Oil-less Reciprocating Compressor Pumps

Operating & Maintenance Manual

Piston Ring Replacement

Per OSHA regulations, ALL power
must be locked out before
performing any maintenance.

Inspection/Replacement
1. Remove cylinder head tubing and cylinder bolts.
2. Pull cylinder and head assembly off slowly. Do
not allow piston to drop out of cylinder and get
damaged.
Figure 11
3. Remove piston rings. Do not use ring tool to
remove ring. Expand by hand only wide enough
to remove from piston. Note orientation of each
for proper replacement.
NOTE: Expanding ring too much and deforming can
cause wear and leakage. (See Figure 12). Mark upper
surface (not lower surface) of removed ring for easy
distinction.
4. Inspect lower surface (A) and outer side surface
(B) of ring (See Figure 13). Measure thickness (C) of
ring with calipers. Replace if foreign matter enters
(A, B) or deep damage is found or (C) dimension
is less than 2.5 mm (0.10 inches) at any point
around the rings circumference.
NOTE: Clean the whole ring and ring groove with soft Figure 12
clean cloth.
Ring and piston dust build up in the
ring groove can cause knocking.
This is sometimes mistaken for bad valve or bearing.
Reassemble: Pay attention to the fit of the piston and
(B)
wrist pin fit. There should be no axial play or looseness
in the wrist pin area.
(C) (A)
NOTE: Do not separate piston from connecting rod
Figure 13
when inspecting piston or ring. If you remove piston
from connecting rod, you may damage oil seal of
Piston rings
connecting rod and needle bearing.

Piston Inspection/Replacement
Piston
1. Inspect for appearance; if there is deep damage
or crack on top of piston or at pin boss, replace
piston.
2. Remove piston ring and inspect for breakage or
droop of ring land; if damage is found, replace O-ring
piston.
Wrist pin
Figure 14

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 Oil-less Reciprocating Compressor Pumps
Operating & Maintenance Manual

3. Remove o-rings on both sides of wrist pin. Push Wrist Pin Bearing Regrease
wrist pin to one side. 1. Remove cylinder/head assembly and piston.
NOTE: Install bearing retention sleeve in grease kit/ 2. For low pressure wrist pin bearings, fill needle
piston set. The retention sleeve is to prevent the needle area with IP634500AJ Powerex approved grease.
bearing from falling out of the bearing area. On the HP
cylinder only. 3. For high pressure wrist pin bearings, replace wrist
pin (#91924680). (OPT Pumps Only)
4. Remove wrist pin; remove piston.
4. Replace cylinder/head assembly and piston as in
5. Install o-ring in flywheel side of new piston (see procedures above.
Page 8).
5. Tighten all fittings and bolts to designated torques.
6. Install piston onto con rod. Slide wrist pin into
place.Install second o-ring. Make sure piston is in
proper direction (see Page 8).
7. Install rings in proper grooves (for inspection) and
proper gap orientation.

Piston Orientation Chart for Oil-less OPS/OPT Series

# of Piston Rings
Pump Compressor Model Bore # of Cylinders Mark on Top of Piston
per Piston
Flywheel side

OPS010 65 mm 1 1

Fan side
Flywheel side

OPS030 65 mm 1 1

Fan side
Flywheel side
LP 105 MM 1 1
OPT050
HP 75 MM 1 1
Fan side
Flywheel side
LP 90 MM 1 1
OPT100
HP 75 MM 1 1
Fan side
Flywheel side
LP 105 MM 2 1
OPT150
HP 75 MM 1 2
Fan side

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 Oil-less Reciprocating Compressor Pumps
Operating & Maintenance Manual

Small end of connecting rod

Wrist pin
Figure 17
Small end of connecting rod
Figure 15 2. Remove the two oil seals by using a screwdriver.

NOTE: The orientation in which the pistons are

reinstalled is very important. Improper placement will
cause premature wear of the ring and piston.
NOTE: When removing HP piston on two-stage pumps,
remove piston and then insert retention sleeve having
the same diameter of wrist pin or piston to small end
of connecting rod. If not, you may drop or lose needles Figure 18
from the bearing, as HP needle bearing does not have 3. Clean both surfaces where oil seals are removed.
support.
Fit piston by referring the s marking
on the top of the piston surface and
list on above chart.
NOTE: Gradually insert wrist pin while turning it.
Inserting with force can damage oil seal of needle
bearing.
Figure 19
* FOR LOW PRESSURE
Powerex Oilless
WRIST PIN BEARINGS 4. Push the oil seal into the small bearing end
Reciprocating horizontally.
Grease ONLY
Oilles
s Rec 6 Grams
Pushing Board
ip
Greas rocating
6G
#IP63 rams
4500
e
#IP634500AJ
AV

Wrist Pin Bearing Seal Replacement

Replacing Oil Seal Figure 20
5. Press the oil seal with a C-clamp into the small
bearing end.
6. Repeat on opposite side.

Figure 16
1. Insert the plastic retention sleeve which protects
the needle bearing from dropping out.

Figure 21
7. Apply a small volume of adhesive at several points.
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 Oil-less Reciprocating Compressor Pumps
Operating & Maintenance Manual

Reassembly
1. Heat bearing housing of crankcase with industrial
dryer or simple burner just the same as
disassembling.
2. Insert crankshaft set into crankcase in reverse
order of disassembling and insert bearing into
Figure 22
housing.
8. Remove the retention sleeve inserted at the first
3. Tap shaft from pulley side with non-shock hammer
step.
and insert it inwards.
NOTE: You may use a “C” clamp or two large washers
4. Fit bearing case. Grease bearing housing of
and bolt with nut through the bearing. Then apply
bearing case.
pressure to install the seals. This makes it easy to
replace the seals without removing the crankshaft. 5. Replace pistons and cylinder/head assemblies
per the inspection procedure listed previously.
Connecting Rod, Wrist Pin and Crankshaft
Per OSHA regulations, ALL power
must be locked out before
performing any maintenance.

Replace Connecting Rod Set and Crankshaft as

a Set
Pressing bearing into connecting rod and connecting
rod set into crankshaft requires special fixtures. Without
such fixtures, the squareness and parallelism of each
part will be affected.

Remove Cylinder/Head Assembly and Pistons

in this Order
1. Bearing at large end of connecting rod: Replace
if it does not move or feels stuck holding and
moving small end of connecting rod.
2. Bearing of crankshaft: Replace if you feel some
resistance when slowly turning shaft.
3. Bearing at wrist pin: Check for breakage of needle Figure 23
bearing and damage of cage.

Disassembling the Crankshaft Set

1. Remove cylinder/head, assemblies and pistons.
2. Remove bolts from bearing cap and remove
bearing cap.
3. Lightly tap shaft fan side with non-shock hammer
(avoid metal hammer) and remove crankshaft.
After bearing leaves the crankcase bore, pull
connecting rod out as illustrated and remove it
from crankcase (See Figure 23).

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 Oil-less Reciprocating Compressor Pumps
Operating & Maintenance Manual

Maintenance Schedule
Operating Hours
Item Action Needed Remarks
500 2500 5000 10000 15000 20000
Tank Drain moisture Daily
Inlet air filter Inspect, replace 0 ∆ ∆ ∆ ∆ ∆ Every 2500 hours or less
Blower fan Clean 0 0 0 0
Fan duct Clean 0 0 0 0
Compressor fins Clean ∆ ∆ ∆ ∆ ∆ Every 2500 hours or less
Inspect, replace
Bearings – HP wrist pin Note 5 ∆ ∆ ∆ ∆ ∆ Every 2500 hours
pin, regrease
Compression rings Inspect, replace Note 5 ∆ ∆ ∆ ∆ ∆ Every 2500 hours
Notes 4
Bearings – LP wrist pin Regrease ∆ ∆ ∆ ∆ ∆ Every 2500 hours
&5
Piston set Replace Note 5 ∆ ∆
Cylinder Inspect, replace 0 0 0 0
Unloader set Inspect, replace 0 ∆ 0 ∆
Gasket set Replace Note 5 ∆ ∆
Bearing seal wrist pin Replace Note 5 ∆
V-belt Inspect, replace 0 ∆ ∆ ∆ ∆
Crankcase air filter Inspect, replace 0 ∆ ∆ ∆ ∆ ∆ Every 2500 hours or less

Legend
0 Inspect
∆ Replace or perform action

NOTES:
1. Inspect and perform maintenance periodically according to maintenance schedule.
2. The maintenance schedule relates to the normal operating conditions. If the circumstances and load condition
are adverse, shorten the cycle time and do maintenance accordingly.
3. The tension of the V-belt should be adjusted during the initial stage (500H) and inspected every 2,500 hours
afterwards. Proper belt tension for 1 to 3 HP units is 2-3 lbs./.5 inch deflection; for 5 to 15 HP units, 4-6 lbs./.5
inch deflection.
4. See page 11 for regreasing procedure.
5. For OPT100 & OPT150, see detailed maintenance schedule on page 15.

IN258609AV • 25 August 2021 Powerex • 150 Production Drive • Harrison, OH 45030 • USA
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 Oil-less Reciprocating Compressor Pumps
Operating & Maintenance Manual

Maintenance Schedule (continued)

To optimize OPT100 & OPT150 pump durability, please use the following maintenance schedule and parts. After
10,000 hours please repeat schedule.

OPT100 OPT150
2,500Hrs or 2 years 2,500Hrs or 2 years
2 @ IP634500AJ Grease 2 @ IP634500AJ Grease
1 @ 91924680 HP Wrist Pin 1 @ 91924680 HP Wrist Pin

5,000Hrs or 4 years 5,000Hrs or 4 years

2 @ IP634500AJ Grease 2 @ IP634500AJ Grease
1 @ 91924680HP Wrist Pin 1 @ 91924680 HP Wrist Pin
2 @ 91236671 PISTON RING LP 2 @ 91236681 PISTON RING LP
1 @ 91930680 HP PISTON RING SET 1 @ 91930680 HP PISTON RING SET

10,000Hours 10,000Hours
2 @ IP634500AJ Grease 2 @ IP634500AJ Grease
1 @ 91924680 HP Wrist Pin 1 @ 91924680 HP Wrist Pin
6 @ 97191000 Bearing Seal 6 @ 97191000 Bearing Seal
2 @ 91903670 LP Piston Set 2 @ 91903680 LP Piston Set
1 @ 91910673HP Piston Set 1 @ 91910673 HP Piston Set
2 @ 91936670 LP Gasket Set 2 @ 91936680 LP Gasket Set
1 @ 91937681HP Gasket Set 1 @ 91937681HP Gasket Set

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 Oil-less Reciprocating Compressor Pumps
Operating & Maintenance Manual

Maintenance Log
Date Maintenance Required Maintenance Performed

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 Oil-less Reciprocating Compressor Pumps
Operating & Maintenance Manual

IP634700AJ Crankcase Filter Kit

91908690 Attachment Kit
ST073907AV Crankcase
Filter Element

Figure 27 - Replacement Parts Illustration for OPT100 and OPT150

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 Oil-less Reciprocating Compressor Pumps
Operating & Maintenance Manual

Replacement Parts – OPT 100 & OPT150

Part Number for Model
Ref. # Description Qty
OPT100 OPT150
1 Cylinder (LP) 91000670 91000680 2
2 Cylinder (HP) 91947680 91947680 1
6 Cylinder Head (LP) 91004670 91004690 2
7 Cylinder Head (HP) 91014680 91014680 1
14 Elbow (Intercooler) 91415690 91415690 4
17 Tee Union Assembly 96803261 96803261 2
18 Unloader Cap 91052451 91052451 3
20 Intake Joint (1) 91345691 91345691 1
21 Intake Joint (2) 91346690 91346690 1
24 Spring Guide Set 91949694 91949694 3
27 Bolt (Cylinder Head) 96137850 96137850 16
31 Bolt (Unloader Cap) 96995831 96995831 30
33 Bolt (Cylinder) 96137130 96137130 12
34 Bolt (Bearing Cap) 96137830 96137830 10
38 Filter (Crank Case) 91348690 91348690 1
47 O-ring (Bearing Cap) 91146690 91146690 1
51 Flywheel Pulley 91201590 91201690 1
52 Woodruff Key 96600016 96600016 1
53 Hex Nut 96994016 96994016 6
54 Washer (Intercooler) 96991512 96991512 1
59 Fan 91220690 91220690 1
60 Fan Cover 91134690 91134690 1
61 Hexagon Bolt (Fan) 96992817 96992817 1
62 Hexagon Bolt (Flywheel) 96992833 96992833 1
63 Hexagon Nut (Intake Joint) 96382086 96382086 1
67 Piston Set (LP) 91909671 91903680 2
67-1 Piston Ring (LP) 91236671 91236681 2
68 Piston Set (HP) 91923680 91923680 1
68-1 Piston Ring (HP) 91930680 91930680 1
68-2 Wrist Pin Set (Prepacked) 91924680 91924680 1
72 Intake Filter Set 91907590 91907690 1
72-1 Intake Filter ST073907AV ST073907AV 1
78 O-ring (Intake Pipe) 96630032 96630032 2
79 Inlet Pipe 91407691 91407691 1
82 Bolt (Crankcase Filter) 96131508 96131508 4
87 Unloader Tube 91420690 91420690 1
96 Unloader Tube 91419600 91419600 1

Powerex • 150 Production Drive • Harrison, OH 45030 • USA IN258609AV • 25 August 2021
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 Oil-less Reciprocating Compressor Pumps
Operating & Maintenance Manual

Replacement Parts – OPT 100 & OPT150 (continued)

Part Number for Model
Ref. # Description Qty
OPT100 OPT150
99 Wear Pad, Valve 91301691 91301691 3
108 Intercooler Joint 91403690 91403690 1
109 O-ring (Intercooler Joint) 96639906 96639906 3
110 Connecting Pipe 91402680 91402680 1
120 Bolt (Intercooler) 91435692 91435692 4
131 Cover Bracket 91413690 91413690 2
143 O-ring (Connecting Pipe) 96632825 96632825 2
145 O-ring (Connecting Pipe) 96632835 96632835 1
157 Hex Bolt (Intercooler) 96996460 96996460 6
165 Nut (Intercooler) 96994015 96994015 6
171 Connecting Pipe Set (1) 91955780 91955890 1
172 Connecting Pipe Set (2) 91955790 91955900 1
173 Intercooler 91404680 91404680 2
174 Intercooler Flange (1) 91405690 91405690 2
175 Intercooler Flange (2) 91406690 91406690 2
176 Gasket (Intercooler) 91432690 91432690 4
193 Fan Guard 91135690 91135690 2
195 Bolt (Intake Joint 1) 91343690 91343690 1
196 Bolt (Intake Joint 2) 91344690 91344690 2
197 Lip Seals Wrist Pin 97191000 97191000 6
200 Unloader Set 91932682 91932682 3
500 Gasket Set (LP) 91936670 91936680 2
550 Gasket Set (HP) 91937681 91937681 1
600 Valve Set with Gasket (LP) 91934691 91933681 2
650 Valve Set with Gasket (HP) 91934683 91934683 1

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Operating & Maintenance Manual

Notes

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 Regenerative Heatless Desiccant Dryer System
IN592401AV 0
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described.
Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or
property damage! Retain instructions for future reference.

Description
The desiccant dryer system utilizes the process of adsorption
in which molecules accumulates on the surface of an adsorbent,
isolating the molecules from its compound. In the case of the dryer,
water molecules accumulate on desiccant bead adsorbent, removing
them and other harmful contaminants from the airstream. It utilizes
a twin-tower design to dry the air coming from the compressor in
one tower while the other tower is being regenerated for future use.
Regeneration is achieved by a process known as purging in which
a portion of the dried air from the pressurized tower is directed
back over the desiccant beads in the depressurized tower. A
heatless desiccant dryer uses no heating elements to regenerate the
adsorbent. The dry air used to purge the desiccant beads of moisture
is considered “wasted” air since it isn’t recoverable for application
use and is for that reason engineered to a minimum.
An additional purge saving mode of operation ensures that the
dryer is operating most efficiently yet providing a dependable dew
point even under continuous load. Dryers capable of achieving
pressure dew points as low as –100oF are available.

Safety Guidelines Specifications

A SEPARATE SAFETY BOOKLET IS PROVIDED ALONG WITH THIS Product Regenerative Heatless Desiccant Dryer
MANUAL. READ AND UNDERSTAND THE SAFETY BOOKLET. This Package, MDD Series
manual contains information that is very important to know and Dew Point Capacity Trident Dryers: -40°F Dew Point @ 100
understand. This information is provided for SAFETY and to PREVENT PSI. (On MDD Systems the Dew Point
EQUIPMENT PROBLEMS. To help recognize this information, observe Monitor Alarms @ +35°F and Switches to
the following symbols. MAKE SURE EVERYONE OPERATING OR Economy mode @ -15°F)
SERVICING THE COMPRESSOR READS AND UNDERSTANDS ALL THE Operating Pressure 60 psig – 125 psig; (4.1 bar – 8.6 bar)
INFORMATION PROVIDED. Operating Temperature +35°F – 120°F; (2°C – 49°C) at inlet
Danger indicates an imminently hazardous Overpressure Protection ASME Safety Valve Factory Set and Sealed
situation which, if not avoided, WILL result in death
California Ordinance 462 (L)(2) Meets Requirements of this Ordinance
or serious injury.
Control Enclosure NEMA 1 50/60 Hz
Warning indicates a potentially hazardous
situation which, if not avoided, COULD result in Power Requirements 110V - 120V, ± 10%, 50/60Hz
death or serious injury. OR 208/230V, ± 10%, 50/60Hz

Caution indicates a potentially hazardous situation Control Panel Fuse FLM 7 amp
which, if not avoided, MAY result in minor or
moderate injury.
Notice indicates important information, that if not
followed, may cause damage to equipment.
NOTE: Note indicates information that requires special attention.

Powerex • 150 Production Drive • Harrison, OH 45030 • USA IN598800AV • 11/2019

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Safety Information
California Proposition 65
This product contains chemicals, including lead,
known to the State of California to cause birth
defects and other reproductive harm. Wash hands after handling.
General
Failure to comply with these instructions can lead
to personal injury and/or property damage.
Always notify the appropriate medical facility staff
before commencing any work on the compressed
air system; air level and quality may be affected during maintenance.
Dryer under pressure. Isolate and depressurize the
dryer and its components before commencing any
electrical maintenance.
Electrical shock hazard exists. Different parts of the
dryer carry electrical current. Any potential must
be properly deenergized before commencing any electrical maintenance.
The dryer’s desiccant towers are spring loaded.
Extreme caution should be taken if/when
disassembling. Please contact the manufacturer for assistance.
Hazard from sudden air ejection. Normal
operation of the dryer consists of sudden vessel
depressurization. Ear and eye risks are present. Always wear proper
protection equipment when around the dryer.
Since the air compressor and other components (material pump,
filters, lubricators, hoses, etc.) used, make up a high pressure
pumping system, the following safety precautions must be observed
at all times:
1. Read all manuals included with this product carefully. Be
thoroughly familiar with the controls and the proper use of the
equipment.
2. Follow all local electrical and safety codes as well as the United
States National Electrical Codes (NEC) and Occupational Safety
and Health Act (OSHA).
3. Only persons well acquainted with these rules of safe operation
should be allowed to use the equipment.
4. Before each use, inspect compressed air system and electrical
components for signs of damage, deterioration, weakness or
leakage. Repair or replace defective items before using.
5. Check all fasteners at frequent intervals for proper tightness.
6. Only persons experienced and properly trained in compressed
air systems or licensed electricians should service or repair this
dryer.
7. The dryer is intended for drying compressed air. Under no
circumstances should it be used to dry any other gases.
8. Do not operate the dryer if a leak is detected.
9. Do not operate the dryer at pressures and/or temperatures
above the marked maximum allowable.
10. Do not operate the dryer if any signs of damage are detected or if
Powerex • 150 Production Drive • Harrison, OH 45030 • USA
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Regenerative Heatless Desiccant Dryer System
the dryer isn’t operating as described in this manual.
11. No conversions or modifications should be made to the dryer
without prior approval by the manufacturer.
Breathable Air Warning
This unit is NOT equipped and should NOT be used “as is” to
supply breathing quality air. For any application of air for human
consumption, you must fit the air compressor with suitable in-
line safety and alarm equipment. This additional equipment is
necessary to properly filter and purify the air to meet minimal
specifications for Grade D breathing as described in Compressed
Gas Association Commodity Specification for Air, OSHA, ANSI
and/or Canadian Standards Associations (CSA).
When the SE series compressor unit is used as part of an
appropriately configured Medical Air System, meeting all
requirements of NFPA 99, it is safe to utilize as a breathing air
source.
DISCLAIMER OF WARRANTIES
IN THE EVENT THE COMPRESSOR IS USED FOR THE PURPOSE
OF BREATHING AIR APPLICATION AND PROPER IN-LINE SAFETY
AND ALARM EQUIPMENT IS NOT SIMULTANEOUSLY USED,
EXISTING WARRANTIES ARE VOID, AND POWEREX DISCLAIMS
ANY LIABILITY WHATSOEVER FOR ANY LOSS, PERSONAL INJURY
OR DAMAGE.
Terms & Definitions
Duplex Dryer System
Per the NFPA 99 Standard for Healthcare Facilities, the dryer system
is completely redundant, having one dryer capable of peak demand
and with one dryer in reserve at all times. Each dryer consists of two
desiccant towers, one prefilter, one after-filter, regulator, safety relief
valve, a dew point dependent control system and bypass plumbing.
The system includes a pre-piped and pre-wired dew point monitor,
carbon monoxide monitor, and certifier’s test port.
Only one dryer should be in service at any given
time, unless a dryer switchover procedure is being
performed. CLOSE THE ISOLATION VALVES FOR THE DRYER NOT IN SERVICE.
Dryer 1 & 2
Each dryer is a regenerative heatless desiccant dryer. It employs
a pressure swing adsorption cycle and purge saving control system.
Refer to page 6 for dryer flow schematic. The pre-filter equipped
with a separator element prevents any liquids and particulates from
entering the dryer. It comes with an automatic condensate drain
valve and filter element change indicator. The after-filter stops any
desiccant dust from leaving the dryer. It comes with an indicator as to
when the element needs to be replaced. Each regulator is factory set
at 55 PSIG and protected with a safety relief valve rated for 75 PSIG.
IN598800AV • 11/2019
Page 2 of 12

Pressure Swing Adsorption Cycle
The dryer uses a fully automatic pressure swing adsorption cycle in
which one tower is online in a drying phase while the other is offline
either preparing or waiting for the next drying phase. The towers
rotate between phases based on either time or dew point status,
depending on the mode of operation.
The two phases are described below:
A. Drying Phase: A tower in a drying phase receives humid
air through the pre-filter and then flows upward through
the desiccant bed. At full system pressure the desiccant
dehumidifies the air by means of adsorption. The dry air is
then distributed out the top of the tower for different uses:
B. Regeneration Phase: Parallel to the tower in a drying phase
the opposing tower is in one of four stages of the regeneration
phase.
1. Expansion: The expansion stage takes place immediately
after a tower switches from the drying phase to the
regeneration phase. During this stage the tower pressure
is expanded to ambient through the purge muffler over
the course of a couple seconds, accompanied by a sudden
blast.
2. Purge: A portion of the dry air from the opposing tower
in the drying phase is bled through an orifice and directed
through the top of the regenerating tower now at ambient
pressure. The moisture stored in the desiccant bed is
picked up by this dry air and expelled out the purge muffler.
3. Pressurize: After the tower is purged, the orifice continues
to bleed dry air into the regenerated tower, building it up
to system pressure. This prevents the dryer’s pre-filter and
desiccant bed from being shocked with a blast of air upon
tower switchover. Shocking a desiccant bed not only puts
a strain on the effectiveness of the filtration and drying
systems but can cause the desiccant material to dust. That
dust will clog the afterfilter and decreases the dryer’s
capacity to dry the air passing through it.
Tower Switchover
When the dryer control system calls for a tower switchover, either
by reaching a certain time or dew point, the towers switch the
function each is performing and the process starts over again.
Installation
Installation Site
1. The dryer must be located in a clean, well lit and well ventilated
area.
2. The installation site must be protected against the weather.
The area should be free of excessive dust, toxic or flammable
gases, moisture, water and direct sunlight.
3. Never install the dryer system where the ambient temperature
will drop below +34oF or rise above +104oF or where humidity
is high.
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Regenerative Heatless Desiccant Dryer System
4. The installation area must be level, firm, and capable of holding
the weight of the dryer system.
5. The site should provide sufficient spacing around the system
in order to be able to carry out routine maintenance on each
dryer. At least three feet is recommended from the front and
sides of the dryer system.
6. Never install the dryer system outside.
Moving & Securing
If it is necessary to move a freestanding dryer, proper technique
is extremely important. The dryer should only be lifted from its
structural points such as the frame or tank brackets, never from its
piping. Caution should be taken when lifting a dryer due to its high
center of gravity. Once the dryer is in position, use suitable anchoring
fasteners in all four holes provided to secure the dryer frame to the
mounting location. Suitable vibration dampening devices should be
used if that is a potential condition at the installation site.
Power Connection
The main dryer control box requires a stable 120VAC ± 10% OR
270VAC ± 10% (depending on model ordered). The individual dryer
control boxes are pre-wired to that main panel. No other installation
procedures to power the dryer are necessary.
Wiring
All electrical connections to the main system control panel must
be performed by a qualified electrician. Installations must be in
accordance with local and national electrical codes.
Dew Point Monitor Connection
The dew point monitor’s relay output contacts are wired to a relay
in the main system control panel. The individual dryer control boxes
are pre-wired to that main panel. No other installation procedures to
run the dryer in a dew point dependent mode are necessary.
Connections
The dryer system inlet and outlet are equipped with female NPT
ports which differ in size depending on the dryer model. Ensure
before plumbing in and out of the dryer that all compressed air lines
are clean, undamaged, and won’t subject any stress to the dryer’s
piping.
1. Make sure the piping is lined up without being strained or
twisted when assembling the piping for the dryer.
2. Appropriate expansion loops or bends should be installed at
the dryer to avoid stresses caused by changes in hot and cold
conditions.
3. Piping supports should be anchored separately from the dryer
to reduce noise and vibration.
4. Never use any piping smaller than the dryer connection.
5. Use flexible hose to connect the outlet of the dryer system to
the customer piping so that the vibration of the dryer does not
transfer to the piping.
IN598800AV • 11/2019
Page 3 of 12
 Regenerative Heatless Desiccant Dryer System

Operation compressed air system downstream of the dryer to pressurize.

This will prevent the dryer from being overloaded.
Before Start Up
14. SLOWLY open the source valve to its fully open position. Dryer
1. Make sure all safety warnings, labels and instructions have 1 is now in service and fully operational
been read and understood before continuing.
Operation
2. Remove any shipping materials.
Variable Cycle
3. Confirm that the electric power source and ground have been
firmly connected. The drying and regenerating phases are based on an elapse of time
as well as dew point. If the dew point is –10oF or above, the control
4. Be sure all pressure connections are tight.
system operates the dryer in the fixed cycle mode. In the case that
5. Check to be certain all safety valves, etc., are correctly installed. the demand on the dryer is low and the dew point is below –15oF, the
6. Securely mount all panels and guards. dryer will switch into an economy mode in which the purge flow is
eliminated and the drying phase time is increased.
7. Check that all fuses, circuit breakers, etc., are the proper size.
8. Make sure the inlet and after filters are properly installed.
Turning the Dryer System On
The dryer system is supplied power through a three position switch
on the main system control panel labeled Dryer 1— BOTH—Dryer 2.
After the appropriate dryer is selected, that dryer’s control box has
electric potential.
Start Up
1. Ensure that all isolation valves (dryer, monitor, and source) are
closed.
2. Ensure the electrical connections are in safe contact and in
good condition.
3. Ensure the compressed air system upstream of the dryer is
pressurized.
4. At the main system control panel there will be a switch labeled
Dryer 1—BOTH—Dryer 2. Place this switch to the Dryer 1
position. This will apply power to the dryer control box for
Dryer 1.
5. SLOWLY open the inlet isolation valve to Dryer 1. Avoid sudden
pressure build-up in every circumstance as it can cause damage
to the dryer.
6. Dryer 1 will now begin cycling between its two desiccant
towers.
7. Check for airflow from Dryer 1’s purge mufflers.
8. SLOWLY open Dryer 1’s outlet isolation valve, making sure the
source valve is still closed.
9. SLOWLY open the monitor isolation valve(s) allowing air to flow
to the CO and dew point monitor’s sensors.
10. Check for airflow from the dew point sensor’s orifice tube.
11. Allow the dryer to cycle in this state for at least 15 minutes.
During this time, test all joints for any leaks using a leak detector
spray or suitable alternative. Repair any detected leaks as they
will cause degraded performance of the dryer.
12. Dryer 1 is now capable of drying air and switching into the
economy mode.
13. SLIGHTLY open the outlet source valve and allow the
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Regenerative Heatless Desiccant Dryer System

IN598800AV • 11/2019
Page 5 of 12
IN592401AV PAGE 6
DEW POINT
MONITOR
TO ATMOS
WATER SEPARATOR AFTER FILTER CARBON FILTER SAFETY
DRYER 1 PRE-FILTER (OPTIONAL) VALVE
ISOLATION OUTLET
ISOLATION VALVE FLEX HOSE
VALVE
DESICCANT DRY AIR
INLET DRYER
FLEX HOSE S C
OUTLET
E A
P R
AIR OUTLET PRESSURE ISOLATION
REGULATOR W/GAUGE VALVE
AIR INLET TO
PURIFICATION SAMPLE PORT
PACKAGE
DESICCANT CO CALIBRATION
DRYER GAS PATH
S C
E A
P R
TO ATMOS
DRYER 2 CO
MONITOR
(SHUT VALVE WHEN
CALIBRATING CO MONITOR)

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TO FLOOR DRAIN
Flow Schematic

Maintenance
Preventive Maintenance Schedule
To ensure reliable, uninterrupted dryer operation, follow the
recommended preventative maintenance schedule provided in the
dryer manual. If done so, the dryer system should provide years of
dependable service.
Monthly Switchover Procedure
In order to maintain proper and unified performance from the
desiccant air dryer system, it is recommended that the dryers be
alternated on a regular schedule (once every month). The following
procedure explains alternating two systems, where Dryer 1 is the
online dryer and Dryer 2 is the offline dryer.
1. At the main system control panel there will be a switch labeled
Dryer 1—BOTH—Dryer 2. Place this switch to the BOTH
position. This will apply power to both dryers’ control boxes.
2. SLOWLY open the inlet isolation valve to Dryer 2. Avoid sudden
pressure build-up in every circumstance as it can cause damage
to the dryer.
3. Dryer 2 will now begin cycling between its two towers.
4. Check for airflow from Dryer 2’s purge mufflers.
5. Allow both dryers to run for a period of 15 minutes to ready
Dryer 2. At this point Dryer 2’s outlet isolation valve is still
closed, and Dryer 1 remains the online dryer. During this time,
test all plumbing joints on Dryer 2 for leaks with a leak detector
spray or suitable alternative. Repair any detected leaks as they
will cause degraded performance of the dryer.
6. SLOWLY open Dryer 2’s outlet isolation valve.
7. Close Dryer 1’s outlet isolation valve.
8. Wait 15 seconds for Dryer 1to fully pressurize and close Dryer
1’s inlet isolation valve.
9. At the main system control panel, rotate the dryer selector
switch labeled Dryer 1—BOTH—Dryer 2 to the Dryer 2
position. Dryer 1is now dormant. Dryer 2 is in service and fully
operational.
Maintenance Shut Down
All of the maintenance items that take place at 6 month intervals or
more require that the dryer be shut down in order for them to take
place. The following procedure explains how to shut down a dryer
that needs maintenance labor.
1. Bring the reserve dryer online by following steps 1 through 7 of
the Monthly Switchover Procedure.
2. Close the outlet isolation valve of the dryer that needs
maintenance.
3. Close the inlet isolation valve of the same dryer.
4. Rotate the dryer cycle switch on the main control box to the
BOTH position and allow the dryer to continue cycling until
the purge exhaust has fully depressurized all towers. Check
all towers’ pressure gauge to confirm that the system is
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Regenerative Heatless Desiccant Dryer System
depressurized.
5. At the main system control panel, rotate the dryer selector
switch labeled Dryer 1—BOTH—Dryer 2 from the BOTH to
whichever is now online.
6. Isolate and disconnect the electrical power to the dryer. Follow
all Lock out/Tag out procedures while maintenance is being
carried out.
Cleaning or Replacing the Prefilter's Auto Drain Valve
The auto drain valve is a float mechanism condensate trap. It
automatically opens and drains the collected condensate as soon
as the level of fluid rises to lift the float. If the valve is suspected
to be malfunctioning it should be cleaned or replaced. A typical
characteristic of valve malfunction is a permanent flow noise from
the drain outlet signifying the float mechanism is stuck open or the
float mechanism is stuck closed indicated by water buildup in the
bowl. In either case, the valve needs to be removed for cleaning or
replacement. To do this:
1. First perform a maintenance shut down, making sure the dryer
needing maintenance is fully depressurized and isolated from
all electrical potential.
2. Remove the drain hose from the auto drain outlet.
3. Remove the filter bowl by twisting counter-clockwise.
4. Loosen and remove the retaining nut at the bottom of the filter
bowl.
5. The auto drain valve can now be pushed out the top of the
bowl to be cleaned or replaced.
6. Place the clean or new auto drain valve in the bowl and tighten
the retaining nut.
7. Return the filter bowl securely to the body and the drain hose
to the auto drain outlet.
Replacing the Filter Elements
The filter elements will eventually become clogged with particulates
and contaminants and should be replaced at regular intervals. A
clogged filter element creates too large of a pressure drop across the
filter and can hurt the dryer’s performance. The differential pressure
indicators on top of the filters will change from green to red when
the pressure drop across the filter is too high, usually signaling an
element that needs to be replaced.
1. First perform a maintenance shut down, making sure the dryer
needing maintenance is fully depressurized and isolated from
all electric potential.
2. Remove the filter bowl by twisting counter-clockwise.
3. Unscrew the filter element from the body and properly discard
it.
4. Screw in the new element and replace the filter bowl securely.
5. Disposed of the old filter element in an environmentally safe
way, in accordance with all current statutory regulations.
IN598800AV • 11/2019
Page 6 of 12
 Regenerative Heatless Desiccant Dryer System

Replacing the Purge Muffler 2. Remove the purge muffler by unscrewing it from the purge
solenoid valve.
The purge muffler is a critical component of the dryer. If it becomes
clogged, dryer performance will degrade quickly due to the restraints 3. Screw the new muffler into place.
on the purge stage of the regeneration phase. A characteristic of a Replacing the Desiccant & Check Valves
clogged muffler is a tower pressure gauge reading anything but zero
while that tower is purging. Refer to the dryer manual for maintenance.
1. First perform a maintenance shut down, making sure the dryer
needing maintenance is fully depressurized and isolated from
all electric potential.

Troubleshooting Guide
Problem
Control valve not cycling
Dew point degradation
Back pressure on a desiccant
tower during the regeneration
phase
Dryer not switching out of
economy cycle when dew point is
above –10oF
Dryer is not switching into the
economy cycle
No pressure build up before
tower switchover; Dryer is
continuously purging
No expansion in tower during
regeneration phase
Excessive compressed air
consumption
No dryer light
Cause
Conductor Connection
1. Control valve failure
2. Pre-filter auto drain clogged
3. Air receiver auto drain malfunctioning
4. Leakage
5. Too much back pressure during regeneration
phase
1. Clogged purge muffler
2. Purge solenoid valve is malfunctioning
3. Check valve leaking
Wrong connection with dew point monitor
1. Wrong connection with dew point monitor
2. Dew point degradation
Purge solenoid valve is not closing
Purge solenoid valve is not opening
1. Dew point monitor not receiving power
2. Leakage
1. Power supply interrupted
2. Blown fuse in control box
Corrective Action
Check and verify conductor connection; see wiring schematic
1. Replace control valve.
2. A clogged pre-filter auto drain will allow liquid condensate to
enter the desiccant tower. Check the auto drain to confirm that it
is operating correctly.
3. An air receiver with a malfunctioning auto drain will send more
than intended amounts of moisture towards the dryer, possibly
resulting in a degradation of dew point. Confirm the auto drain is
working properly in regular intervals.
4. All plumbing joints and filter valves should be checked for
leaks. Any small leak can degrade the dew point and result in a
shortened life span.
5. Too much back pressure on a regenerating tower hinders its
ability to purge itself of moisture in preparation for the next
drying phase. The causes listed below should be investigated.
1. Contact an authorized distributor for a replacement purge
muffler.
2. The purge solenoid valve should be removed and inspected for
repair or replacement. See dryer manual.
3. Remove, inspect, and clean the check valve; replace if
necessary. See dryer manual.
Check the dew point monitor wiring diagram and confirm that the
proper controller outputs are relaying to the dryer.
1. Check the dew point monitor wiring diagram and confirm that
the proper controller outputs are relaying to the dryer.
2. Check the possible causes from the list above.
The purge solenoid valve should be removed and inspected for
repair or replacement. See dryer manual.
The purge solenoid valve should be removed and inspected for
repair or replacement. See dryer manual.
1. Check that the dew point monitor is powered and in normal
operation. It sends the signal to the dryer controller to switch in
and out of the economy cycle
2. Check the auto drain valve of the dryer pre-filter to confirm that
it’s not stuck open. Clean or replace if necessary
1. Check and verify that the correct dryer is receiving power from
the main panel dryer selector switch.
2. Replace fuse.

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 Section 1
Intended use

Dryspell Plus dryers are compressed air drying devices manufactured for industrial & other uses.

Water is invariably found in compressed air in the form of vapour and condensed droplets. Dryspell Plus dryers remove this
water.

1
 INSTRUCTION MANUAL - Dryspell Plus

Section 2
Unpacking the dryer

Your Dryspell Plus dryer is shipped fully assembled in one or multiple cartons or wooden containers. When you have selected
a suitable location and installed the air line and a suitable system of bypass valves and a pre-filter (refer to Section 6.
Installation), take the dryer out of the carton or container. Remove all protective plastic packaging material.

The shipping carton/container is made of cardboard/wood and is biodegradable.

The polyethylene covers wrapped around the dryers and the bubble wrapping provided around the controllers are recyclable.
They must be disposed of in accordance with prevailing environmental laws.

You will find the following in the shipping carton/container:

1. Dryer assembly
2. User manual (this manual)
3. Connectors and others
4. Cleansweep filter user manual (if pre-filter was obtained from Trident)

If any of the expected items is missing, please contact the vendor with details of your purchase.

The unpacked dryer must be installed according to the procedure described in this manual (Section 6. Installation).

2 Reference : Manual Version

 Section 3
Using this manual

This manual has been specially designed so that you can use your Trident Dryspell Plus dryer optimally and safely. Before
you start using the filter, go through this manual thoroughly. It contains vital information regarding the installation, operation
and maintenance of the dryer.

All the information, illustrations and specifications in this manual are based on the latest product information at the time
of preparation of the manual. Trident reserves the right to make changes in the product at any time without notice.

Ensure that this manual is available at all times to the personnel operating your compressed air system.

3
 INSTRUCTION MANUAL - Dryspell Plus

Section 4
Functional description

Figure 1. View of Dryspell Plus dryer with canopy and Trident Cleansweep pre-filter. The control panel may be seen in the
front, at the top. The pre-filter is fitted on the side.

The following are among the major components of your Dryspell Plus:

l Two desiccant towers

l Top and bottom blocks, including air seals and check valves
l Two solenoid valves
l Two inbuilt after-filters
l One electronic control unit and control panel
l One pressure gauge (optional)
l Two silencers

4 Reference : Manual Version

Your Dryspell Plus dryer may have an optional canopy. There may be an optional pre-filter also. If present, the pre-filter
is fitted outside the dryer assembly.

Figure 2. View of Dryspell Plus dryer without canopy

The function of each of the major components is outlined in the following description of the operation of the dryer.

5
 INSTRUCTION MANUAL - Dryspell Plus

4.1 Description of operation

Figure 3. Schematic of Dryspell Plus dryer

Compressed air containing moisture and oil droplets enters the pre-filter. Bulk liquids are removed from the air by the pre-
filter. The air then flows through the inlet shuttle valve, which diverts it to tower 1. The desiccant in tower 1 dries the
compressed air to -40°F PDP as it flows through. The dried air leaves tower 1 via the after-filter. A small part (15%) of
the compressed air is passed through the purge orifice by means of opening a two-way purge valve and thereby expanded
till its pressure is near-atmospheric. This expansion of the already-dry gas (purge air) to near-atmospheric pressure increases
its capacity to strip adsorbed water vapour from the desiccant bed in tower 2. The purge-air stream passes through tower
2, removing water vapour from the desiccant. This purge operation is carried out for 1 minute and 30 seconds. Then the
purge valve is closed, and the pressure in tower 2 begins to rise again. The repressurisation is carried out for 30 seconds.
The purge valve is opened, and purge air passes through tower 1.

During the first 2 minutes of each 4-minute cycle of operation, the following processes take place:
l The online tower (tower 1) dries compressed air for 2 minutes.
l The offline tower (tower 2) regenerates (adsorbed moisture is removed from the desiccant in it) for 1 minute and 30
seconds.
l The offline tower is re-pressurised for 30 seconds.
During the next half of the cycle, these processes are repeated with tower 2 being the online tower and tower 1 the offline
tower.

6 Reference : Manual Version

4.2 External dewpoint control

The dryer can be optionally operated under external dewpoint control. In this optional system, a dewpoint meter is fitted
at the outlet of the dryer. The dewpoint meter (1) provides an indication of the dewpoint of the dried air and (2) when
the dewpoint of the dried air increases (this happens when the water vapour content of the dried air increases because
the desiccant is saturated and water vapour cannot be adsorbed any more), it provides a signal to end the cycle. The air
is then diverted to the other tower, which contains dry desiccant. Thus the dewpoint meter allows the moisture loading time
of each desiccant bed to stretch as long as the desiccant absorbs moisture. In general, there is no fixed cycle time of 4
minutes' duration when external dew point control is used. The operating cycle with external dew point control is referred
to as a stretch cycle.

4.3 Purge economiser

In practical situations, the airflow through the dryer is not maintained at the maximum flow value that the equipment is
designed for. The moisture load may also vary. At such times, less purge-air may be required to remove the moisture from
the desiccant in a tower. The amount of purge-air used can be reduced by reducing the regeneration time.
Dryspell dryers feature a purge economising feature that can reduce the amount of purge air used by changing the
regeneration time from the maximum value of 90 seconds. The purge is stopped by the purge economiser after a
preprogrammed duration. However, the cycle time is maintained at 4 minutes.

The regeneration flow can be reduced in steps of 20% from 100% to 40% according to the flow through the dryer or the
moisture load. The purge optimisation option may be selected from the control panel.

Control panel. The control panel is used to adjust the purge optimiser and external dewpoint control settings. The control
panel in models 10, 20, 30, 45 and 60 is different from the panel in models 100, 125, 200, 250, 300 and 375.

Figure 4. Control panel of Dryspell Plus (models 10, 20, 30, 45 and 60)

7
 INSTRUCTION MANUAL - Dryspell Plus

Figure 5. Control panel of Dryspell Plus (models 100, 125, 200, 250, 300 and 375)

8 Reference : Manual Version

The following are found on the control panel:
l A schematic of the dryer
l Two LED indicators for each drying tower-these indicate whether the tower is drying (D) or regenerating/re-pressurising
(R).
l One LED indicating the operation of the pre-filter drain (only in models 10, 20, 30, 45 and 60)
To adjust the purge flow, press the button marked 'PURGE OPTIMIZER' continuously for 8 seconds, and then set the purge
flow to the required value (40%, 60%, 80% or 100%).

Setting the Purge economizer

Through front panel - Steady conditions

To set the purge economizer please refer the tables below:

Inlet Pressure Correction Factor

Temperature Correction Factor

Dewpoint Correction

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 INSTRUCTION MANUAL - Dryspell Plus

Principle

Pressure swing adsorption dryers purge 15% compressed air at 100 PSI pressure and 1000F inlet compressed air tempera-
ture. This is required to regenerate the bed of adsorbent. The requirement of purge is from basic physical laws and cannot
be altered substantially. Purge loss is a function of Dew point required, Inlet air temperature, Operating pressure and rated
flow. These parameters are have certain values as per standards and Dryers are designed for same. The common standards
are ISO 7183 or CAGI which specifies the standard inlet conditions for the dryer as air temperature 38 deg (1000F) C and
pressure of 7 bar (g) (100 PSI). In practice this is very different. Further a dryer will never be used at its rated flow. When
a dryer is not used at its rated capacity the purge still happens at 15% of the rated capacity. For e.g a Dryspell Plus 100
would purge 15 scfm at 7 bar irrespective of the flow through the dryer. Hence the above dryer with a 80% flow ie 60
scfm would still be purging 15 scfm making the actual purge loss to 25%. This is a common problem with all dyers. Dryspell
plus series dryers come with a front panel purge economizer. Select the Purge economiser switch and the purge flow is
correspondingly reduced. This is done changing the purge time. The purge flow requirement is governed by the Flow rate,
Inlet air temperature, Air pressure and dew point.

Purge optimizer setting = Percentage of rated flow/ (Pressure correction factor * temperature correction factor * Dew point
correction factor) e.g In a given system the Pressure is 120 PSI, Temperature is 1000F, Dew point requirement is -400F
and flow is 80% of rated flow.

Purge optimizer setting = 80/(1.18 x 1 x 1.15) = 58.9 =60%. This saves 40% of purge air. When conditions are not known
or stable set purge optimizer at 100% to ensure dew point.

Through Dewpoint controller - Dynamic Conditions The second method of saving purge is to interface the Dryspell controller
with a dew point switch. A potential free contact of the dew point switch is connected to the controller terminals. The
controller purges correct quantity of air and stops purging. It remains at this state till the dew point at the outlet of the
dryer falls below the set value. At this point the controller changes over to the fresh desiccant tower and starts purge to
regenerate the saturated tower. With this interface highly fluctuating load, varying temperature and pressure can also
factored to save purge air. Please refer user manual for terminal details. This interface also guarantees dew point.

10 Reference : Manual Version

 Section 5
Technical specifications

5.1 Recommended ratings

Pre-filter rating : 0.01 micron (coalescer)

After-filter rating (built-in) : 25 microns (within the diffuser screen or compactor plate)

5.2 Physical description

Model Overall dimensions (mm)

Height Width Depth Weight (kg)
Dryspell Plus 10 1038 330 150 21
Dryspell Plus 20 963 371 213 29
Dryspell Plus 30 1227 371 213 39
Dryspell Plus 45 999 497 313 49
Dryspell Plus 60 1192 523 313 61
Dryspell Plus 100 1603 439 372 106
Dryspell Plus 125 1913 439 372 119
Dryspell Plus 200 1615 449 582 214
Dryspell Plus 250 1925 449 582 238
Dryspell Plus 300 1615 457 764 256
Dryspell Plus 375 1925 457 764 286

5.3 Operating conditions

Maximum pressure : 16 bar g (225 psi g)
Rated operating pressure : 7 bar g (100 psi g)
Rated operating temperature : 38°C (100°F)
Cycle time : 4 minutes
Purge loss : 15%

5.4 Power
Voltage : 100-240 V AC, 50/60 Hz, 1 phase
Maximum power consumption : 20 W
Length of power cord : 10 feet * (Optional for US suppliers only)

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 INSTRUCTION MANUAL - Dryspell Plus

5.5 Capacity
Model Nominal inlet flow (cfm)
Dryspell Plus 10 10
Dryspell Plus 20 20
Dryspell Plus 30 30
Dryspell Plus 45 45
Dryspell Plus 60 60
Dryspell Plus 100 100
Dryspell Plus 125 125
Dryspell Plus 200 200
Dryspell Plus 250 250
Dryspell Plus 300 300
Dryspell Plus 375 375

5.6 Air inlet conditions

Rated operating temperature : 38°C (100°F)
Rated operating pressure : 7 bar g (100 psi g)
Oil should be less than 2 ppm
** As per ISO 7183 option B rated condition

5.7 Air outlet conditions

-40°C (-40°F) PDP (ISO 8573-1:2010 (E) Class 2)

12 Reference : Manual Version

 Section 6
Installation

6.1 General
l Make sure that the dryer is not close to any equipment that does not comply with EU directive 2004/108/EC (relating
to electromagnetic compatibility) and that may affect the operation of the dryer.
l Do not drop the dryer or lift it by the piping or control panel. Doing so may damage the dryer.
l Ensure that the dryer is installed in the vertical position.
6.2 Location
l Install the dryer in a closed, clean, dry room protected from freezing
l Access to the room should be restricted to personnel qualified in the maintenance and operation of Dryspell Plus dryers
l The room must be adequately ventilated
l The dryer must not be directly exposed to sources of heat
l The temperature of the room must not exceed 43°C (109°F)
6.3 Layout
l There must be a minimum distance of 3 feet between the dryer and any other equipment around it that uses electricity
6.4 Air line

Figure 6. Bypass arrangement to be provided on air line

l Install a system of bypass valves between the dryer inlet and outlet as shown in Figure 6 so that the dryer can be
serviced without having to interrupt the compressed air supply from the circuit
l If the dryer has been bought without a pre-filter, install a suitable filter ahead of the dryer
l The upstream and downstream valves must be closed during installation
6.5 Manpower required
l One skilled technician
6.6 Tools required
l Standard tool set
6.7 Procedure
l Secure the dryer by bolting it down
l Connect a drain line to the pre-filter
l Check for leaks after all connections have been made

13
 INSTRUCTION MANUAL - Dryspell Plus

Section 7
Operation

Warning : Dryspell Plus dryers are designed and manufactured for drying compressed air. Under no circumstances
should they be used to dry any other gases.
Warning : The adsorbents used in the dryer are non-toxic. However, they may cause respiratory problems if they are
inhaled as dust. The use of dust masks is sufficient to protect personnel.
Warning: This dryer should be used for drying only filtered compressed air. Ensure that the air supplied to the inlet
of this air dryer is filtered. Failure to follow this instruction can lead to serious injury or death.

7.1 Do's and don'ts

l Do not turn on or operate the dryer if there is a leak.
l Make sure that the dryer's protection rating matches the conditions at your installation
l Verify that the voltage of the power supply matches the voltage marked on the data label
l Do not operate the dryer at pressures above the maximum allowable limits marked on the data label. This label is found
on the leg of the dryer

Figure 7. Name plate of Dryspell Plus dryer

7.2 Turning the dryer on

Always pressurise the dryer before powering it up:
l Make sure that the power supply to the dryer is turned off
l Open the bypass valve and close the outlet valve
l Open the inlet valve and pressurise the dryer
l Open the outlet and close the bypass valve
l Turn on the power to the dryer

14 Reference : Manual Version

7.3 Running
The LEDs on the control panel light up as shown in the accompanying table.
Lighting sequence of LEDs on control panel during a 4-minute cycle
Stage of cycle Tower 1 Tower 2
D R D R
I (90 seconds) On Off Off On
II (30 seconds) On Off Off Blinks
III (90 seconds) Off On On Off
IV (30 seconds) Off Blinks On Off

Caution: Each time that a regeneration tower depressurises, a loud noise is produced. This occurs every 2 minutes.

In dryer models with pre-filters and electronic auto-drains, every 4 minutes, the valve at the bottom of the pre-filter opens
automatically and discharges condensate for 4 seconds.

The cycle times are fixed and cannot be adjusted by the user.

7.4 Shutting down

Follow this procedure when shutting the dryer down:
l Open the bypass valve.
l Close the inlet valve.
l Close the outlet valve.
l Turn off power to the dryer.

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 INSTRUCTION MANUAL - Dryspell Plus

Section 8
Maintenance

Warning: Only experienced and licensed electricians who are trained to handle compressed air systems should service
or repair Trident products.

Adsorption dryers are robust, reliable machines. To ensure uninterrupted, problem-free operation, perform the inspections
described in the following sections at the specified intervals.

In this section, the item codes of the various parts of the dryer are marked on the respective illustrations. Refer to the
list of spares (Section 11. Recommended parts and consumables) in this manual for details. Cite the item codes when
obtaining spares.

Before starting up or performing any maintenance on any Trident air dryer, filter, drain system or other equipment, you must
first turn off and disconnect the electrical power supply to the equipment at the main switch. Also, be sure to bypass and
depressurise the dryer to 0 psi g.

8.1 Monthly inspections

l Verify that the drying-and-regeneration cycle is normal (as described in the section 'Running' in the chapter 'Operation'.
If it is found that the operating cycle is not normal, use the troubleshooting section of this manual (Section 10.
Troubleshooting) to address the problem
l Verify that the silencers are not clogged. There will be no air flow through a silencer that is clogged. A clogged silencer
must be replaced with a new silencer. The silencer may be removed by unscrewing it. Fit the new silencer on the exhaust
valve and tighten it

8.2 Semi-annual inspections

l Verify that the dryer is cycling normally
l Verify that the silencers are not clogged.
l Replace clogged silencers with new silencers as described under 'Monthly inspections'Replace the filter elements of
the filters

8.3 Annual inspections

l Verify that the dryer is cycling normally as described in this manual.
l Verify that the silencers are not clogged. If any silencer is clogged, replace it with a new silencer.
l Replace the filter elements of the filters.
l nspect and determine the state of the desiccant. If the desiccant is brown (this indicates oil pollution) or if there is a
lot of dust in the desiccant (this condition is caused by disintegration of the desiccant), then change the desiccant (see
following section).
l Replace the O-rings of the top and bottom blocks.

Note: The compressor and the dryer must be shut down when the state of the desiccant and the state of the O-rings are
inspected. It is recommended that all personnel present wear dust masks when desiccant is replaced.

16 Reference : Manual Version

8.4 Replacing the desiccant
In models 10, 20 and 30, the towers must be filled directly with desiccant. In all other models, desiccant bags must be
used. The graphic here explains which procedure applies to your model, the item code to be cited when ordering the
desiccant and the quantity required.

Figure 8. Changing the desiccant in the Dryspell Plus range of models-types of filling,
item codes and quantities of desiccant required

8.5 Service procedures

The procedures to be followed for servicing/replacement of sub-assemblies in Dryspell Plus dryers are described in this
section. Servicing/replacement must be carried out when there is failure of the respective parts and if found necessary
during the monthly, semi-annual and annual inspections.

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 DRYSPELL PLUS 100 EXPLODED VIEW
Drw. No.PD242
8.5.4 Dryspell Plus models 100 & 125

37
8.5.4.1 Changing the desiccant

Figure 25. Changing desiccant-Dryspell Plus model 100

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 INSTRUCTION MANUAL - Dryspell Plus

Figure 26. Changing desiccant-Dryspell Plus model 125

l Disconnect the solenoid coil and inlet valve wire connection

l Remove the pilot air connection from the top block assembly
l Remove the socket head cap screws M8 * 40
l Remove the top chamber with the controller
l Remove the drying tower gasket and replace with new ones
l Remove the top compactor plates (two)
l Remove the old desiccant bags
l Clean the drying towers
l Filling the Desiccant bag assembly :
Dryspell Plus model 100:
Fill the desiccant bag assembly firstly with 3 bags of Activated Alumina AD1398 followed by a bag of molecular sieves
AD1424 as shown in the figure 25

40 Reference : Manual Version

Dryspell Plus model 125:
Fill the desiccant bag assembly firstly with 3 bags of Activated Alumina AD1398 followed by a bag of mixed Activated
alumina and Molecular Sieves AD1425, lastly with a bag of molecular sieves AD1424 as shown in the figure 26
l Replace the top compactor plate with new one
l Fix the top block assembly and tighten the cap screws
l Connect the solenoid coil , inlet valve and pilot air connections

8.5.4.2 Changing the top shuttle

Figure 27. Exploded view of top shuttle-Dryspell Plus 100 & 125

l Using circlip pliers, remove the circlip B 45

l Using an M12 bolt, push the shuttle closer assembly out.
l Discard and replace the O-ring (38.5 mm * 3.53 mm) in the shuttle closure
l Clean the shuttle closer
l Take the shuttle guide out of the shuttle housing.
l Clean the shuttle guide
l Discard and replace the O-ring (38.5 mm * 3.53 mm) in the shuttle guide
l Replace with new shuttle
l Reassemble the parts in the shuttle housing

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 INSTRUCTION MANUAL - Dryspell Plus

8.5.4.3 Changing the inlet valve assembly in Dryspell Plus model

Figure 28. Exploded view of inlet valve assembly-Dryspell Plus models 100 & 125

l Using an Allen key, remove the screws M8 *20 at the bottom cover assembly
l Remove the bottom cover and clean it.
l Discard the O- ring (48 mm × 3.0 mm)
l Remove the M8 hex nut and take out the spacer machined. Clean the spacer machined
l Remove and discard the poppet moulded AD1059
l Discard the O-ring (7.6 mm × 2.4 mm).
l Remove the spacer machined and clean it.
l Using an Allen key, remove the screws at the top of the assembly.

42 Reference : Manual Version