Van Air Systems D42-D84 User Manual

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Page 1

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.

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Page 2

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.

Page 3

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

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.

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Page 4

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.

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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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SECTION 2 INSTALLATION

FIGURE 4 DRYER DIMENSIONAL DETAILS

MODEL

NO.

D-42

D-48

D-54

D-60

D-66

D-72

D-78

D-84

APPROX

WEIGHT

w/o Desiccant

1275 LBS

2150 LBS

2640 LBS

2700 LBS

3200 LBS

4075 LBS

4775 LBS

5700 LBS

42-3/4"

1085.9mm

48-3/4"

1238.3mm

54-3/4"

1390.7mm

60-3/4"

1543.1mm

66-3/4"

1695.5mm

72-3/4"

1847.9mm

78-7/8"

2003.4mm

85"

2159mm

85-5/8"

2174.9mm

91-1/4"

2317.8mm

94-1/4"

2393.9mm

97-1/4"

2470.2mm

100-1/4"

2546.4mm

109-7/16"

2779.7mm

114-9/16"

2909.9mm

123-9/16"

3138.5mm

16"

406.4mm

18-1/2"

469.9mm

18-1/2"

469.9mm

18-1/2"

469.9mm

18-1/2"

469.9mm

18-7/16"

468.3mm

20-11/16"

525.5mm

20-11/16"

525.5mm

4" 150#

FLANGE

4" 150#

FLANGE

4" 150#

FLANGE

4" 150#

FLANGE

6" 150#

FLANGE

6" 150#

FLANGE

6" 150#

FLANGE

6" 150#

FLANGE

27-13/16"

706.4mm

31-7/8"

809.6mm

34-3/8"

873.1mm

35-5/16"

896.9mm

36-3/8"

923.9mm

36-15/16"

938.2mm

41-1/2"

1054.1mm

41-1/2"

1054.1mm

1" NPT

2" NPT

152.4mm

203.2mm

5-5/8"

142.9

5-5/8"

142.9mm

5-5/8"

142.9mm

5-5/8"

142.9mm

5-5/8"

142.9mm

7-1/16"

179.4mm

7-1/16"

179.4mm

7-1/16"

179.4mm

40"

1016mm

46"

1168.4mm

52"

1320.8mm

58"

1473.2mm

64"

1625.6mm

70"

1778mm

76"

1930mm

82"

2082.8mm

PAGE 5

Page 6

SECTION 3 OPERATION

3.1 START UP PROCEDURES

Close the inlet isolation valve and open the bypass valve.

Open the outlet isolation valve SLOWLY and allow some air to bleed through the drain valve; then close the drain valve. When the dryer reaches normal operating pressure, SLOWLY turn the inlet valve to full open position; then close the bypass valve.

If the vessel was installed without the bypass or isolation valves, SLOWLY pressurize the air system. Allow some air to bleed through the drain valve. Once the vessel starts to pressurize, the drain valve can be closed.

Close the bypass valve. The dryer is now on stream.

CAUTION

Make sure that the dryer is not subjected to sudden flow surges. Always open the valves slowly to permit gradual equalization of pressure between the dryer and the air supply lines.

3.2 OPERATING THE DRYER

The simple design of the single tower dryer allows for easy operation. The dryer requires two procedures to ensure peak performance.

3.2-A DAILY DRAINING

The accumulated solution in the bottom of the dryer should be drained at least once for every 8 hours of operation. Depending upon actual operating conditions, the dryer may require draining on a more frequent basis.

If an automatic ball valve type drain valve was installed on the dryer, set the time cycle for every 4 to 8 hours. If a manual drain valve was installed, it must be opened at least once every 4 to 8 hours to drain the dryer.

CAUTION

If the dryer is not drained regularly, it may become flooded. Accumulated liquid may enter the air system and cause damage to downstream equipment.

On a new installation, continue to drain all downstream traps for several days (or until no water is evident) after dryer is installed. This period is required to dry out any accumulated water in the compressed air system. Once the water is removed, the downstream traps should not need to be drained again.

3.2-B REFILLING THE DRYER WITH DESICCANT

During the VAN AIR drying process, the desiccant tablets dissolve slowly. More tablets must be added to the supply when the top of the bed drops to the sight window level (minimum level). Reference FIGURE 5.

The desiccant consumption rate depends on several factors, such as inlet temperature, flow, pressure and the type of desiccant being used . With average conditions, the desiccant will usually need to be added only two to three times per year when the dryer is operating one shift per day. However, until the actual usage rate is determined, check the bed level monthly.

Reference Section 4.5 for estimated consumption rates and refilling instructions.

IMPORTANT Use VAN AIR desiccant only. Filling dryer with any other material will void the warranty.

3.3 USING THE SIGHT WINDOWS

WARNING

IF THE SIGHT WINDOWS ARE DAMAGED IN ANY WAY, REPLACE THEM IMMEDIATELY WITH VAN AIR PART NO. 26-0104 only. REFERENCE SECTION 4.3.

To check the level of the desiccant bed, look into one of the sight windows. When the top of the desiccant bed is level with the sight windows, the desiccant supply has dropped to the minimum level. The bed must be replenished to raise the bed level to the maximum level.

SECTION 4 MAINTENANCE

4.1 DAILY PROCEDURES

After every 8 hour period of operation, drain accumulated solution from the bottom of dryer. Open manual drain valve and allow the solution to discharge from the dryer, then close the manual drain valve securely.

4.2 MONTHLY PROCEDURES

Check the level of the desiccant bed by looking into the sight window. If the top of the desiccant bed is level with the sight window, the desiccant bed must be replenished.

Check the operation of all equipment installed before and after the dryer.

Check the afterfilter element condition. If the pressure differential across the filter is high (6 to 9 PSID), replace the element.

Inspect the hatch cover for signs of corrosion and/or leaks. Replace the cover and/or gasket if necessary.

PAGE 6

4.3 REPLACING THE SIGHT WINDOWS (P/N 26-0104)

WARNING

DEPRESSURIZE DRYER COMPLETELY BEFORE REMOVING THE SIGHT WINDOW.

Using a pipe wrench, unthread the old sight window. Remove all pipe sealant, rust or dirt from the coupling.

Apply a layer of pipe sealant to the threads of the new sight window. DO NOT USE TEFLON TAPE. Tape may prevent the sight window from threading into the coupling far enough.

4.4 DESICCANT SUPPORT GRID

If the grid becomes damaged, it can be replaced. The grid consists of plastic grid pipes and steel top rings.

Should the grid require replacment, detailed instructions for replacement will be provided with the new grid.

Page 7

SECTION 4 MAINTENANCE

4.5 ADDITION OF DESICCANT

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 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.

INSPECT THE COVER AND SEALING SURFACE EVERY TIME THE COVER IS REMOVED, OR AT LEAST ONCE A 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.

Open the bypass valve. Close the dryer inlet and outlet isolation valves. If the bypass and inlet and outlet isolation valves were not installed, shut down the air system.

Open the drain valve and allow the dryer to depressurize completely.

Loosen the wing nut on the hatch cover. Do not remove the nut, or the cover will fall into the vessel.

Push on the hatch cover. If the vessel is depressurized, the cover will unseal. Once the seal is broken, slide the handle so that it is parallel with the centerline of the long side of the opening. Tilt the hatch cover and remove it from the dryer.

Add the amount of desiccant tablets required to raise the supply to the normal operating level or to maximum level (see FIGURE 5); then level off the tablet bed.

CAUTION

Make sure that the desiccant does not cover the screen on the outlet pipe.

Check the sealing surface of the opening. If it is contaminated with dirt or rust, it must be cleaned before installing the hatch cover. A contaminated surface may prevent the gasket from properly sealing.

Install the filler hatch cover and gasket. Finger tighten the wing nut on the hatch cover. Overtightening will cause damage to the nut. The cover will seal when the vessel is pressurized.

Start the dryer following the start up procedures in Section 3.1

4.5-A BED LEVEL GUIDE

To determine the supply of desiccant in the dryer, insert a measuring stick through the filler hatch until it reaches the top of the desiccant bed; dimensions in FIGURE 5 are calculated from the filler hatch to levels indicated on the drawing. (NOTE: Dimensions are approximate and are intended as a general guide only.)

4.5-B DESICCANT USAGE GUIDE

The chemical and physical characteristics of Van Air desiccant contribute to its effectiveness and economy.

The DESICCANT CONSUMPTION RATE should be used as a guide to estimate the usage of desiccant your installation will require. The formula is based on an annual usage rate of one shift per day, 5 days per week and 50 weeks per year or 2,000 operating hours per year. The figure is an average and may vary depending upon your actual conditions (i.e. 24 hour operation, higher inlet temperature, excessive liquid water content and/or contaminants.)

DESICCANT CONSUMPTION

(Based upon 1 shift for a one year period @ 100 psig inlet pressure and 75oF inlet temperature, 100% RH.)

FLOW SCFM

100

1,000

10,000

To use the chart, first determine the SCFM that is being processed through the dryer. Locate the nearest flow rate listed on the chart and interpolate as necessary.

The consumption rate is proportional to the moisture loading. Each 20oF change in inlet temperature changes the moisture loading by a factor of nearly 2:1.

The quantity shown in the consumption rate chart is NOT the quantity that must be added to the dryer at one time. The bed level should be maintained at least to the minimum level at all times to ensure optimum drying capabilities. The consumption

rate is an approximation of how much desiccant will be added over a period of one year.

DRY-O-LITE

LBS/YEAR

132

1,320

13,200

LBS/YEAR

665

6,650

66,500

10 BF

LBS/YEAR

576

5,760

57,600

Do NOT overfill the vessel. Adequate space must be left to allow the hatch cover to be installed.

Check the condition of the hatch covet. If is damaged, it must be replaced. The gasket should be replaced every time.

PAGE 7

Page 8

SECTION 4 MAINTENANCE

FIGURE 5 BED LEVEL DETAIL

BED DIMENSIONS

INCHES (centimeters)

MODEL

D-42

D-48

D-54

D-60

D-66

D-72

D-78

D-84

A MAX. Level

16-13/16

42.7

18-3/8

46.7

19-7/8

50.5

21-3/8

54.3

22-7/8

58.1

24-1/2

62.2

25-15/16

65.9

27-7/16

69.7

MIN.

Level

26-9/16

67.5

28-1/8

71.4

29-5/8

75.2

31-1/8

79.1

32-5/8

82.9

40-1/4

102.2

41-11/16

105.9

43-3/16

109.7

Total

Depth

44-9/16

113.2

46-1/8

117.2

47-5/8

121.0

49-1/8

124.8

50-5/8

128.6

58-1/4

148.0

59-11/16

151.6

61-3/16

155.4

DRY-O-LITE QUANTITY*

POUNDS (kilograms)

MIN to

Lbs./In

MODEL

D-42

of bed**

60.75

27.6

D-48

78.75

35.7

D-54

99.75

45.3

D-60

123.0

55.8

D-66

148.5

67.4

D-72

177

80.3

D-78

207

93.9

D-84

241.5

109.5

* Amounts are pounds (kilograms) required to fill dryer to levels indicated. ** Amounts in italics are kilograms per centimeter of bed depth.

PAGE 8

MIN.

Level

1094

496

1418

643

1796

815

2214

1004

2673

1212

3186

1445

3726

1690

4347

1972

MAX

Level

1686

765

2186

991

2769

1256

3413

1548

4121

1869

5974

2710

6986

3169

8151

3697

MAX

Level

592

269

768

348

973

441

1199

544

1448

657

2788

1265

3260

1479

3804

1725

SP or HPD QUANTITY*

POUNDS (kilograms)

Lbs./In

of bed**

44.6

20.2

57.75

26.2

73.2

33.2

90.2

40.9

108.9

49.4

129.8

58.9

151.8

68.9

177.1

80.33

MIN.

Level

803

364

1040

472

1318

598

1624

737

1960

889

2336

1060

2732

1239

3188

1446

MAX

Level

1238

562

1603

727

2032

922

2503

1136

3022

1371

4380

1987

5123

2324

5977

2711

MIN to

MAX

Level

435

197

563

255

714

324

879

399

1062

482

2044

927

2391

1085

2789

1265

10 BF QUANTITY*

POUNDS (kilograms)

Lbs./In

of bed**

52.7

23.9

68.3

31.0

86.5

39.2

106.6

48.4

128.7

58.4

153.4

69.6

179.4

81.4

209.3

94.9

MIN.

Level

949

430

1229

557

1557

706

1919

870

2317

1051

2761

1252

3229

1465

3767

1709

MAX

Level

1463

663

1895

859

2400

1088

2958

1341

3572

1620

5177

2348

6055

2747

7063

3204

MIN to

MAX

Level

514

233

666

302

843

382

1039

471

1255

569

2416

1096

2826

1282

3296

1495

Page 9

SECTION 5 TROUBLESHOOTING

1. DECREASED PERFORMANCE - High desiccant usage.

High inlet air temperatures.

Check the aftercooler performance. Make sure that the aftercooler was properly sized and installed. Check the aftercooler operation manual for further details.

If an aftercooler was not installed, one may be required.

Check the compressor capacity or air usage vs. the dryer rating.

3. DECREASED PERFORMANCE - low desiccant usage.

The desiccant bed may be contaminated.

The dryer will tolerate normal amounts of compressor lubricant. If the compressor manufacturer's recommended lubrication rate is exceeded, the desiccant bed can become contaminated with compressor lubricants.

Periodically check the desiccant bed. If the tablets are discolored (deep yellow or brown), the bed may be contaminated.

Was a different compressor installed?

High ambient temperatures.

Check the location of the dryer for changes in ambient temperatures.

Was the dryer moved to a different location?

Was a piece of equipment or piping installed near the dryer that caused an increase in ambient temperatures? Relocate the dryer or equipment if possible. If relocation is not possible, correct the ambient temperature.

Dryer overloaded.

Check the flow through the dryer. Check the flow at peak usage periods. Have the flow requirements of the system increased?

Was the dryer properly sized for the actual operating conditions? Check the capacity of the dryer for the system conditions. If the system requirements exceed the dryer's capability, a larger dryer must be installed.

Desiccant bed below required level.

Check the desiccant bed level. The level should be checked at least once a month. The usage of desiccant will vary with the operating conditions and the type of desicccant being used. The dryer will require more desiccant during the warmer months of the year.

Desiccant quantities and filling procedures are outlined in Section

4.4 of this manual.

If the bed has become contaminated, it can be flushed with an adequate supply of water. Depending upon the severity of contamination, it might be necessary to completely flush the entire bed from the dryer and replace it with new desiccant.

Check the compressor for proper operation. The compressor might be worn or over lubricated. Check the compressor operator's manual and correct.

Check the atmospheric air near the compressor air intake. Heavy concentrations of acid fumes or smoke and dust will cause contamination if they are drawn into the air system. Check or install a filter on the compressor intake.

If it is not possible to reduce the amount of lubricants in the air system, a separator and/or coalescing filter should be installed before the dryer.

2. LIQUID DOWNSTREAM OF THE DRYER.

Improper draining. The dryer may be flooded.

The dryer must be drained at least once for every 8 hours of operation.

Check the drain valve(s) and piping for clogs. Repair or replace faulty valves. If the piping is clogged, it must be cleared.

If the dryer is installed outdoors where ambient temperatures fall below freezing, the drain line and valve(s) may freeze. If ambient temperatures fall below freezing, the drain line can be wrapped with heat tracing and/or insulation to prevent freezing.

If maintaining the required draining schedule is a problem, an automatic ball type drain valve should be installed. Reference Section 2.2-F in this manual for installation instructions.

IMPORTANT: Never install a float type or solenoid type drain valve on this dryer.

Bypass valve open or faulty.

Check the dryer bypass valve. It might be faulty or open allowing untreated air to enter the air system.

Low or no desiccant in the dryer.

Check the dryer deissiccant bed level. Reference Section 4.4 for filling quantities and procedures.

If the above check list does not remedy the problem, consult your local VAN AIR distributor or call the VAN AIR factory in Lake City, Pennsylvania PHONE (814) 774-2631 or FAX (814) 774-3482.

PAGE 9

Page 10

SECTION 6 REPLACEMENT PARTS

ITEM

Gasket for 12" x 16" hatch cover

Hatch Cover, 12" x 16"

Sight Window

Manual Drain Valve 1" NPT

Manual Drain Valve 2" NPT

DRY-O-LITE Desiccant, 55 LB BAG DRY-O-LITE Desiccant, 506 LB DRUM SP Desiccant, 50 LB BAG 10BF Desiccant, 25 LB PAIL

OPTIONAL PRESSURE RELIEF VALVES

1-1/2" NPT 150# set pressure 2" NPT 150# set pressure 2" NPT 125# set pressure 2-1/2" NPT 125# set pressure 2" NPT 125# set pressure

Pressure gauge kit Temperature gauge kit Combination pressure and temperature

DESCRIPTION

DESICCANT

OPTIONAL GAUGE KITS

PART NO.

18-0347 46-2147 26-0104 29-0451 29-0542

33-0159 33-0203 33-0205 33-0232

14-0540 14-0990 14-1664 14-1665 14-1663

29-0252 29-0326 29-0200

D42

QTY

1 1 2 1

4 34 68

D48

QTY

1 1 2 1

5 46 92

D54

QTY

1 1 2 1

116

-1

1 1 1

D60 QTY

1 1 2

-1

144

-1

1 1 1

D66

QTY

1 1 2

-1

176

-1

1 1 1

D72 QTY

1 1 2

-1

115

13 126 252

-1

1 1 1

D78

QTY

1 1 2

-1

135

15 148 296

-1

1 1 1

D84

QTY

1 1 2

-1

182

20 200 400

-1

1 1 1

a b c d

OPTIONAL HIGH LEVEL ALARM

HLA-120 High level alarm kit

OPTIONAL AUTOMATIC DRAIN VALVE

MDV-400I

REPLACEMENT GRID PARTS BOLT NUT WASHER D-42 TOP RING SECTION D-48 TOP RING SECTION D-54 TOP RING SECTION D-60 TOP RING SECTION D-66 TOP RING SECTION D-72 TOP RING SECTION D-78 TOP RING SECTION D-84 TOP RING SECTION D-42 GRID TUBES D-48 GRID TUBES D-54 GRID TUBES D-60 GRID TUBES D-66 GRID TUBES D-72 GRID TUBES D-78 GRID TUBES D-84 GRID TUBES

26-3667

39-2411121

28-0105 28-0104 28-0301 46-1505 46-1506 46-1507 46-1508 46-1509

46-1510 Call Factory Call Factory

17-0502

17-0504

17-0506

17-0508

17-0512

17-0510

17-0520

17-0518

4 4 4 4

-1

4 4 4

-4

-1

4 4 4

-4

-1

5 5 5

-5

-1

6 6 6

-6

-1

6 6 6

-6

-1

7 7 7

CALL

-1

7 7 7

CALL

-1

PAGE 10

Page 11

SECTION 6 REPLACEMENT PARTS

PAGE 11

Page 12

YOUR VAN AIR REPRESENTATIVE IS:

NAME:

COMPANY:

ADDRESS

CITY: STATE: ZIP

PHONE: FAX:

ATTACH BUSINESS CARD HERE

MAKING COMPRESSED AIR AND GAS WORK BETTER SINCE 1944.

PAGE 12

2950 Mechanic Street

Lake City, PA 16423-2095

Phone: 814/774-2631

Fax: 814/774-3482