READ ALL INFORMATION IN THIS MANUAL BEFORE INSTALLING OR OPERATING THE DRYER SYSTEM.
BEFORE STARTING MAINTENANCE PROCEDURES, TURN OFF THE MAIN POWER TO THE DRYER SYSTEM
AND COMPLETELY DEPRESSURIZE THE UNIT TO PREVENT PERSONAL INJURY.
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS DRYER SYSTEM WHILE IT IS PRESSURIZED.
NEVER OPERATE THIS DRYER SYSTEM ABOVE THE RATED OPERATING CONDITIONS. OPERATION
ABOVE SPECIFIED CONDITIONS WILL RESULT IN DECREASED PERFORMANCE, POSSIBLE DAMAGE TO
THE UNIT AND/OR PERSONAL INJURY.
PAGE 1
www.vanairsystems.com
HANDLING SECTION 1
1.1 HANDLING INSTRUCTIONS
If outside storage is required, the unit MUST BE adequately covered to
DO NOT LIFT THE DRYER SYSTEM BY PIPING OR CONTROL
WARNING
BOX SUPPORT BARS. THESE COMPONENTS ARE NOT DESIGNED TO HOLD THE WEIGHT OF THE DRYER. PERSONAL
INJURY AND/OR EQUIPMENT DAMAGE MAY RESULT.
Lift the dryer system by the lifting lugs on both vessels in combination
with the lifting lugs on the pre-cooler supports, or by the base using a
fork lift truck.
If the unit is to be lifted by an overhead device, attach the lifting chains
or cables to the vessel lifting lugs and the lifting lugs on the pre-cooler
supports. Make sure that the chains or cables are clear of all piping
and dryer components.
prevent rain or snow from accumulating on the dryer system. The unit
must be placed on a paved surface to keep it out of standing water and
mud.
1.3 EQUIPMENT CHECK
Inspect the dryer system for any damage that may have occurred
during shipment. Inspect all ttings, piping connections, fasteners,
etc. for loose connections. Also check gauges and lights for cracks or
breakage.
IF DRYER SYSTEM WAS DAMAGED DURING SHIPMENT:
(1) NOTIFY CARRIER IMMEDIATELY AND FILE A CLAIM.
(2) CONSULT FACTORY BEFORE OPERATING THE DRYER
SYSTEM.
1.2 STORAGE INSTRUCTIONS
If the unit is to be placed in storage before it is installed, it should be
stored indoors and covered with a tarpaulin to keep it clean. The location should be free from corrosive gasses and extreme humidity, which
can cause damage to the unit.
SAFETY SECTION 2
2.1 HANDLING
DO NOT LIFT THE DRYER SYSTEM BY PIPING OR CONTROL BOX
SUPPORT BARS. THESE COMPONENTS ARE NOT DESIGNED
TO HOLD THE WEIGHT OF THE DRYER SYSTEM. PERSONAL
INJURY AND/OR EQUIPMENT DAMAGE MAY RESULT.
LIFT THE DRYER SYSTEM BY THE LIFTING LUGS ON BOTH
VESSELS IN COMBINATION WITH THE LIFTING LUGS ON THE
PRE-COOLER SUPPORTS, OR BY THE BASE USING A FORK LIFT
TRUCK.
MAKE SURE THAT ALL LIFTING EQUIPMENT IS CAPABLE OF
SUPPORTING THE WEIGHT OF THE DRYER SYSTEM.
2.2 INSTALLATION
THESE ASME CODE VESSELS MUST BE PROTECTED BY PRESSURE RELIEF VALVES. 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 state and
local codes.
WHEN INSTALLING AND OPERATING THIS EQUIPMENT, COMPLY
WITH THE NATIONAL ELECTRICAL CODE AND ALL APPLICABLE
FEDERAL, STATE, AND LOCAL CODES.
ALWAYS WEAR EYE PROTECTION, GLOVES AND A RESPIRATORY
PROTECTIVE DEVICE WHEN HANDLING THE DESICCANT.
DESICCANT DUST MAY CAUSE EYE AND SKIN IRRITATION. AVOID
BREATHING THE DUST AND PROLONGED CONTACT WITH THE
SKIN.
FIRST AID IN CASE OF EYE CONTACT WITH DESICCANT DUST;
IMMEDIATELY FLUSH THE EYES WITH PLENTY OF WATER FOR
AT LEAST 15 MINUTES. CONSULT A PHYSICIAN.
DURING NORMAL OPERATION, THE INLET PIPING MAY REACH
TEMPERATURES OF 150°F. CONTACT WITH THE PIPING MAY RESULT IN SERIOUS PERSONAL INJURY.
DO NOT OPERATE THIS DRYER SYSTEM ABOVE THE MAXIMUM
RATED WORKING PRESSURE.
OPERATING CONDITIONS FOR PROPER PERFORMANCE OF THIS
DRYER SYSTEM ARE DIFFERENT THAN MAXIMUM OPERATING
CONDITIONS FOR THE VESSELS. BE SURE TO CHECK THE DRYER
SYSTEM OPERATING CONDITIONS. SEE SECTION 3.1.
USE THIS DRYER SYSTEM FOR COMPRESSED AIR ONLY.
AIR FROM THIS DRYER SYSTEM IS NOT SUITABLE FOR BREATHABLE AIR SYSTEMS WITHOUT FURTHER TREATMENT.
DO NOT OPERATE THIS DRYER SYSTEM IF EITHER VESSEL HAS
BEEN DAMAGED BY FIRE. TAKE OUT OF SERVICE IMMEDIATELY AND NOTIFY YOUR CERTIFYING AUTHORITY.
FILTER DISCHARGE MAY CONTAIN COMPRESSOR LUBRICANTS.
COMPLY WITH ALL REGULATIONS CONCERNING THEIR DISPOSAL.
2.4 MAINTENANCE
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THE
DRYER SYSTEM WHILE IT IS PRESSURIZED. TURN OFF MAIN
POWER TO THE DRYER SYSTEM AND DEPRESSURIZE THE
DRYER SYSTEM COMPLETELY BEFORE STARTING MAINTENANCE PROCEDURES.
DO NOT WELD OR GRIND EITHER VESSEL. IT WILL NOT BE
SAFE TO OPERATE. (Note: Any uncertied alteration to the vessels VOIDS the ASME Code Certication and the Warranty.)
2.3 OPERATION
DO NOT OPERATE DRYER SYSTEM IF EITHER VESSEL IS LEAKING. IMMEDIATELY TAKE THE DRYER SYSTEM OUT OF SERVICE.
DO NOT OPERATE DRYER SYSTEM IF THE FILTERS, OR OTHER
COMPONENTS ARE LEAKING. IMMEDIATELY TAKE THE DRYER
SYSTEM OUT OF SERVICE AND FIX OR REPLACE THE LEAKING
COMPONENT.
ANY DAMAGE TO THE VESSELS CAN MAKE THEM UNSAFE TO
USE. INSPECT OUTSIDE AND INSIDE OF VESSELS REGULARLY
FOR CORROSION AND ANY DAMAGE (I.E., DENTS, GOUGES OR
BULGES). IF DAMAGED, TAKE OUT OF SERVICE IMMEDIATELY.
PAGE 2
NEVER REMOVE THE FAN GUARD WHILE THE AFTERCOOLER IS
OPERATING. CONTACT WITH THE ROTATING FAN BLADES MAY
RESULT IN SERIOUS PERSONAL INJURY.
DO NOT INSTALL THIS DRYER SYSTEM IN AN ENVIRONMENT
OF CORROSIVE CHEMICALS, EXPLOSIVE GASSES, POISONOUS
GASSES, OR SATURATED STEAM HEAT.
Locate dryer system in a protected, well vented area where ambient
temperatures are between 40oF and 120oF. Allow sufcient clearance
over and around the dryer system for access to desiccant ll and drain
ports and controls. Refer to SECTION 3.2 for dryer dimensions.
If this dryer system must be installed where ambient temperatures are
below 40oF, insulation and heat tracing must be properly installed on
the inlet piping, prelter, purge exhaust line and the desiccant towers to
prevent freezing of the equipment.
Position the dryer system in the upright position on a solid, level,
vibration free surface capable of supporting the dryer system’s weight.
Refer to SECTION 3.1 for dryer system specications.
The dryer system should not be located in extremely dirty areas where
airborne contaminants can accumulate on the dryer system. If this
cannot be prevented, the dryer system should be cleaned periodically.
An accumulation of dirt on the precooler will greatly reduce its
efciency. Accumulated dirt may also cause the inlet transfer valve to
fail.
4.2 DESICCANT INSTALLATION
The desiccant was factory installed in both towers before the dryer
was shipped.
4.3 ELECTRICAL CONNECTIONS
WARNING
SERIOUS PERSONAL INJURY AND DAMAGE TO THE DRYER
SYSTEM WILL OCCUR IF THE DRYER SYSTEM IS CONNECTED
TO A POWER SOURCE OTHER THAN THE VOLTAGE LISTED
ON THE DATA TAG.
Connect the dryer system power cord to a 115V/1PH/60Hz power
source capable of supplying a minimum of 2 AMPS.
4.4 INSTALLING THE PURGE MUFFLERS
Purge mufers were shipped separately. They should NOT be installed
until the dryer system has been operated for several hours. From
desiccant installation, some dust may be present in the desiccant tow-
ers. Operating the dryer system with the mufers installed immediately
after the towers have been lled with the desiccant or during initial start
up may cause the mufers to clog. See SECTION 5.6 for purge mufer
installation.
4.5 FILL LUBRICATOR WITH OIL
The lubricator is located in the air line between the regulator and the
pre-cooler air motor. Fill the lubricator with Pneumatic Lubricating Oil
SAE10 AD220 (Van Air p/n 26-7032 quart).
4.6 CONNECT DRAIN LINE
Drain lines for the separator/prelter and prelter are run to a common
drain coupling located on the skid. Connect drain line from skid to an
appropriate collection container as lter discharge may contain
compressor lubricants. Comply with all regulations concerning their
disposal.
4.7 CONNECTING THE INLET AND OUTLET
The inlet and outlet of this dryer system are 3" 150# RF ange. Connect the inlet and outlet air piping to the dryer system.
START UP SECTION 5
5.1 START UP
WARNING
BEFORE STARTING THIS DRYER SYSTEM, FOLLOW THE INSTALLATION INSTRUCTIONS AND PROCEDURES COMPLETELY. SERIOUS PERSONAL INJURY CAN RESULT IF INSTRUCTIONS ARE NOT
CAREFULLY AND COMPLETELY FOLLOWED.
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS
DRYER SYSTEM WHILE IT IS PRESSURIZED.
Make sure that the Power switch is in the OFF position.
If the dryer system is being started up for the rst time or after the desiccant has been changed, the purge mufers must be removed. See
SECTION 2.2 for safety precautions concerning the desiccant dust.
Install the purge mufers per SECTION 5.6.
5.2 ADJUSTING THE PURGE FLOW
IMPORTANT
NEVER OPERATE THE DRYER SYSTEM WITH THE PURGE METERING VALVE CLOSED. IF THE VALVE IS CLOSED, THE TOWERS WILL
NOT REPRESSURIZE AND SWITCHING FAILURE WILL OCCUR.
DO NOT ADJUST THE PURGE METERING VALVE ABOVE OR
BELOW THE RECOMMENDED SETTING FOR THE OPERATING
CONDITIONS OF THIS INSTALLATION. IMPROPER SETTING MAY
CAUSE POOR DRYER SYSTEM PERFORMANCE AND/OR EXCESSIVE USE OF PROCESS AIR.
WARNING
WHEN OPERATING THIS DRYER SYSTEM WITHOUT THE MUFFLERS INSTALLED, USE HEARING PROTECTION.
Pressurize the air system.
Place the Power switch in the ON position. One tower will already be
pressurized. The other tower will depressurize. The purge valve on
the depressurized tower will be open, air should be exhausting from
the mufer.
The dryer system is equipped with a purge metering valve. The setting
should be checked per SECTION 5.2 before placing the dryer system
on stream.
Set the control pressure regulator per SECTION 5.3.
Set the lubricator and regulator for the pre-cooler air motor per
SECTION 5.4.
Condition the desiccant bed per SECTION 5.5 before placing the dryer
system on-stream.
PAGE 5
The Prep-40 dryer system is equipped with a purge metering valve and
gauge located in the purge piping. The gauge indicates the back pres-
sure on the purge ow orice, which is in direct correlation to the purge
ow in SCFM.
The purge ow can be adjusted for the operating conditions.
This dryer system was shipped with the purge ow set for the rated inlet
ow at 100 PSIG. Reference SECTION 3.1 for rated ow. This setting
should be correct for most installations. Before placing the dryer system
on stream, check the purge metering valve setting.
FIGURE 5B shows the purge ow, in SCFM, and the pressure setting
required. This ow is required to properly regenerate the desiccant beds.
FIGURE 5B REQUIRED PURGE FLOW
DRYER
MODEL
FR-1600
PURGE
FLOW
290 SCFM
PURGE FLOW
GAUGE SETTING
40 PSIG
START UP SECTION 5
5.3 SETTING THE CONTROL PRESSURE REGULATOR
The control pressure regulator is located in line with the control lter and
it is used to protect the pneumatic control components. This regulator
should be set at 100 PSIG.
CAUTION
DO NOT OPERATE THIS DRYER SYSTEM WITH
THE CONTROL AIR PRESSURE REGULATOR
ABOVE 100 PSIG TO PREVENT DAMAGE TO
THE PNEUMATIC CONTROLS.
5.4 ADJUST THE REGULATOR & LUBRICATOR
The regulator and lubricator for the pre-cooler air motor must be properly
set to ensure trouble-free air motor operation.
The regulator is used to set the speed of the pre-cooler fan. The regulator
is factory set using a tachometer and a clean precooler core. See FIGURE 5C. As the core becomes dirty, a higher regulator pressure setting may
be required to maintain the fan speed.
FIGURE 5C FACTORY REGULATOR SETTING
DRYER
MODEL
FR-1600
Set the lubricator per FIGURE 5D.
SETTING
(PSIG)
30
FIGURE 5D LUBRICATOR SETTING
DRYER
MODEL
FR-1600
AIR USAGE
(SCFM)
25
DROPS PER
FAN SPEED
(RPM)
1725
MINUTE
1
At initial start up or after extended shutdowns (over one month), the dryer
system may take 24 to 48 hours of continuous operation for the bed to be
conditioned. Moisture that has accumulated on the desiccant bed should
be removed before the dryer system is placed on stream.
Once the moisture indicator on the dryer system turns blue, the desiccant
bed is ready. The Prep-40 dryer is now ready for operation.
5.6 INSTALLING THE PURGE MUFFLERS
To reduce the sound level during purge and tower depressurization,
this dryer system was supplied with mufers for installation on the
purge exhaust valves.
Mufers were shipped separately. They should NOT be installed until
the dryer system has been operated for several hours. From desiccant installation, some dust may be present in the desiccant towers.
Operating the dryer system with the mufers installed immediately after
the towers have been lled with the desiccant or during initial start up
may cause the mufers to clog.
Operate the until NO desiccant dust is visible at the purge valves.
Then the mufers can be installed.
IMPORTANT
The dryer system must be operated for several hours without
the mufers after the towers have been lled with desiccant.
This will prevent the mufers from becoming clogged.
FIGURE 5A PURGE MUFFLER INSTALLATION
5.5 CONDITIONING THE DESICCANT BED
To condition the desiccant bed, the dryer system is operated without any
outlet ow while the towers regenerate with purge air.
Observe the dryer system for several cycles to make sure that it is operating properly.
OPERATION SECTION 6
6.1 DESCRIPTION OF OPERATION
The Prep-40 is a portable skid mounted system consisting of a strainer,
pre-cooler, separator/prelter, prelter, heatless regenerative dryer and
an afterlter. Wet warm air enters the pre-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 separator/prelter where the liquid water is removed. Then
the saturated air enters the coalescing lter where additional oil and liquid
water is removed. Then the air enters the heatless twin tower dryer where
it moves upward through the desiccant bed. The moisture is adsorbed
onto the surface of the desiccant. Dry air exits the heatless dryer and
passes through the general purpose particulate after-lter where residual
particulate is removed.
This package dryer will take saturated air at rated conditions and reduce
the mositure content to -40°F pressure dew point.
6.2 HEATLESS DRYER PRINCIPLE OF OPERATION
The Heatless Regenerative Air Dryer utilizes the pressure swing principle
of operation. The desiccant bed in one tower dries the air stream while
the desiccant bed in the other tower is regenerated.
A purge of dry air is used for tower regeneration. It is taken from the
outlet of the dryer.
The dryer is equipped with a purge metering valve to allow the correct
amount of dry air to ow into the regenerating tower. The heat created
during adsorption of moisture in the drying tower is retained in the desiccant
bed and increases the moisture removal capacity of the purge air.
The timing cycle of the dryer is controlled by two 3-way pilot valves.
To achieve maximum performance from this dryer, it should be operated
continuously. Operating this dryer for single shift periods may result in
varied outlet dew point performance.
PAGE 6
The dryer operation consists of four stages; REPRESSURIZATION,
CHANGEOVER/DEPRESSURIZATION, DRYING, and REGENERATION.
OPERATION SECTION 6
FIGURE 6A PNEUMATIC SCHEMATIC
6.2-1 REPRESSURIZATION STAGE
Repessurization occurs in the off-stream (regenerating) tower.
Repessurization must occur before tower changover to reduce shock
to the desiccant and the possibility of downstream pressure spikes.
Pilot valve SV1 or SV2 de-energizes causing the purge valve on the
off-stream (regenerated) tower to close. The purge air, which was
vented to atomosphere earlier in the cycle, is now used to
repressurize the off-stream tower.
6.2-2 CHANGEOVER/DEPRESSURIZATION STAGE
Tower changeover occurs after the off-stream (regenerated) tower is
pressurized. The SmartRelay signals SV1 or SV2 to open causing pilot
air to be supplied to the opposite side of the inlet transfer valve and
cause exhaust valve to open on regenerative tower. The inlet transfer
valve shuttle will move to the side that has pilot pressure placing the
regenerated tower on-stream. The tower that was on line and drying
the process air is now off-stream.
When the inlet transfer valve changes position, the position indicator
will move.
6.2-3 DRYING AND REGENERATION STAGE
One tower is on-stream (pressurized) drying process air. The process air
passes through the desiccant bed, which adsorbs moisture from the air.
The regeneration stage of the off-stream tower occurs at the same time
as the drying stage in the on-stream tower. During the regeneration
stage, a percentage of dry air is directed through the desiccant bed of
the offstream tower. The purge air is vented through the purge valve
to the atmosphere.
If pilot valve SV2 is energized, the LEFT tower is drying and if pilot
valve SV1 is energized, the RIGHT tower is drying.
6.3 MOISTURE INDICATOR
The moisture indicator is in the center of the panel. The moisture
indicator is a clear plastic tube lled with moisture sensing crystals. A
sample of outlet air is directed through the indicator.
The crystals will change colors from PINK (indicating wet air) to
BLUE (indicating dry air) as the dew point of the air changes from
+20OF to -40OF.
PAGE 7
OPERATION SECTION 6
6.4 DRYER CONTROLS
The control is housed in a NEMA 4X enclosure and it has the following
features:
- Power switch
- Power On light
- Fail to Switch light
- Alarm Reset pushbutton
- Hour Meter
See Figure 6B for control box door.
6.4-1 SMART RELAY:
The dryer cycle is controlled by a SmartRelay, two solenoid valves
and two pressure switches. The dryer timing chart is shown in FIG-URE 6C. The SmartRelay has a battery back-up that will hold the
program in memory safely for 2 years.
6.4-2 SWITCHING FAILURE:
When there is a switching failure (failure of control solenoid valves
SV1 & SV2; failure of exhaust valve to open; or clogging of exhaust
mufer), the Fail to Switch LED will be lit. This will energize the
Alarm Contacts shown in FIGURE 10D. The contacts can be wired
for remote annunciation. To reset the Switching Failure Alarm press
the Alarm Reset Pushbutton on the front of the control box. If the
condition causing the alarm is not corrected, the alarm will
re-activate in 90 seconds.
6.4-3 HOUR METER:
The Hour Meter is located on the front of the control box. It is used
to log the total number of hours that the Prep-40 dryer system has
been in operation.
FIGURE 6B CONTROL BOX DOOR
6.5 PDV-500T
The PDV-500T drain valve is an automatic drain valve tubed to the
separator/prelter to automatically drain liquid water from the lter.
Reference PDV-500T manual attached.
FIGURE 6C DRYER TIMING CHART
PAGE 8
= ON
SHUTDOWN SECTION 7
Shut off the air supply to the Prep-40 dryer system. Allow the dryer to
depressurize. Turn the dryer system off by placing the Power Switch to
the OFF position. Open the ball valve on the afterlter and completely
depressurize the dryer system.
Disconnect the power supply to the dryer system.
If maintenance is to be preformed on the dryer system, make sure the
dryer system is completely depressurized. Tower pressure gauges
must read 0 PSIG before removing any item on the dryer system.
STORAGE SECTION 8
WARNING
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.
INSPECT VESSEL, INSIDE AND OUT, REGULARLY FOR
BULGES, CORROSION, DENTS, GOUGES OR LEAKS. IF
DAMAGED, REMOVE FROM SERVICE IMMEDIATELY AND
NOTIFY YOUR CERTIFYING AUTHORITY.
8.1 REMOVE THE PREP-40 FROM SERVICE
Shutdown the dryer system per SECTION 7.
Close the ball valve on the afterlter.
The pre-cooler air motor needs to be ushed 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.
8.3 SET THE REGULATOR FOR THE AIR MOTOR
Set the regulator for the air motor per FIGURE 5C.
8.4 PREPARATION FOR STORAGE
Open the ball valve on the afterlter to completely depressurize
the Prep-40 system.
If long term storage is required, cover the inlet and outlet air
connections to prevent the accumulation of dirt and debris on the
piping.
8.5 STORAGE
Store the Prep-40 in location that is free from extreme humidity
and corrosive gasses, which can cause damage to the unit.
Perform Flushing procedure, per SECTION 8.2, when Prep-40 is
to be idle for more than 5 days, or if it is to be placed in storage.
Use only Van Air Flushing Solvent (p/n 26-7157). DO NOT use
kerosene or ANY other combustible solvents to ush the air
motor.
8.2 FLUSHING PROCEDURE
Remove the pipe plug in the air supply line near the air motor.
Drain the exhaust mufer / oil lter.
Disconnect tubing line to air motor exhaust mufer / oil lter at the air
motor.
Spray ushing solvent (Van Air p/n 26-7157) into air motor through tee
for 5 to 10 seconds.
Rotate motor shaft/fan, by hand, for one minute in each direction.
Reinstall the plug in the tee and cover the exhaust port with a cloth.
You must wear eye protection for this step.
Restart the motor at a low pressure (approximately 10 PSIG) and run it
until there is no trace of solvent in the exhaust air.
Listen for changes in the sound of the motor. If the motor sounds
smooth, the Prep-40 is ready for storage. If the motor does not sound
like it is running smoothly, the motor will need to be serviced.
Install the exhaust mufer / oil lter tubing line to the air motor.
PAGE 9
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