Page 1
OPERATION AND MAINTENANCE INSTRUCTIONS
FOR
BLAST PAK
PACKAGED COMPRESSED AIR TREATMENT SYSTEM
MODELS: FD-250 & FD-250-DC
WARNING
DO NOT OPERATE THIS SYSTEM ABOVE MAXIMUM WORKING
PRESSURE (MWP) AND/OR MAXIMUM OPERATING
TEMPERATURE (
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 comply
with all applicable state and local codes.
O
F) SHOWN ON THE VESSEL ASME DATA
December 2007
P/N 32-0294
REGULATOR SETTING FOR AIR MOTOR
22 PSIG TO GET 3450 RPM
DRY-O-LITE
MODEL
FD-250
FD-250-DC
* - ORIGINAL FILL OF DESICCANT SUPPLIED - CUSTOMER
WEIGHT
660 lbs
675 lbs
TO INSTALL
DESICCANT *
250 lbs
250lbs
DO NOT ATTEMPT TO REMOVE OR REPAIR ANY PART OF THE
SYSTEM UNTIL IT IS COMPLETELY DEPRESSURIZED. SERIOUS
PERSONAL INJURY MAY RESULT IF THIS SAFETY RULE IS
NOT FOLLOWED.
DO NOT WELD, GRIND, OR SAND VESSEL, THIS WILL MAKE
IT UNSAFE TO OPERATE. (Note: Any alteration to the vessel
will void the ASME Code Certification and the warranty.)
INSPECT VESSEL, INSIDE AND OUT, REGULARLY FOR
BULGES, CORROSION, DENTS, GOUGES, LEAKS OR SIGNS
OF FIRE. IF DAMAGED, REMOVE FROM SERVICE
IMMEDIATELY AND NOTIFY YOUR CERTIFYING AUTHORITY.
DO NOT TRY TO TIGHTEN A LEAKING HATCH COVER.
IMMEDIATELY SHUT OFF THE AIR SUPPLY AND
DEPRESSURIZE THE SYSTEM.
DO NOT ATTEMPT TO REMOVE THE HATCH COVER UNTIL
THE SYSTEM IS COMPLETELY DEPRESSURIZED. WHEN
THE VESSEL PRESSURE IS REDUCED TO ZERO, THE
HATCH COVER CAN BE REMOVED BY HAND.
INSTALL A NEW GASKET EVERY TIME THE HATCH COVER
IS REMOVED, OR AT LEAST ONCE PER YEAR. INSPECT
THE COVER AND SEALING SURFACE FOR DAMAGE SUCH
AS CORROSION, CRACKS, OR DISTORTION. IF THERE IS
ANY DAMAGE, REPLACE COVER. 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 HATCH 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. When the vessel is pressurized, the pressure
on the cover will complete the seal.)
THE USE OF CHEMICALS OTHER THAN VAN AIR
DESICCANT WILL VOID THE WARRANTY ON THE BLAST
PAK.
PAGE 1
Page 2
SECTION 1 DESCRIPTION OF OPERATION
A Blast Pak is a skid mounted system consisting of an air-cooled trim cooler, a single tower dryer with a bed of desiccant tablets and a
coarse afterfilter. Wet warm air enters the trim cooler where it is cooled to a temperature approaching ambient. Water is condensed out
during this cooling process. The saturated air and the liquid water proceed to the inlet of the single tower dryer. The liquid water and any
solid particles present are separated by gravity and fall to the dryer sump area. The process air moves upward through the bed of desiccant
tablets which attract and absorb moisture from the air before it flows through the dryer outlet. The tablets dissolve gradually as they absorb
the moisture. The solution, which consists of dissolved desiccant and water, falls into the sump area at the bottom of the vessel. The dryer
must be drained periodically to remove the accumulated solution. A manual ball valve is supplied for this purpose. A pneumatic drain valve
is available as optional equipment for automatic draining. Likewise, the desiccant in the dryer must be periodically replenished to maintain
performance. The coarse afterfilter is supplied to catch any residuals that may work their way downstream.
SECTION 2 PERFORMANCE
2.1 INLET CONDITIONS
The FD-250 and the FD-250-DC Blast Paks are rated for 250 SCFM at 100 PSIG, 180° F into the trim cooler [sized for 90° F ambient and 10°
approach (FD-250-DC) and 15° approach (FD-250)]. Approach temperatures will vary with changes to the inlet conditions (flow, pressure,
temperature) and the ambient temperature. The dew point out of the dryer tower is directly related to the inlet temperature entering the dryer
vessel. The lower the inlet temperature, the lower the dew point of the outlet air.
The aftercooler maximum inlet temperature is 250° F. When using DRY-O-LITE desiccant, the inlet temperature to the dryer tower should not
exceed 100° F.
2.2 MAXIMUM CAPACITIES FOR DRYER - SCFM (Nm3/hr)
MAXIMUM
WORKING
PRESSURE
200 PSIG
13.8 Bar
60 PSIG
4.1 Bar
163
262
80 PSIG
5.5 Bar
206
331
100 PSIG
6.9 Bar
250
402
125 PSIG
8.6 Bar
304
489
150 PSIG
10.3 Bar
359
577
175 PSIG
12.1 Bar
413
664
200 PSIG
13.8 Bar
468
752
SECTION 3 OPTIONS
3.1 PRESSURE RELIEF VALVE
A 1" NPT coupling is provided on the back of the dryer vessel for
installing the 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 all other federal, state
or local codes concerning pressure vessels.
See section 6 for recommended relief valve (available from your Van Air
rep.)
3.2 PNEUMATIC DRAIN VALVE (P/N 39-0284)
The 1"NPT drain connection can be fitted with a PDV-500T pneumatic
drain valve for automatic draining of the vessel. Ask your local Van
Air representative for details.
3.3 GAUGE KITS
A 1/2" NPT connection is provided on the lower front of the dryer for
installing gauges.
See Section 6 for optional gauge kits (available from your Van Air
rep.)
SECTION 4 OPERATION
4.1 DESICCANT INSTALLATION
IMPORTANT
The Blast Pak is shipped WITHOUT the desiccant installed.
The desiccant MUST BE INSTALLED before using the
system.
THE USE OF CHEMICALS OTHER THAN VAN AIR
DESICCANT WILL VOID THE WARRANTY ON THE DRYER.
The procedure for filling the dryer with desiccant is outlined in
Section 5.6 of this manual.
4.2 LUBRICATOR OIL (FD-250 only)
Check oil level in lubricator regularly and add oil as required.
Note: 1 Quart of oil shipped with the BlastPak.
plug shown in section 6 of this manual. Another way to make
the connections is to cut the plug off the motor leads and
wirenut the supply wires to the motor wires.
The BLUE wire is POSITIVE and the BLACK wire is NEGATIVE.
Make sure all electrical connections comply with the National
Electrical Code and all applicable state and local codes.
4.4 START UP PROCEDURES
SLOWLY pressurize the air system. Allow some air to bleed
through the manual drain valve. Once the system starts to
pressurize, the manual drain valve can be closed. The Blast Pak
is now in operation.
IMPORTANT
The Blast Pak is shipped WITHOUT the lubricator oil
installed. The lubricator oil MUST BE INSTALLED before
using the system.
4.3 ELECTRICAL CONNECTIONS (FD-250-DC only)
Electrical requirement for trim cooler motor is 12 VDC 19 Amps.
Connect 12 VDC supply to the air motor by using optional male
PAGE 2
Make sure that the Blast Pak is not subjected to sudden
CAUTION
flow surges. Always open the valves slowly to permit
gradual equalization of pressure between the Blast Pak
and the air supply lines.
Verify that regulator pressure is set as shown on page 1 of this
manual to maintain 3450 rpm fan speed to ensure proper
aftercooler performance. (FD-250 only)
Page 3
4.4 OPERATION
The simple design of the single tower dryer allows for easy
operation. The dryer requires two procedures to ensure peak
performance.
4.4-A DAILY DRAINING
The accumulated desiccant and water solution in the bottom
of the dryer should be drained frequently. If a manual drain
valve is installed on the dryer, it must be opened at least
once every 4 to 8 hours to drain the dryer.
The dryer may require draining on a more frequent basis on
humid days. If a pneumatic drain valve is installed on the
dryer, it will drain automatically as needed.
4.4-B REFILLING THE DRYER WITH DESICCANT
During the drying process, the desiccant tablets dissolve slowly.
The desiccant consumption rate is dependent on several factors,
such as inlet temperature, flow and pressure. To check the level
of the desiccant bed, look into one of the sight windows. If light can
be seen through the opposite sight window, the desiccant supply
must be replenished to ensure dryer performance.
Reference Section 5.6 for refilling instructions and Section 5.7
for estimated consumption rates.
IMPORTANT
The use of other than Van Air desiccant will void the
warranty on the Blast Pak.
CAUTION
If the dryer is not drained regularly, it may become
flooded and the accumulated liquid may enter the air
system and cause damage to downstream equipment.
SECTION 5 MAINTENANCE
5.1 DRAIN VESSEL DAILY
Drain the vessel by opening the drain valve and allowing the solution
to discharge; then close the drain valve completely. The accumulated
solution must be drained after every 4 to 8 hours of operation. An
optional pneumatic drain valve can be installed to drain the vessel
automatically as needed.
IMPORTANT
The drain solution may contain lubricants. Comply with all
applicable regulations concerning the disposal of these
chemicals.
5.2 CHECK DESICCANT LEVEL BEFORE OPERATION
Look into one of the sight windows. If light can be seen through the
opposite sight window, the desiccant supply must be replenished to
ensure dryer performance.
WARNING
IF THE SIGHT WINDOWS ARE DAMAGED IN ANY WAY,
THEY MUST BE REPLACED IMMEDIATELY WITH VAN AIR
PART NO. 26-0104 only.
Check the operation of all equipment installed before and after the
Blast Pak.
Inspect the hatch cover for signs of corrosion and/or leaks. Replace
the cover and/or gasket as necessary.
5.3 CHECK OIL LEVEL IN LUBRICATOR (FD-250 only)
Verify that there is sufficient amount of oil in the lubricator and add
oil as needed. Note: 1 quart of oil shipped with the BlastPak. See
section 6 for oil part number.
Loosen the nut on the hatch cover and push on the hatch cover. If
the vessel is depressurized, the cover will unseal. Once the seal is
broken, tilt the hatch cover and remove it from the dryer.
The initial fill of the dryer requires 250 lbs of desiccant.
A 100 lbs of desiccant is required to fill the FD-250 & FD-250-DC from
the sight window to maximum fill level.
Add the desiccant and then level off the tablet bed.
CAUTION
Make sure the desiccant level is below the screen on the
outlet pipe.
Do NOT overfill the vessel. Adequate space must be left
to allow the hatch cover to be installed.
Inspect the hatch cover and sealing surface. If there is any damage,
replace the cover. Replace the cover every 5 years regardless of
condition. The gasket should be replaced every time the hatch cover
is removed or at least once a year.
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 a new gasket. Tighten the nut on the
hatch cover until it is snug. Overtightening can cause damage to the
cover. The cover will seal when the vessel is pressurized.
Start up the dryer following the procedures in Section 4.4.
5.4 CHECK FILTER IN FRL (FD-250 only)
Replace filter as needed. See section 6 for filter part number.
5.5 CLEAN AFTERCOOLER CORE
The core should be cleaned regularly. Accumulation of dirt or other
contaminants such as oils will greatly reduce the efficiency of the
aftercooler.
Normal accumulation of dirt can be removed by blowing the core off
with compressed air. If the core becomes contaminated with oilladen particles, it can be steam cleaned. Clean with extreme care
as the aluminum fins can be easily damaged.
5.6 ADDING DESICCANT
Shut down the air system and open the drain valve to allow the dryer
to depressurize completely.
5.7 ESTIMATING DESICCANT USAGE
The ANNUAL DESICCANT CONSUMPTION RATE table is a guide
to estimate the desiccant usage for your installation.
The consumption rate is an approximation of how much
desiccant will be added over a period of one 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, contaminants etc.)
The desiccant bed level should be maintained to at least the sight
window level at all times to ensure optimum drying capabilities.
To use the chart, first determine the SCFM that is being processed
through the Blast Pak. Then locate the nearest flow rate listed on
the chart and interpolate as needed.
PAGE 3
Page 4
(This chart is based on 1 shift for a one year period (2,000 hours)@ 100 psig inlet pressure and 75oF inlet
temperature into dryer vessel, 100% RH.)
The consumption rate is proportional to the moisture loading. Each 20
changes the moisture loading by a factor of nearly 2:1.
For special applications requiring desiccants other than DRY-O-LITE, consult factory.
o
F increase in inlet temperature
FLOW
SCFM
100
150
200
250
DRY-O-LITE
LBS/YEAR
132
198
264
330
SECTION 6 REPLACEMENT PARTS
DESCRIPTION
Gasket for 3"x4" hatch cover
Hatch Cover, 3" x 4"
Sight Window
Manual Drain Valve 1" NPT
Manual Drain Valve 1/2" NPT
Air Motor for Aftercooler
Filter-Regulator-Lubricator
Element for FRL
Oil for Lubricator (Quart)
DESICCANT - DRY-O-LITE, 50 LB BAG
Flushing Solvent
OPTIONAL EQUIPMENT
Relief Valve 1/2" NPT 200# set pressure
Pressure gauge kit
Pressure gauge only
Temperature gauge kit
Temperature gauge only
Thermowell only
Combination pressure/temperature gauge
Automatic drain valve PDV-500T
White touch up paint (9 oz. spray can)
Male connector for 12 VDC motor wires
PART NO.
18-0391
46-3002
26-0104
14-0451
14-0450
26-6277
26-7039
26-7056
26-7032
33-0311
26-7157
14-1810
29-0252
29-0151
29-0326
29-0108
29-0107
29-0200
39-0284
45-0152
26-7178
FD-250 QTY
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
-
FD-250-DC QTY
1
1
2
1
1
-
-
-
-
2
-
1
1
1
1
1
1
1
1
1
1
SECTION 7 PREPARATION FOR STORAGE (FD-250 only)
The air motor on the FD-250 cooler needs to be flushed to remove excessive dirt, foreign particles, moisture and/or oil that accumulate in the air
motor during normal operation. Flushing helps to maintain proper motor performance and extend service life. Perform flushing procedure when
BlastPak is to be idle for more than 5 days, or if it is to be placed in storage.
Use Van Air Flushing Solvent (p/n 26-7157). DO NOT use kerosene or ANY other combustible solvents to flush the air motor.
Shutdown the air supply to the BlastPak and open the afterfilter drain valve to completely depressurize the system.
FLUSHING PROCEDURE
1. Remove the 1/4" NPT plug from the tee in the air line at air motor.
2. Remove the exhaust muffler from the air motor.
3. Spray flushing solvent (Van Air p/n 26-7157) directly into tee where plug was removed for 5 to 10 seconds.
4. Rotate motor shaft/fan, by hand in both directions for several revolutions.
5. Install the 1/4" NPT plug back into the tee and cover the motor exhaust port with a cloth.
6. You must wear eye protection for this step. Restart the air motor at a low pressure (approx. 10 PSIG) and run it until there is no trace of
solvent in the exhaust air.
7. Listen for changes in the sound of the motor. If the motor sounds smooth, the BlastPak is ready for storage. If the motor is not running
smooth, it will need to be serviced.
8. Disassemble the exhaust muffler that was removed in step 2. Clean the felt and reassemble the exhaust muffler.
9. Install the exhaust muffler on the air motor.
STORAGE
Store the Blast Pak in a location that is free from extreme humidity and corrosive gasses, which can cause damage to the unit.
2950 Mechanic Street
Lake City, PA 16423-2095
Phone: 814-774-2631
PAGE 4
www.vanairsystems.com
Loading...