GEM's Heatless Dryer is based on the principle of pressure swing adsorption system, where in there is a tendency of desiccants to establish equilibrium with the surroundings. The air dryer system consist of high quality moisture adsorbing desiccant. During the drying cycle, the desiccant adsorbs moisture from the in coming wet air. During the regeneration cycle, a small portion of the dry air is passed through the desiccant at lower pressure to pick up and remove adsorbed moisture. Heatless Air Dryers unit consists of two towers with beds of activated alumina desiccants. An automatic timing devices alternatively sends air to either one of the tower. When one tower is drying the air, the other tower regenerates the desiccant. This is a self contained process which uses a purge of already dried air to pass through the desiccant bed at lower pressure. This purge air removes the adsorbed moisture particles from the desiccant.

All Dryers are fixed on a rugged frame with all rigid tubings. It is provided with initial fill of desiccant, pressure gauge, safety valve, electrical control panel, valves etc.

TIPS FOR SUCCESSFUL OPERATION:

Do not exceed Dryerss rated design flow to avoid poor dew point suppression and excessive "dusting" of the desiccant and pressure drop.
Do not pass air through the Dryers when the timer is not operating as one tower will remain on stream and become saturated. At this point, all drying will cease. However, when the timer is re energized and operating, the compressed air flow will be switched from the tower to tower and complete drying efficient restored within a few hours.
The practical useful service life of an adsorbent desiccant bed is direct function of the following:
1. Contamination from compressor crankcase oil carry over and other contaminants, such as gases which might be injected at the compressor intake.
2. Liquid entrainments in the air stream.
3. Attrition losses due to abrasion of the desiccant particles against each other in the bed. (Estimated at 5% per year). Desiccant replacement is recommended every 24 to 36 months.
When the towers alternates, flow is momentarily dead ended. If a receiver is located upstream from the Dryers, it must be capable of absorbing compressor out put when the towers alternate. If no receiver is provided between compressor and Dryers, the piping system should have a pressure relief valve.
Maintain inlet air temp. below 40°C only.

INSTALLATION

GEM air Dryers is a self contained unit with all accessories provided on the skid. No special foundation is required. A closed room protected from rain moisture and dust is preferable. The compressor room will be an ideal location.
The air to the Dryers should be sufficiently cool (25 Deg.C to 40 Deg.C) to get the best performance, so an after cooler is necessary. Check if your compressor has one in good working condition.
Dryers should be mounted vertical level and free from any transmitted vibration. The surroundings temperature should not be abnormally high (above 40 Deg. C). Air pressure must not be less than 60 psi (4 kg/sq.cm.) nor more than 175 PSI (12 kg/sq.cm.).

Connect pipe lines as follows :
✅ Connect compressor to after cooler of either aircooled type or water cooled type.
✅ Connect after cooler to moisture seperator.
✅ Moisture seperator to Receiver.
✅ Receiver to dryer.
✅ Dryer to Machine end or Zero Oil Filter Set.

PREVENTIVE MAINTENANCE

GEM Dryers is built for trouble free operation round the clock service. But it requires some small care which keeps the equipment in best condition to give better performance and to last longer.

Daily

Drain water condensate from the pre filter moisture seperator and oil filters every 3 hrs or use an Automatic drain

Weekly

Check functioning sequence of the dryer

Monthly

Clean/Service Main flow valves.
Clean/Service check valves & solenoid valves.
Check Auto drain for proper functioning.
Clean filter elements with compressed air from outside.
Check all joints for leakages.

Yearly

Change Filter catridges; effective working hours only 5000 running hours.
Check overall functioning of the equipment.
Check condition of the desiccant.
Check valve seal / '0' rings etc.,

RECOMMENDED SPARES FOR PREVENTIVE MAINTENANCE OF GEM DRYER
S.No.	Description	Recommendation For Change
1	Check Valve	- To be changed only on fault
2	Solenoid valve NO	- To be changed only on fault
3	Solenoid valve NC	- To be changed only on fault
4	Main flow valve seal kit	- To be changed if it found worn out
5	Exhaust valve seal kit	- To be changed if it found worn out
6	Pre Filter Catridge	- To be changed after 5000 running hours
7	After Filter Catridge	- To be changed after 5000 running hours
8	Oil Filter Catridge	- To be changed after 5000 running hours
9	Desiccant	- To be changed on GEM service personnel's recommendation
10	Timer unit	- To be changed only on fault
Desiccant has a normal life of approx 3 years. But if found oil contamination or size lost (Powder Form) it has to be changed.

TROUBLE SHOOTING

Minor Problems : 1.Cycle Failure, 2.Purge Failure, 3.No exhausting

Major Problems : 1.Continuous Exhaust, 2.Moisture after the Dryer, 3.Air not coming out of Dryer.

Detailed Analysis

Nature of Problem	Reason for the Defect	Remedy
1. Cycle Failure	Electrical loose contact	Check electrical wirings
2. Purge Failure	Purge valve chocked or closed	Check the purge valve
3. No exhausting	Exhaust valve chocked	Check the valve
3. No exhausting	'NO' solenoid valve fault	Check solenoid valve
4. Continuous exhaust for 5 minutes	Exhaust valve diaphragm failure	Check diaphragm condition if found damaged change it
5. Continuous exhaust for 21/2 minutes only	'NO' Solenoid valve of exhaust side fault	Check/Clean and Service solenoid valves
	Main flow valve struck up	Clean/Service valve
	Check valve struck	Clean/Service check valve
	Purge open fully	Reset purge valve
	Main flow valve pilot solenoid valve fault	Check and clean service solenoid valve
6. Moisture coming after the drier	Check piping route raw air mixing with dried air elsewhere	Check thoroughly the piping arrangement
	Purge not enough/failed	Check purge system
	Dryer not exhausting	Follow the remedy as instructed in 3
	Cycle Failure	Follow the remedy in 1
	Not draining filters Properly	Check filter drain and make sure draining properly
7. Pressure drop in the dryer	Desiccant is oil contaminated or Powder form	Check & replace the desiccant

Desiccant has a normal life of approx 3 years. But if found oil contamination or size lost (Powder Form) it has to be changed.

GENERAL INSTRUCTION FOR OPERATION

✅ Do not operate your air dryer without an after cooler & moisture seperator. Since the load to the dryer is reduced 50% by using proper after cooler & moisture seperator.
✅ Do not operate dryer without proper oil filter since the oil entry to the desiccant will spoil the desiccant instantly.
✅ Never reset the purge valve after commissioning. It shall be set only by GEM personnel.
✅ Please follow the operating and maintenance instructions to obtain best results.

GENERAL SERVICE INSTRUCTIONS TO CUSTOMERS

✅ Please make Service calls only to GEM Spares & Service Division and give adequate time to arrange on service personnel for your call.
✅ Please keep available the recommended spares with you prior to calling Service personnel.
✅ Please assist GEM Service personnel for arranging local works & local purchases.
✅ In warranty claim materials have to be sent to M/s. GEM Spares & Service Division on freight PAID basis.
✅ Write to us for any assistance in operation/service of the equipment.

Contact Gem Equipments Pvt Ltd to learn how an adiabatic cooling tower can help your facility save water, cut energy bills, and improve system hygiene — all while delivering high performance.

Website : www.gemindia.com
Email : sales@gemindia.com
Phone : +91 9344455927
Address : Avinashi Road, Arasur, Coimbatore - 641407, Tamil Nadu, India.

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About Us

Gem Equipments entered the engineering and fabrication industry in 1984. We specialise in design, engineering and fabrication of Cooling Towers, Compressed Air Dryers, Industrial Chillers and Compressed Air Treatment Accessories.

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