Solenoid 'D' When Active
6 - Ground For Solenoid 'E' When Active ↑
7 - AMLOC® Hold AMLOC® Hold
8
9
-
-
} No Connection Required
For This Application No Regeneration
|
↓
No Regeneration
10 - Common Input From Power Supply
11 - +24 VDC Input From Power Supply
12 - Common Dry Contact From Alarm Relay 30000 Hz 30000 Hz
13 - Normally Closed Contact From Alarm Relay
14 - Normally Open Contact From Alarm Relay
↑
Low Alarm Low Alarm
|
Fixed Cycle Fixed Cycle
↓
AMLOC® PCB Board (inside control box door)
CAT #
SER # TB1
1 Left - White
Ground 2 Black X2 Pins 1 And 4

U3
Are Frequency Inputs
+5VDC 3 Red X2 From AMLOC®
J1 U6 EPROM 4 Right - White
J3
Input from Left Pressure Switch 1 LPS
Ground 2 For
Pressure
Input from Right Pressure Switch RPS
3
Switch
Ground 4
J2 1
2
Pins 2 - 6 Will
3
Have 24VDC On
4 Them When Energized
5 By Program With
6 Respect To Pin 1.
7
SW1
This is Common 8
1 2 3 4 5 6 7 8
This is 24VDC 9
K1 10
11
12
MEC CPU BOARD REV B 13
14
This Is A 24VDC Relay With Contacts

Rated For 6 Amps At 120VAC or
30VDC With Resistive Loads.
Figure 4.13 — AMLOC® Control Board

5
Troubleshooting
Guide
WARNING!
Ensure that the Dryer and any associated Prefilters and Afterfilters are valve isolated and fully depressurized be-
fore attempting to remove or disassemble any components or subassemblies. Failure to do so may result in
serious personal injury and/or equipment damage.
WARNING!
Some of the following troubleshooting checks require entering the Dryer Control System enclosure while the
Dryer’s electrical power supply is energized. Therefore, a potential electrical shock hazard exists. These checks
should be conducted by a qualified electrical technician or a Pneumatic Products Authorized Field Service Engi-
neer ONLY. The Dryer’s electrical power supply must be de-energized before any electrical maintenance or repair
work is conducted.
CAUTION: Do not open or enter the Dryer Control System without exercising proper precautions for Static Sensitive
Devices. DO NOT remove the factory programmed microcomputer chip or any I.C. chip from the Logic Control Circuit
Board. Improper removal or handling will cause irreparable damage to these highly Static Sensitive Components. Dam-
age to these components will render the Dryer Control System inoperative until replacement is accomplished by a Pneu-
matic Products Authorized Field Service Engineer. DO NOT remove the program identification sticker from the microcom-
puter chip.
IMPORTANT: Water molecules can diffuse through a pinhole size leak even though pressure inside the piping is several
hundred PSIG. It is not at all uncommon to have a minute pinhole leak in a gas line cause an increase in dew point from
-40°F to -10°F at a distance of forty or more feet downstream of the leak.
CAUTION: Do not change settings of DIP switches. DIP switches are factory set to meet dryer design specifications.
Improper DIP switch settings may cause the Dryer Control System to operate erratically, or malfunction. Contact your
local Pneumatic Products Sales Representative to obtain the correct DIP switch settings for your dryer.
PROBLEM POSSIBLE CAUSE CHECKS AND REMEDY

Dew point degradation 1. Insufficient or excessive purge gas 1. Refer to the Calculation of Purge
flow during regeneration. Pressure Setting instructions in Ap-
pendix A. Ensure that the dryers
purge flow has been properly calcu-
lated and adjusted.
2. Inlet gas pressure is below the de- 2. Check the dryer’s inlet pressure
sign pressure specified on the and correct if necessary. The effi-
Specification Sheet located in the ciency of the dryer decreases as
front of this manual. the inlet pressure decreases.
Troubleshooting Guide 5-1

Dew point degradation. 3. Inlet gas flow (scfm) is above the 3. Verify the actual flow rate through
dryer’s design flow rate. dryer. Reduce flow rate if operating
above the inlet flow rate specified
on the Specification Sheet located
in the front of this manual.
4. Inlet gas temperature is above the 4. Check the compressor aftercooler
dryer’s design inlet temperature and cooling system. Adjust as nec-
specified on the Specification Sheet essary to bring the dryer inlet tem-
located in the front of this manual. perature to design specification.
5. Liquids entering the dryer inlet. 5. Isolate and Depressurize Prefilter
Assembly. Inspect prefilter car-
tridges and end seals for loosening
and/or damage. Tighten or replace
as necessary.
CAUTION: Each component of a
Pneumatic Products DHA Series air pu-
rification system has been selected to
compliment the performance of the
other components of the system.
Therefore, use of unauthorized parts or
supplies or improper operation will de-
grade system performance.
5a. Check the compressor aftercooler
for tube leakage if the aftercooler
uses water as the cooling medium.
5b. Inspect the prefilter automatic drain
valve or drain trap. Ensure that it is
not clogged, and is draining prop-
erly. Repair or replace as neces-
sary, if a problem is noted.
6. Desiccant is badly broken or coated 6. Shutdown and Depressurize
with oil. The “normally white” desic- Dryer. Inspect desiccant through
cant will appear tan or brown if oil fill ports and replace if badly bro-
contamination has occurred. ken, coated with oil or otherwise
fouled. Inspect prefilter if fouling is
noted.
7. Union or other piping/component 7. Soap test the dryer outlet manifold
leaks at dryer outlet manifold or and piping downstream of dryer.
downstream of dryer outlet. Repair ALL leaks noted.
AQUADEX® Moisture Indica- 1. Moisture indicator’s bleed valve is 1. Open bleed valve installed in mois-
tor has changed color from closed. ture indicator body until a SLIGHT
BLUE (dry) to a PINK (wet) continuous gas bleed is felt ex-
indication. hausting from bleed valve’s drilled
exhaust port. Granular indicating
desiccant MUST remain motionless
after final adjustment.
5-2 Troubleshooting Guide

AQUADEX® Moisture Indica- 2. Moisture indicator supply valve is 2. Fully open the moisture indicator
tor has changed color from closed. supply valve. Adjust indicator’s
BLUE (dry) to a PINK (wet) bleed valve as instructed in previ-
indication. ous step 1.
3. Moisture indicator is internally 3. Refer to AQUADEX® Moisture Indi-
clogged, preventing gas from exit- cator Recharging Procedure sec-
ing through indicator’s bleed valve. tion of this manual for maintenance
instructions. Clean or replace com-
ponents as necessary.
4. Sample tubing to Moisture Indicator 4. Perform a soap bubble leak test on
is leaking permitting “wet” atmos- indicator’s tubing and fittings.
pheric air to enter tubing and con- Tighten or repair all noted points-of-
taminate dry gas sample. leakage.
5. If the previous items 1 through 4 5. Refer to “dew point degradation”
have been checked, and the Mois- section of this TROUBLESHOOT-
ture Indicator fails to return to blue ING GUIDE. Determine and elimi-
within 3 to 5 hours, an actual dew nate fault.
point problem may exist.
IMPORTANT: If granular indicating desiccant is discolored (any color other than

light pink to dark blue, replace the granular indicator.
Back pressure on a desic- 1. Purge Adjusting Valve is supplying 1. SLOWLY rotate Purge Adjusting
cant chamber during the re- excessive purge gas to regenerat- Valve until correct purge pressure
generation cycle. (Chamber’s ing chamber as indicated by the setting is noted on the Purge Pres-
pressure gauge indicates Purge Pressure Indicator (gauge). sure Indicator.
above zero (0) PSIG.)
Note: If correct setting is unknown, Note: The purge pressure setting
Note: The presence of back refer to the Calculation of Purge can only be read and adjusted
pressure will result in insuffi- Pressure Setting instructions in Ap- when the off-stream chamber has
cient regeneration followed pendix A. depressurized for regeneration.
by dew point degradation. When the off-stream chamber is
An off-stream chamber’s pressurized the Purge Pressure In-
pressure gauge MUST indi- dicator will read system pressure.
cate zero (0) PSIG through-
out all regeneration cycles. 2. Purge or Outlet Check Valve seat is 2. Shutdown and Depressurize
worn, damaged, or fouled (allowing Dryer. Refer to the Purge and Out-
slight pressure leakage to enter re- let Check Valve Maintenance pro-
generating chamber). cedure which is applicable to your
specific dryer model. Disassemble,
clean and inspect the Purge and
Outlet Check Valves. Replace all
worn or damaged components as
noted.

Back pressure on a desic- 3. Off-stream chamber’s Inlet Switch- 3. Shutdown and Depressurize
cant chamber during the re- ing Valve or on-stream chamber’s Dryer. Refer to the Inlet Switching
generation cycle. Purge Exhaust Switching Valve Valve and Purge Exhaust Switching
seat is worn, damaged or fouled Valve Maintenance procedures
(allowing slight pressure leakage to which are applicable to your spe-
enter regenerating chamber). cific dryer model. Disassemble,
clean and inspect the Inlet Switch-
ing Valves and Purge Exhaust
Switching Valves. Replace all worn
or damaged components as noted.
4. Repressurization Valve internals 4. Shutdown and Depressurize
are worn, damaged or fouled (al- Dryer. Refer to the Repressuriza-
lowing slight pressure leakage to tion Valve Maintenance Procedure.
enter regenerating chamber). Disassemble, clean and inspect the
Repressurization Valve. Replace
all worn or damaged components
as noted.
Chamber depressurization 1. The purge exhaust muffler’s inter- 1. Shutdown and Depressurize
(prior to each regeneration nal spring/orifice flow restrictor is Dryer.
cycle) is excessively loud. damaged, or not fully seated in re-
ceptacle. a) Provide adequate support
for muffler and flow restric-
tor assembly. Unscrew muf-
fler and flow restrictor assem-
bly from the purge exhaust
switching valve's threaded muf-
fler port.
CAUTION: Exercise caution
when lowering muffler and flow
restrictor to prevent damaging
control tubing, and the Purge
Pressure Indicator.
b) Remove, clean and inspect the
“spring and orifice-type” flow re-
strictor. Install a new flow
restrictor if damage is noted.
IMPORTANT: When installing
Flow Restrictor, its spring must
be fully seated in the muffler's
spring receptacle. This must
be accomplished for proper op-
eration.
c) Reinstall muffler and flow
restrictor assembly in the re-
verse order of removal.

Excessive pressure drop 1. Badly broken, dusted or fouled des- 1. Shutdown and Depressurize
across dryer. iccant. Dryer. Inspect desiccant through
fill ports and replace if badly bro-
ken, dusted or fouled.
Note: If the “normally white” desic-
cant is fouled or discolored, inspect
prefilter cartridges and drain valve
or trap.
2. Inlet flow rate (scfm) is exceeding 2. Reduce the inlet flow rate as neces-
the dryer’s design flow rate as sary to meet the dryer’s design flow
specified on the Specification Sheet rate.
located in the front of this manual.
3. Desiccant retaining screens are 3. Shutdown and Depressurize
clogged or fouled. Dryer. Drain desiccant from cham-
ber. Inspect retaining screens
through fill and drain ports and
clean if fouling is noted. Investigate
and remedy source of fouling.
CAUTION: Desiccant may be rein-
stalled if it is not fouled or badly bro-
ken.
4. Inlet and/or outlet pressure gauges 4. Shutdown and Depressurize
are out of calibration, or damaged. Dryer. Replace damaged, faulty or
out-of-calibration gauges.
Loss of power to Operating 1. Loss of power supply to (or at) 1. Check power disconnect switch (or
Status and Alarm Indicators dryer’s electrical disconnect switch, breaker) CLOSED. If tripped
(no illumination). (Both or breaker (customer supplied). breaker or blown fuse is noted, in-
chambers are at line pres- vestigate and remedy cause.
sure, as indicated by the left
and right chamber pressure 2. Loose connection(s) at customer 2. De-energize Dryer Power Supply.
gauges.) power connections (L1, N, GND). Check power supply input wiring
connections (L1, N, GND).
3. Loose connections at Power Supply 3. De-energize Dryer Power Supply.
terminal connector, or at J2 on Check wiring connections at both
MEC CPU Board. Power Supply connector and J2.
4. The MEC CPU Board's fuse (F1) is 4. De-energize Dryer Power Supply.
blown. Replace fuse if blown, investigate
and remedy cause.
5. Red indicating light on Power Sup- 5. De-energize Dryer Power Supply.
ply is not illuminated. Replace Power Supply.
6. Damaged component(s). 6. For damaged solid state compo-
nents and/or circuit boards, contact
your local Pneumatic Products
Sales Representative for assis-
tance.

VALVE MALFUNCTION 1. During Depressurization Cycle. 1. Check for pilot gas pressure at off-
ALARM with excessive pres- Off-stream chamber's Inlet Switch- stream chamber inlet valve's pilot
sure exhausting through muf- ing Valve has failed to close due to tubing connection.
fler. BOTH chamber pres- fouled or worn valve internals.
sure gauges read below nor- If pilot pressure is present, refer to
mal system pressure. the Inlet Switching Valve Mainte-
nance procedure which is appli-
cable to your specific dryer model.
Shutdown and Depressurize
Dryer. Disassemble, clean and in-
spect the Inlet Switching Valve. Re-
place all worn or damaged parts as
noted.
2. During Depressurization Cycle. 2. Check red pneumatic indicators on
Off-stream chamber's Inlet Switch- solenoid valves B and C to deter-
ing Valve has failed to close due to mine whether energized.
the associated solenoid valve's (B up position — energized
or C) failure to energize. down position — de-energized
If de-energized, De-energize Dryer
Power Supply. Trip manual over-
ride switch located on top of sole-
noid valve to determine if function-
ing. Replace if not functioning.
Note:
For Left Chamber Drying;
Solenoid C is energized.
Solenoid B is de-energized.
For Right Chamber Drying;
Solenoid B is energized.
Solenoid C id de-energized.
3. During Depressurization Cycle. 3. Shutdown and Depressurize
Purge or Outlet Check internals are Dryer. Refer to the Purge and Out-
worn, damaged, or fouled, permit- let Check Valve Maintenance pro-
ting "blowby" of on-stream cedure which is applicable to your
chamber's pressure (through faulty specific dryer model.
check valve) to the off-stream
chamber. Disassemble, clean and inspect the
Purge and Outlet Check Valves.
Replace all worn or damaged com-
ponents as noted.
4. During Depressurization Cycle. 4. Check for pilot pressure at Repres-
Repressurization Valve has failed to surization Valve's pilot tubing con-
close due to fouled or worn valve nection.
internals.
If pilot pressure is present, Shut-
down and Depressurize Dryer.
Disassemble, clean and inspect the
Repressurization Valve. Replace
all worn or damaged parts as
noted.

VALVE MALFUNCTION 5. During Repressurization Cycle. 5. Check for pilot gas pressure at on-
ALARM with excessive pres- Purge Exhaust Switching Valve has stream chamber exhaust valve's pi-
sure exhausting through muf- failed to close due to fouled or worn lot tubing connection.
fler. BOTH chamber pres- valve internals.
sure gauges read below nor- If pilot pressure is present, refer to
mal system pressure. the Purge Exhaust Switching Valve
Maintenance procedure which is
applicable to your specific dryer
model.
Shutdown and Depressurize
Dryer. Disassemble, clean and in-
spect the Purge Exhaust Switching
Valve. Replace all worn or dam-
aged parts as noted.
VALVE MALFUNCTION 1. During Depressurization Cycle. 1. Check yellow pneumatic indicators

ALARM. BOTH chamber Off-stream chamber's Purge Ex- on solenoid valves A and D to de-
pressure gauges read nor- haust Switching Valve has failed to termine whether energized.
mal system pressure. open due to the associated sole- up position – de-energized
noid valve's (A or D) failure to ener- down position – energized
gize.
If de-energized, De-energize Dryer
Power Supply. Trip manual over-
ride switch located on top of sole-
noid valve to determine if function-
ing. Replace if not functioning.
Note:
For Left Chamber Drying;
Solenoid D is energized.
Solenoid A is de-energized.
For Right Chamber Drying;
Solenoid A is energized.
Solenoid D id de-energized.
2. During Depressurization Cycle. 2. Shutdown and Depressurize
Damaged or out-of-calibration pres- Dryer. Replace pressure sensor.
sure sensor.
CHECK AMLOC SYSTEM 1. Bad or loose wire connection(s) at 1. De-energize Power Supply. Pro-
(steady) the Remote Sensor Assembly Ter- ceed as follows:
minal Block TB1 or a faulty Probe
Connector Cable. a. Remove the Probe Connector
Cable from Remote Sensor As-
sembly which is associated
with the indicated alarm.
(Squeeze the pin connector's
"ribbed" area while CARE-
FULLY pulling downward.)
b. Remove the subject Probe
Connector Cable leads from
the associated terminals on the
Remote Sensor Assembly Ter-
minal Block TB1.

CHECK AMLOC SYSTEM c. Check for continuity through
(steady) each of the disconnected
Probe Connector Cable's wire
leads.
d. Repair any loose wiring noted
or replace Probe Connector
Cable, if necessary.
e. If continuity is noted throughout
all wire leads, reconnect Probe
Connector Cable to TB1 and
the Remote Sensor Assembly.
2. Remote Sensor Assembly to 2. De-energize Power Supply. Pro-
AMLOC® Probe connectors have ceed as follows:
corroded.
a. Remove Remote Sensor
Assembly's four (4) mounting
screws and nuts.
b. Pull Remote Sensor Assembly
straight away from its associ-
ated Probe.
c. Inspect and clean Remote
Sensor Assembly to AMLOC®
Probe clip connectors. (Two
pins on AMLOC® Probe and
two connectors in Remote Sen-
sor Assembly.)
d. Reinstall Remote Sensor As-
sembly. Re-energize dryer's
power supply and monitor dryer
for at least ten (10) minutes to
ensure that the alarm has
cleared and does not reoccur.
3. If alarm still exists after the previous 3. Contact your local Pneumatic Prod-
CHECKS AND REMEDIES have ucts Sales Representative for direc-
been completed AND the dryer is tion or service BEFORE attempting
NOT being overloaded (excessive to replace either printed circuit
inlet flow rate which is exceeding board, or AMLOC® Probe.
the specified design flow rate), the
malfunction is due to a faulty MEC CAUTION: Never attempt to re-
Board, or a desiccant chamber in- move, loosen or tighten an AMLOC®
stalled AMLOC® Probe. Probe which is installed in a desic-
cant filled chamber. Desiccant must
first be drained to prevent AMLOC®
Probe damage.

HIGH HUMIDITY WARNING 1. AMLOC® Probe has sensed a
(flashing) moisture overload condition within a
desiccant bed due to the presence
of one (or both) of the following
conditions:
1a. Inlet flow rate (SCFM) is above 1a. Verify the actual inlet flow rate. Re-
dryer's design inlet flow rate, as duce flow rate if operating above
specified on the Specification Sheet the inlet flow rate specified on the
located in the front of this manual. Specification Sheet located in the
Excessive flow rates will result in front of this manual.
excessive moisture loading of the
desiccant beds. This overload con-
dition would raise the AMLOC®
Probe's moisture related frequency
signal above the microcomputer's
comparator set point range, and
therefore, would be interpreted as
an Alarm.
1b. Gas has been allowed to flow 1b. Allow the dryer to remain ener-
through dryer for an extended pe- gized. On-stream frequencies are
riod of time with the dryer control constantly monitored and updated
system de-energized. When the for dry, wet, and failure conditions.
control system is de-energized, one
chamber is automatically placed The ALARM will de-energize AF-
on-stream and regeneration is not TER the excessive moisture load
conducted. has been purged from the desic-
cant beds.
Without regeneration, the desiccant
beds will eventually be overloaded
with moisture. When the power
supply was re-energized, the mois-
ture-overload condition raised the
AMLOC® Probe's moisture related
frequency signal above the
microcomputer's comparator set
point range, and therefore, would
be interpreted as an Alarm.
Automatic drain valve con- 1. Clogged diaphragm. 1. Clean diaphragm.

tinually discharging or vent-
ing. 2. Short in electrical component. 2. Check and replace connector or
timer assembly.
Automatic drain valve not dis- 1. No electrical power. 1. Check and correct power supply
charging. and connections.
2. Timer malfunction. 2. Replace timer assembly.
3. Solenoid coil malfunction. 3. Replace solenoid coil.
4. Clogged ports. 4. Clean ports.

No response when push-to- 1. No electrical power. 1. Check and correct power supply
test button on automatic and connections.
drain valve is pressed.
2. Timer malfunction. 2. Replace timer assembly.
5 - 10 Troubleshooting Guide
Appendix A
Purge Curves
Calculation of Purge Pressure Setting
1. Determine air pressure (psig) at the dryer inlet. 6. Locate the Purge Adjusting Valve. Slowly rotate
dryer’s Purge Adjusting Valve until the Purge Pres-
2. Refer to Table A-1. Determine the inlet airflow for sure Indicator indicates the calculated purge pres-
your model and inlet air pressure. sure setting. (See following Note).
3. To calculate purge flow consumption on the critical Note: The purge pressure can only be read and ad-
orifice curve: justed when an off-line desiccant chamber has de-
Inlet Flow (SCFM) × 14.7 PSIG pressurized for regeneration. (When the off-line
× 1.15 = Purge (SCFM) chamber is pressurized, the Purge Pressure Indica-
Inlet Pressure (PSIG) + 14.7 PSIG
tor will read “system pressure”.)
4. Locate the Critical Orifice Calibration Curve that has
been sized for your specific dryer model.
5. Cross the Purge Flow requirement calculated above
to the same number on the Critical Orifice Calibra-
tion Curve. Follow this line vertically and then hori-
zontally once intersection is made with the curve line
to find the actual purge pressure setting.
Table A - 1 Inlet Airflow at Various Inlet Air Pressures¹
Inlet Air Pressure (psig)

Model 60 70 80 90 100 110 120 130 140 150
Average Inlet Airflow (scfm)²
60 DHA 39 44 50 55 60 65 70 76 81 86
110 DHA 72 81 91 100 110 120 129 139 148 158
130 DHA 85 96 107 119 130 141 153 164 175 187
185 DHA 120 137 153 169 185 201 217 233 250 266
240 DHA 156 177 198 219 240 261 282 303 324 345
270 DHA 176 199 223 246 270 294 317 341 364 388
360 DHA 234 266 297 329 360 391 423 454 486 517
505 DHA 329 373 417 461 505 549 593 637 681 725
630 DHA 410 465 520 575 630 685 740 795 850 905
760 DHA 495 561 627 694 760 826 893 959 1,025 1,091
¹ Maximum inlet air pressure, 150 psig.

² Based on standard inlet conditions of 100 psig, 100°F and 100% RH. Maximum recommended inlet temperature, 120°F. For capacity at inlet
temperature higher than 100°F, consult your local distributor.
Purge Curves A-1

Orifice Dia.: .120 P1
Gas: Air
Temp: 100°F
CD: .65
80
70
PURGE PRESSURE P1 PSIG
60
50
40
30
20
10
0
3 4 5 6 7 8 9 10 11 12 13
PURGE GAS FLOW RATE (SCFM)
Figure A.1 — Critical Orifice Calibration Curve

(60DHA)
A-2 Purge Curves

Gas: Air
Temp: 100°F
CD: .65
80
70
60
50
40
30
20
10
0
6 8 10 12 14 16 18 20 22 24 26

(110DHA)
Purge Curves A-3

Gas: Air
Temp: 100°F
CD: .65
80
70
60
50
40
30
20
10
0
8 10 12 14 16 18 20 22 24 26 28

(130DHA)
A-4 Purge Curves

Gas: Air
Temp: 100°F
CD: .65
80
70
60
50
40
30
20
10
0
10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5

(185DHA)
Purge Curves A-5

Gas: Air
Temp: 100°F
CD: .65
80
70
60
50
40
30
20
10
0
12 16 20 24 28 32 36 40 44 48 52

(240DHA)
A-6 Purge Curves

Gas: Air
Temp: 100°F
CD: .65
80
70
60
50
40
30
20
10
0
10 15 20 25 30 35 40 45 50 55 60

(270DHA)
Purge Curves A-7

Gas: Air
Temp: 100°F
CD: .65
80
70
60
50
40
30
20
10
0
20 25 30 35 40 45 50 55 60 65 70 75

(360DHA)
A-8 Purge Curves

Gas: Air
Temp: 100°F
CD: .65
80
70
60
50
40
30
20
10
0
15 25 35 45 55 65 75 85 95 105 115

(505DHA)
Purge Curves A-9

Gas: Air
Temp: 100°F
CD: .65
80
70
60
50
40
30
20
10
0
30 40 50 60 70 80 90 100 110 120 130

(630DHA)
A - 10 Purge Curves
Gas: Air
Temp: 100°F
CD: .65
80
70
60
50
40
30
20
10
0
40 50 60 70 80 90 100 110 120 130 140 150

(760DHA)
Purge Curves A - 11
PNEUMATIC PRODUCTS
SPX Dehydration & Process Filtration
4647 S.W. 40th Avenue
Ocala, Florida 34474-5788 U.S.A.
Phone: 352-873-5793 • Fax: 352-873-5770
Email: [email protected]
www.pneumaticproducts-spx.com
© 2007 SPX Dehydration & Process Filtration. All rights reserved.

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Installation, Operation and

Models 60DHA-EM1 Through 760DHA-EM1

This instruction manual must be read by everyone

Form No: 3201784 (12/2007)

Chapter 1 General Information

Chapter 4 Maintenance and Repair

Chapter 5 Troubleshooting Guide

Appendix A Purge Curves

STANDARD DESIGN OPERATING CONDITIONS

MODEL FLOW CAPACITY¹

130 DHA 130

Dryer Cycle: NEMA Cycle 6 minutes

Dryer Adsorbent: Type DE-4 Activated Alumina

Pressure Vessels: ASME Section VIII, DIV. 1 Stamped

Dryer: Operation Automatic

Electrical: NEMA Type NEMA 4

MODEL PREFILTER AFTERFILTER

1.1 Foreword 1.2.1 Warranty

General Information 1-1

1.2.4 Start-Up Process 1.5 Shipping Damage Claims

1-2 General Information

To ensure that material or equipment being returned for

3. Return subject equipment or material to Pneumatic

General Information 1-3

Note 1: Use the proper pressure rated piping, fittings

posed by local and/or municipal codes may also

tions, downtime, component failure or conse-

semblies. The recommended block valve OUTLET

MUST be of a type which will provide bubble- SERVICE

1. Refer to the following sources of information as nec-

Piping will be as follows: 2.8 Electrical Connection

1. Refer to the dryer-mounted Specification Plate, (or

AMLOC® Energy Management Purge Flow Indicator

Check AMLOC® Alarm

STATIC SENSITIVE DEVICES CAN BE DAMAGED BY ELECTROSTATIC DISCHARGE.

1. KNOWING THAT THERE IS A POTENTIAL STATIC SENSITIVE PROBLEM.

2. ADHERING TO THE GUIDELINES LISTED BELOW FOR HANDLING THEM.

3. USING RECOMMENDED PACKAGING AND BENCH TECHNIQUES.

FOLLOW THESE PRACTICES TO MINIMIZE DAMAGE TO STATIC SENSITIVE DE-

1. DO NOT WELD ON THIS EQUIPMENT AND/OR ASSOCIATED PIPING. THE CON-

2. DISCHARGE PERSONAL STATIC BEFORE HANDLING DEVICE. (USE GROUND-

4. HANDLE STATIC SENSITIVE DEVICES BY THE BODY ONLY. DO NOT TOUCH

5. KEEP PARTS IN ORIGINAL CONTAINERS UNTIL READY FOR USE.

6. DO NOT SLIDE STATIC SENSITIVE DEVICE OVER ANY SURFACE.

7. USE ANTI-STATIC CONTAINERS FOR HANDLING AND TRANSPORT.

9. WHEN REMOVING ASSEMBLIES HANDLE ONLY BY NON-CONDUCTIVE EDGES

10. HANDLE STATIC SENSITIVE DEVICES ONLY AT A STATIC-FREE WORK STATION.

11. USE ONLY ANTI-STATIC TYPE SOLDER-SUCKERS.

12. USE ONLY GROUNDED TIP SOLDERING IRONS.

STATIC SENSITIVE SYMBOL ©

CONDITION 1 Operation of the automatic drain valve is controlled by an

1. De-energize the dryer’s electrical supply. When the

4.1 Preventative Maintenance For optimum dryer operation and performance,

Maintenance and Repair 4-1

4-2 Maintenance and Repair

WARNING! 9. Utilizing an appropriately sized funnel, fill each desic-

Maintenance and Repair 4-3

4-4 Maintenance and Repair

GASKET BRASS DIAPHRAGM

Figure 4.1 — Automatic Drain Valve Components