Van Air Systems D42-D84 User Manual
p/n 32-0120 rev D
INSTALLATION, OPERATION, & MAINTENANCE INSTRUCTIONS
FOR
SINGLE TOWER
COMPRESSED AIR DRYER
MODELS
D-42 through D-84
MARCH 2005
WARNING
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THE
DRYER WHILE IT IS UNDER PRESSURE. DEPRESSURIZE THE
DRYER COMPLETELY BEFORE STARTING INSTALLATION AND/
OR MAINTENANCE PROCEDURES. SERIOUS PERSONAL
INJURY MAY RESULT IF THESE SAFETY RULES ARE NOT
FOLLOWED.
DO NOT OPERATE THIS PRESSURE VESSEL ABOVE MAXIMUM
WORKING PRESSURE (MWP) AT MAXIMUM OPERATING
TEMPERATURE (OF) AS SHOWN ON THE ASME DATA PLATE.
THIS ASME CODE VESSEL MUST BE PROTECTED BY A
PRESSURE RELIEF VALVE. Refer to OSHA 1910.169 Par. b,
Sub. Par (3) and ASME Boiler and Pressure Vessel Code,
Section VIII, Division 1, UG-125 through UG-136. Also check
government regulations, i.e., state and local codes.
DO NOT WELD, GRIND, OR SAND VESSEL, OR IT WILL NOT
BE SAFE TO OPERATE. (Note: Any alteration to the vessel
will void the ASME Code Certification and the warranty.)
ANY DAMAGE TO THE VESSEL CAN MAKE IT UNSAFE.
INSPECT OUTSIDE AND INSIDE OF VESSELS REGULARLY
FOR BULGES, CORROSION, DENTS, GOUGES, LEAKS OR
SIGNS OF FIRE. IF DAMAGED, TAKE OUT OF SERVICE
IMMEDIATELY AND NOTIFY YOUR CERTIFYING AUTHORITY.
USE THE PROPER SAFETY RULES FOR THE GAS BEING
PROCESSED.
DO NOT REMOVE THE HATCH COVER UNTIL ALL AIR
PRESSURE IS OUT OF THE VESSEL. PUSH ON THE HATCH
COVER BY HAND TO FIND OUT IF THE VESSEL PRESSURE IS
REDUCED TO ZERO.
DO NOT TRY TO TIGHTEN THE HATCH COVER IF YOU HEAR
OR FEEL A LEAK. IMMEDIATELY SHUT OFF THE AIR OR GAS
SUPPLY TO THE VESSEL AND REDUCE THE DRYER
PRESSURE TO ZERO.
ALWAYS INSTALL A NEW GASKET EVERY TIME THE HATCH
COVER IS REMOVED, OR AT LEAST ONCE PER YEAR.
REPLACE THE HATCH COVER EVERY FIVE YEARS
REGARDLESS OF CONDITION. USE VAN AIR AUTHORIZED
PARTS ONLY.
DO NOT USE POWER TOOLS OR CHEATER BARS TO
TIGHTEN THE NUT ON THE COVER. TOO MUCH FORCE CAN
DISTORT THE COVER AND/OR THE GASKET. IF DAMAGED
BY OVERTIGHTENING, THE COVER CAN BLOW OUT AND
CAUSE SERIOUS INJURY. (Note: Tighten the nut until it is
snug only. When pressure is in the vessel, the seal will be
complete.)
INSPECT THE COVER AND SEALING SURFACE EVERY TIME
THE COVER IS REMOVED, OR AT LEAST ONCE PER YEAR,
FOR DAMAGE SUCH AS CORROSION, CRACKS, OR
DISTORTION. IF THERE IS ANY DAMAGE, INSTALL A NEW
COVER AND GASKET. USE VAN AIR AUTHORIZED PARTS
ONLY.
PAGE 1
SECTION 1 INTRODUCTION
1.0 PURPOSE OF OPERATION
The purpose of installing a Van Air single tower dryer in
a compressed air system is to remove the water vapor
(humidity) which has been drawn into the system at the
compressor intake. The Van Air process dries the air as
it flows through the vessel, which is filled with a special
drying agent. The dryer operates automatically. There
are no moving parts and no external source of power is
required. If an automatic drain is installed, a power
source is required only to operate the valve.
The wet air enters the centrally located inlet which
channels the flow into the lower portion of the dryer.
Liquid water and solid particles are separated by gravity
and fall to the bottom of the vessel.
The process air moves upward through the bed of
desiccant tablets which attract and absorb the moisture
from the air before it flows through the dryer outlet. The
tablets dissolve gradually as they absorb the moisture.
The tablets create a structured bed that does not crush
under its own weight. In the bed of an operating dryer,
the lower tablets are consumed first.
The tablets in the top portion are virtually unused and
serve as a reserve supply. When the reserve supply is
depleted, the dryer must be refilled to maintain
performance.
The solution, which consists of dissolved desiccant and water, falls
into the claim area at the bottom of the vessel. The dryer must be
FIGURE 1 DRYER DETAILS
drained at least once each shift to remove the accumulated solution.
SECTION 2 INSTALLATION
2.1 LOCATION
The ability of a dryer to provide dry compressed air depends on the
correct location of the unit. Inlet air temperature and pressure are the
keys to selecting the proper location.
IMPORTANT
ALWAYS PROCESS AIR THROUGH THE DRYER AT THE
LOWEST POSSIBLE TEMPERATURE AND THE HIGHEST
PRACTICAL PRESSURE.
2.1-A INLET AIR TEMPERATURE
The dew point of the outlet air is directly related to the inlet air
temperature and the type of desiccant being used. The lower the inlet
temperature, the lower the dew point of the outlet air. Determine the
lowest ambient temperature where the compressed air is used or
where the lines are located. If you are using DRY-O-LITE or 10BF
desiccants, do not exceed 100oF inlet air temperature. If you are
using SP desiccant, do not exceed 80oF inlet air temperature.
2.1-B AFTERCOOLING
Air discharged by the compressor is extremely hot (from 150oF to
350oF). An aftercooler, finned tubing or extended run of piping will
usually be necessary to reduce the inlet air temperature to the dryer.
area. When air equipment or piping is located in an air conditioned
area, install the dryer in the coolest area--usually the air conditioned
area.
2.1-E AIR RECEIVER
In relation to the air receiver, the Van Air single tower dryer should
be located where it will be provided with the coolest inlet temperature.
If the receiver is located in an area where the ambient temperature
is lower than the outlet air from the aftercooler, locate the dryer
downstream of the receiver to allow additional cooling of the air
before it enters the dryer. (Exception: In systems where usage
creates sudden demands on the air supply, locate dryer before the
receiver to minimize air surges through the dryer.) If the ambient
temperature around the receiver is higher than the outlet air
temperature from the aftercooler, locate the dryer between the
aftercooler and the receiver.
2.1-F SPECIAL EQUIPMENT INSTALLATION
If the Van Air Dryer is being installed on a branch line to protect a
specific piece of air-operated equipment, locate the dryer on the high
pressure side of any pressure regulators.
2.1-G OPERATING PRESSURE
2.1-C OUTDOOR AIR USAGE
If some or all of the air supplied by the Van Air single tower dryer will
be used outdoors, install the dryer outdoors in the coolest possible
area. Make sure that the dryer is not exposed to ambient temperatures
below the minimum design temperature stamped on the vessel data
tag. When the dryer will be exposed to the direct rays of the sun,
install a sun shield to protect it (i.e. a roof).
2.1-D INDOOR AIR USAGE
If all of the air from the dryer will be used indoors where temperatures
remain within a fixed range, locate the dryer in the coolest indoor
PAGE 2
More air can be processed through the dryer at higher pressures.
Locate the dryer at the highest practical pressure, but do not exceed
the maximum rated working pressure of the dryer. Refer to the
capacity chart located on Page 3 for the maximum working pressure
for your dryer.
2.2 PIPING AND ANCILLARY EQUIPMENT
Locate the dryer in the proper location as explained in the previous
section.
If the dryer is being installed in an existing piping system, make sure
that the pipe is free of scale and rust.
SECTION 2 INSTALLATION
FIGURE 2 MAXIMUM CAPACITIES -SCFM (Nm3/hr)
MAXIMUM
378
642
454
771
605
756
908
40 PSIG
2.8 Bar
596
1013
715
1215
954
1620
1192
2026
1431
2431
1669
2836
1908
3241
2146
3646
50 PSIG
3.4 Bar
705
1198
846
1438
1128
1917
1410
2396
1692
2875
1974
3354
2256
3833
2538
4313
60 PSIG
4.1 Bar
814
1383
977
1660
1303
2213
1628
2766
1954
3319
2279
3873
2605
4426
2931
4979
80 PSIG
5.5 Bar
1032
1753
1238
2104
1651
2805
2064
3507
2477
4208
2890
4910
3303
5611
3715
6312
90 PSIG
6.2 Bar
1141
1939
1369
2326
1826
3102
2282
3877
2738
4653
3195
5428
3651
6203
4108
6979
100 PSIG
6.9 Bar
1250
2124
1500
2549
2000
3398
2500
4248
3000
5097
3500
5947
4000
6796
4500
7646
125 PSIG
8.6 Bar
1522
2587
1827
3104
2436
4139
3045
5173
3654
6208
4263
7243
4872
8277
5481
9312
150 PSIG
10.3 Bar
1795
3050
2154
3659
2872
4879
NO.
D-42
D-48
D-54
D-60
D-66
D-72
D-78
D-84
WORKING
PRESSURE
150 PSIG
150 PSIG
150 PSIG
125 PSIG
125 PSIG
125 PSIG
125 PSIG
125 PSIG
5 PSIG
0.3 Bar
215
365
258
438
344
584
429
730
515
875
601
1021
687
1167
773
1313
10 PSIG
0.7 Bar
269
457
323
549
431
732
538
915
646
1098
754
1281
861
1463
969
1646
20 PSIG
1.4 Bar
1028
1285
1542
1059
1799
1210
2056
1361
2313
MODEL
FIGURE 3 RECOMMENDED INSTALLATION DRAWING
NOTE:
ITEMS CALLED OUT IN THIS DRAWING ARE NOT SUPPLIED WITH THE DRYER. REFERENCE FIGURES 1 & 4
FOR ITEMS INCLUDED WITH DRYER.
PAGE 3
SECTION 2 INSTALLATION
2.2-A INLET AND BYPASS PIPING
Using Figure 3 as a reference, make the necessary piping
connections into the dryer.
Inlet and outlet isolation valves should be installed on the dryer.
These valves will aid in the start up and shutdown of the dryer.
A bypass valve and piping should also be installed. This will allow
the dryer to be taken off stream without interrupting the air system.
2.2-B OPTIONAL PRESSURE RELIEF VALVE
A pressure relief valve should be installed to conform to OSHA
safety standards. Refer to OSHA Standard Section 1910.169,
paragraph b, subparagraph 3 and any other federal, state or
local codes concerning pressure vessels.
A coupling was provided on the upper back side of the vessel for
installing the relief valve. A bushing will be necessary to reduce
the coupling to the valve inlet size. Reference FIGURE 3 for
location.
Listed below is the recommended relief valve available for
each dryer. Contact your local Van Air representative to order.
DRYER
D-42
D-48
D-54
D-60
D-66
D-72
D-78
D-84
PART NO.
14-0540
14-0540
14-0990
14-0990
14-0990
14-1664
14-1665
14-1665
CONN. SIZE
3" NPT
3" NPT
3" NPT
3" NPT
3" NPT
3" NPT
3" NPT
3" NPT
VALVE SIZE
1-1/2" NPT
1-1/2" NPT
2" NPT
2" NPT
2" NPT
2" NPT
2-1/2" NPT
2-1/2" NPT
2.2-C OPTIONAL GAUGE KIT INSTALLATION
A coupling was provided on this dryer for the installation of a
gauge.
Three gauges are available for this dryer from your Van Air
representative.
Thread the gauge into the coupling provided on the lower, front
side of the vessel as shown in FIGURE 3.
GAUGE KIT
PRESSURE
TEMPERATURE
COMBINATION PRESSURE/TEMPERATURE
PART NO.
29-0252
29-0326
29-0200
The drain of the dryer can be remotely piped away from the dryer.
DO NOT connect the drain line to a pressurized line. Make sure that
the line is vented to atmospheric pressure.
Any remote drain piping should be of the same size and on the same
level or lower than the drain valve.
When installing the drain line, make sure that the discharge end of
the line or valve is directed away from people and equipment.
2.2-E OPTIONAL AUTOMATIC DRAIN VALVE
The MDV-400I drain valve is recommended. Contact your local
VAN AIR representative to order.
MODEL VOLT SIZE PART NO.
MDV-400I 115 1" NPT 39-2411121
Complete the automatic drain valve installation as shown in
FIGURE 3 and outlined in the instructions supplied with the drain.
The drain line can be remotely piped. Follow the precautions as
outlined in Section 2.2-D.
2.2-F AFTERFILTER
The installation of an afterfilter prevents any accidental flow of
materials from the dryer into the downstream piping.
The afterfilter can be installed before or after the outlet isolation
valve. If the afterfilter is installed before the isolation valve, the filter
can be isolated from the air system when the dryer is isolated for
DRYER
D-42
D-48
D-54
D-60
D-66
D-72
D-78
D-84
maintenance.
Below is a chart of VAN AIR recommended filters. Contact your
local VAN AIR representative to order.
FILTER
F101-1500-B
F101-1500-B
F101-2000-B
F101-3500-B
F101-3500-B
F101-3500-B
F101-5000-B
F101-5000-B
IN/OUT
3" NPT
3" NPT
4" RF FLG
6" RF FLG
6" RF FLG
6" RF FLG
6" RF FLG
6" RF FLG
DEL-P GAUGE
PD-2
PD-2
PD-2
PD-2
PD-2
PD-2
PD-2
PD-2
2.2-G DESICCANT INSTALLATION
2.2-D MANUAL DRAIN VALVE
A brass ball valve was shipped separately with the dryer. Install
the valve on the drain line. Reference FIGURE 3 for location.
CAUTION
DO NOT CONNECT THE DRAIN TO A PRESSURIZED LINE.
DO NOT INSTALL THE DRAIN LINE IN THE DIRECTION OF
PEOPLE AND EQUIPMENT. WHEN THE DRYER IS
DRAINED THE DRAIN SOLUTION WILL BE DISCHARGED
UNDER LINE PRESSURE. POINTING THE DRAIN IN THE
DIRECTION OF PEOPLE AND EQUIPMENT MAY RESULT
IN INJURY AND DAMAGE.
DO NOT INSTALL A FLOAT TYPE OR SOLENOID TYPE
DRAIN ON THE DRYER. THE DRAIN SOLUTION WILL
CAUSE THESE TYPES OF DRAINS TO FAIL, THUS
RESULTING IN FLOODING OF THE DRYER.
PAGE 4
This dryer was shipped WITHOUT the desiccant installed.
IMPORTANT
The desiccant MUST BE INSTALLED before using the dryer
THE USE OF CHEMICALS OTHER THAN VAN AIR
DESICCANT WILL VOID THE WARRANTY ON THE DRYER.
The procedures for filling the dryer with desiccant are outlined in
Section 4.5 of this manual.
2.2-H HIGH LEVEL ALARM HLA-120 (P/N 26-3667)
The HLA-120 high level alarm is designed to alert personnel that
the drain solution in the dryer has reached an unacceptable level.
A connection is provided on the dryer.
Contact your local VAN AIR representative to order.
Install the HLA120 high level alarm in the connection as shown in
FIGURE 3 and as outlined in the instructions supplied with the
alarm.
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