Van Air Systems FR-400 User Manual
OCTOBER 2012
2950 Mechanic Street
Lake City, PA 16423 USA
Phone: 800-840-9906
Fax: 814-774-3482
www.vanairsystems.com
INSTALLATION, OPERATION & MAINTENANCE MANUAL
FOR
PREP-40 PORTABLE COMPRESSED AIR DRYER SYSTEM
model
FR-400 (P/N 81-2441)
REV A
WARNING
READ ALL INFORMATION IN THIS MANUAL BEFORE INSTALLATING 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
HANDLING SECTION 1
1.1 HANDLING INSTRUCTIONS
DO NOT LIFT THE DRYER SYSTEM BY PIPING OR CONTROL BOX
WARNING
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.
If outside storage is required, the unit MUST BE adequately covered
to 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.
DURING NORMAL OPERATION, THE INLET PIPING MAY REACH
TEMPEREATURES 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.
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.
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 AFTERCOOLER CORE,
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.
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 AND SEPARATOR 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.)
NEVER REMOVE THE FAN GUARD WHILE THE AFTERCOOLER
IS OPERATING. CONTACT WITH THE ROTATING FAN BLADES
MAY RESULT IN SERIOUS PERSONAL INJURY.
PAGE 2
SPECIFICATIONS SECTION 3
3.1 SPECIFICATIONS
WEIGHT.............................. 1790 lbs (with desiccant installed)
DIMENSIONS...... ............... See SECTIONS 3.2
IN/OUT CONNECTION...... 2" 4-lug coupling (Dixon #AM28)
VESSELS (desiccant towers)
Construction ................... Manufactured to the ASME CODE, Section VIII, Division 1.
Vessels stamped "U" symbol.
Design Pressure ............. 175 PSIG
Design Temperature ....... -20OF TO 300OF
PIPING
Threaded ttings: ........... ASME B16.3
Threaded unions: .......... ASME B16.39
Flanges: ......................... ASME B16.5
Pipe: .............................. Carbon steel, Schedule 40
VALVES
Inlet ............................... Proprietary 3-Way piloted shuttle valve
Outlet .............................. Two (2) Check valves, buttery type
Purge .............................. Normally closed, air operated type
CONTROL AIR FILTER
Construction ................... Aluminum housing
PREFILTER/AFTERFILTER
Construction ................... Aluminum housing
PRE-COOLER
Core. ............... ................Aluminum
Fan..................................Polypropylene blades with Aluminum hub
Fan Guard ......................Steel
SEPARATOR/PREFILTER
Construction ................... Aluminum housing
ELECTRICAL
Standard 115 Volt ........... 115-120V/1PH/50-60Hz
DESICCANT
Material ........................... Activated Alumina, 1/8" (2-5 MM) Bead type
Quantity Per Tower..........215 LBS
OPERATING CONDITIONS
Inlet Air Pressure ............................ MAX 175 PSIG
Inlet Air Temperature ...................... MAX 150OF
Ambient Air Temperature................ MIN 40OF..........MAX 120OF
SYSTEM RATED INLET CONDITIONS
Inlet Air Pressure ............................ 100 PSIG
Inlet Air Temperature ...................... 150OF (based on 85°F ambient and 15°F approach from the pre-cooler)
Relative Humidity (saturation) ........ 100% RH
DRYER FLOW CAPACITIES (SCFM) at various pressures (1000F)
60 PSIG 80 PSIG 100 PSIG 110 PSIG 125 PSIG 140 PSIG 150 PSIG 160 PSIG 175 PSIG
FR-400 260 330 400 417 441 465 479 494 514
PAGE 3
SPECIFICATIONS SECTION 3
3.2 DIMENSIONS
PAGE 4
INSTALLATION SECTION 4
4.1 LOCATION
WARNING
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, separator, 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
shipped.
4.3 ELECTRICAL CONNECTIONS
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.
WARNING
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
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. 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 LINES
Connect the automatic drains for the separator/prelter and the prelter
to an appropriate collection container. Filter and separator/prelter
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 equipped with 2" 4-lug
couplings. Connect the inlet and outlet air hoses to the dryer system.
Remember to use SAFETY CLIPS.
PAGE 5
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.
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 tower that is not pressurized 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.
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.
The Prep-40 dryer system is equipped with a purge metering valve and
gauge. Reference SECTION 3.2 for Location. The gauge indicates the
back pressure on the purge ow orice, which is in direct correlation to
the purge ow in SCFM.
FIGURE 5B REQUIRED PURGE FLOW
DRYER
MODEL
FR-400
PURGE
FLOW
72.0 SCFM
PURGE FLOW
GAUGE SETTING
39 PSIG
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 115 PSIG.
CAUTION
DO NOT OPERATE THIS DRYER SYSTEM WITH
THE CONTROL AIR PRESSURE REGULATOR
ABOVE 115 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-400
Set the lubricator per FIGURE 5D.
SETTING
(PSIG)
22
FIGURE 5D LUBRICATOR SETTING
DRYER
MODEL
FR-400
AIR USAGE
(SCFM)
15
DROPS PER
MINUTE
FAN SPEED
(RPM)
1725
1
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.
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.
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 for each model. This ow is required to properly regenerate
the desiccant beds.
PAGE 6
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