Van Air Systems HL-2500 User Manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL
FOR
HEATLESS REGENERATIVE
COMPRESSED AIR DRYER
model HL-2500
January 2007
P/N 32-0289
READ ALL INFORMA TION IN THIS MANU AL BEFORE BEGINNING INST ALLA TION OR OPERATION OF THE DRYER. BEFORE STARTING INSTALLATION AND/OR MAINTENANCE PROCEDURES, TURN OFF THE MAIN POWER TO THE DRYER AND COMPLETELY DEPRESSURIZE THE UNIT TO PREVENT PERSONAL INJURY.
DO NOT REMO VE, REPAIR, OR REPLACE ANY ITEM ON THIS DRYER WHILE IT IS PRESSURIZED.
NEVER OPERATE THIS DRYER ABOVE THE RA TED OPERATING CONDITIONS. OPERA TION ABOVE SPECI­FIED CONDITIONS WILL RESULT IN DECREASED PERFORMANCE, POSSIBLE DAMAGE TO THE UNIT AND/ OR PERSONAL INJURY.
SEE BACK OF THIS MANUAL FOR ADDITIONAL SAFETY INSTRUCTIONS.
PAGE 1
HANDLING THE DRYER SECTION 1
1.1 HANDLING INSTRUCTIONS
WARNING
DO NOT LIFT THE DRYER BY PIPING OR CONTROL BOX. THESE COMPONENTS ARE NOT DESIGNED TO HOLD THE WEIGHT OF THE DRYER. PERSONAL INJURY AND/OR EQUIPMENT DAMAGE MAY RESULT.
Lift the dryer by the lifting lugs on both vessels. If the unit is to be lifted by an overhead device, attach the lifting chains or
cables to the skid angle and the vessel lifting lugs. Make sure that the chains or cables are clear of all piping and dryer components.
1.2 STORAGE INSTRUCTIONS
The unit 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 will cause damage to the unit.
If outside storage is required, the unit MUST BE adequately covered to prevent rain or snow from accumulating on the dryer. 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 for any damage that may have occurred during shipment. Inspect all fittings, piping connections, fasteners, etc. for loose connections. Also check gauges and lights for cracks or breakage.
IF DRYER HAS BEEN DAMAGED DURING SHIPMENT:
(1) NOTIFY CARRIER IMMEDIATELY AND FILE A CLAIM. (2) CONSULT FACTORY BEFORE OPERATING THE DRYER.
SAFETY INSTRUCTIONS SECTION 2
2.1 HANDLING
DO NOT LIFT THE DRYER BY PIPING OR CONTROL BOX. THESE COMPONENTS ARE NOT DESIGNED TO HOLD THE WEIGHT OF THE DRYER. PERSONAL INJURY AND/OR EQUIPMENT DAMAGE MAY RESULT.
WHEN LIFTING THE DRYER, ALWAYS USE THE LIFTING LUGS PROVIDED ON BOTH TOWERS.
MAKE SURE THAT ALL EQUIPMENT BEING USED TO LIFT THE DRYER IS CAPABLE OF LIFTING THE WEIGHT OF THE DRYER.
2.3 OPERATION
DO NOT OPERATE DRYER IF EITHER VESSEL IS LEAKING. IMMEDIATELY TAKE THE DRYER OUT OF SERVICE.
NOTE OPERATING CONDITIONS FOR PROPER PERFORMANCE OF THIS DRYER ARE DIFFERENT FROM MAXIMUM OPERATING CONDITIONS FOR THE VESSELS. BE SURE TO CHECK THE DRYER OPERATING CONDITIONS. SEE SECTION 3.1
USE THIS DRYER FOR COMPRESSED AIR ONLY.
2.2 INSTALLATION
BEFORE STARTING INSTALLATION PROCEDURES, TURN OFF POWER TO THE AREA WHERE THE DRYER WILL BE INSTALLED. SERIOUS PERSONAL INJURY MAY RESULT IF THIS SAFETY RULE IS NOT FOLLOWED.
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON DRYER WHILE IT IS PRESSURIZED.
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.
WHEN INSTALLING THIS DRYER, MAKE SURE THAT THE NEMA RATING OF THE CONTROL BOX IS APPLICABLE TO THE INSTALLATION.
MAKE SURE THAT ALL CUSTOMER SUPPLIED WIRING AND ELECTRICAL DEVICES ARE PROPERLY SIZED TO HANDLE THE ELECTRICAL REQUIREMENTS OF THE DRYER.
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.
AIR FROM THIS DRYER IS NOT SUITABLE FOR BREATHABLE AIR SYSTEMS WITHOUT FURTHER TREATMENT.
DO NOT OPERATE THIS DRYER IF EITHER VESSEL HAS BEEN DAMAGED BY FIRE. TAKE OUT OF SERVICE IMMEDIATELY AND NOTIFY YOUR CERTIFYING AUTHORITY.
2.4 MAINTENANCE
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THE DRYER WHILE IT IS PRESSURIZED. TURN OFF MAIN POWER TO THE DRYER AND DEPRESSURIZE THE DRYER COM­PLETELY BEFORE STARTING MAINTENANCE PROCEDURES.
DO NOT WELD OR GRIND EITHER VESSEL. IT WILL NOT BE SAFE TO OPERATE. (Note: Any alteration to the vessels VOIDS the ASME Code Certification.)
INSPECT OUTSIDE AND INSIDE OF VESSEL REGULARLY FOR CORROSION AND DAMAGE (I.E. DENTS, GOUGES OR BULGES). ANY DAMAGE TO THE VESSELS CAN MAKE THEM UNSAFE TO USE. IF DAMAGED, TAKE OUT OF SERVICE IMMEDIATELY.
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.
PAGE 2
DIMENSIONS AND SPECIFICATIONS SECTION 3
3.1 DRYER SPECIFICATIONS
APPROXIMATE WEIGHT:5800 lbs (with desiccant installed)
DIMENSIONS .............. See SECTION 3.2
IN/OUT CONNECTION: 4" - 150# R.F. Flange VESSELS (desiccant towers)
Construction.................. Manufactured to the ASME CODE, Section VIII, Division 1.
Design Pressure ........... 150 PSIG
Design Temperature..... -20 to 300OF
PIPING
Threaded fittings: ANSI B16.3 Threaded unions ANSI B16.39 Flanges: ANSI B16.5 Weld fittings: ANSI B16.9 Pipe: Carbon steel, Schedule 40
VALVES
Inlet ...............One (1) Proprietary 3-Way piloted shuttle valve
Outlet ............. Two (2) Check valves, metal hinge type
Purge ............. Two (2) Normally closed, diaphragm type valves
CONTROL AIR FILTER
Construction.................. Zinc housing
Vessels stamped "U" symbol.
ELECTRICAL
Standard 115 Volt.......... 115 -1 20V /1 PH /6 0H z
Optional 230 Volt ........... Main power: 220-240V/1ph/50-60Hz
Control Power: Transformed to 115V-120V/1ph/50-60Hz, on EMCON II only.
DESICCANT
Material .......................... Activated Alumina, 1/8" (2-5mm) Bead type
Quantity Per Tower: 1450 lbs
OPERATING CONDITIONS
Inlet Air Pressure ...........................MIN 60 PSIG ..........MAX 150 PSIG
Inlet Air Temperature ..................... MIN 40OF ............... MAX 120OF
Ambient Air Temperature ............... MIN 40OF ............... MAX 120OF
RATED INLET CONDITIONS
Inlet Air Pressure ........................... 100 PSIG
Inlet Air Temperature ..................... 100OF
Relative Humidity (saturation) ....... 100% RH
FLOW CAPACITIES (SCFM) at various pressures (1000F)
60 PSIG 80 PSIG 100 PSIG 110 PSIG 125 PSIG 140 PSIG 150 PSIG
HL-1500 1628 2064 2500 2607 2759 2903 2996
PAGE 3
DIMENSIONS AND SPECIFICATIONS SECTION 3
3.2 DIMENSIONS
PAGE 4
Note: Standard control panel (115V) is depicted on this drawing
INSTALLING THE DRYER SECTION 4
4.1 LOCATION
WARNING
DO NOT INSTALL THIS DRYER IN AN ENVIRONMENT OF CORROSIVE CHEMICALS, EXPLOSIVE GASSES, POISONOUS GASSES, OR SATURATED STEAM HEAT.
Basic bypass piping should include an inlet isolation valve, a bypass valve, and an outlet isolation valve. The isolation and bypass valves must be bubble-tight.
4.2-2 FILTERS
Locate dryer in a protected, well vented area where ambient temperatures are between 40oF and 120oF. Allow sufficient clearance over and around the dryer for access to desiccant fill and drain ports and controls. Refer to SECTION 3.2 for dryer dimensions.
If this dryer must be installed where ambient temperatures are below 40oF, insulation and heat tracing must be properly installed on the inlet piping, purge exhaust line and the desiccant towers to prevent freezing of the equipment.
Position the dryer in the upright position on a solid, level, vibration free surface capable of supporting the dryer’s weight. Refer to SECTION
3.1 for dryer specifications.
The dryer should not be located in extremely dirty areas where airborne contaminants can accumulate on the dryer. If this cannot be prevented, the dryer should be cleaned periodically.
4.2 PIPING AND ANCILLARY EQUIPMENT
CAUTION
Make sure that the inlet air piping is connected at the bottom and the outlet air piping is connected at the top of the dryer.
Make sure that the inlet and outlet piping to and from the dryer is properly supported. Excessive stress may cause damage and/or dryer malfunction.
Remove protective caps or covers from all valves before installing this dryer.
If this dryer is to be installed into an existing piping system, clean the existing inlet piping to remove all accumulated dirt, pipe scale, etc., before connecting the dryer. Make sure that the inlet and outlet shutoff valves are tightly closed before connecting to the existing piping system.
If excessive vibrations are present in the piping, install a flexible hose between the compressor and the dryer inlet.
When installing the piping and any additional components, make sure that adequate pipe supports are used. Excessive stress on the dryer and components may cause damage or premature failure. Use either overhead or stiff-leg type supports.
Make sure that the piping is correctly connected to the dryer. The inlet is the bottom connection and the outlet is the top connection.
Reference SECTION 3.2 for dryer dimensions and connection locations.
CAUTION
A PROPERLY RATED COALESCING PREFILTER MUST BE INSTALLED BEFORE THE DRYER TO REMOVE LUBRICATING OILS, DUST AND PIPE SCALE CONTAMINATION. FAILURE TO USE A PREFILTER WILL RESULT IN DAMAGE TO THE DRYER AND VOIDS THE WARRANTY.
Make sure that the elements are installed in all filter housings prior to start up.
THE DRYER AND PREFILTER ARE NOT DESIGNED TO HANDLE LIQUID WATER. IF LIQUID WATER IS PRESENT IN THE AIR SYSTEM, A SEPARATOR WITH AN AUTOMATIC DRAIN MUST BE INSTALLED UPSTREAM TO THE PREFILTER AND DRYER TO PREVENT FLOODING.
A coalescing prefilter must be installed before the dryer to remove lubricating oils, dust and pipe scale contamination. It is recommended that a high efficiency coalescing filter with an automatic drain or electric drain valve be installed. The filter should be equipped with a pressure differential indicator to monitor the condition of the element.
A particulate afterfilter should be installed downstream of the dryer to remove any desiccant dust. The filter should be equipped with a pressure differential indicator to monitor the condition of the element.
Make sure that the filters are properly installed according to the instructions provided with them.
4.3 INSTALLING THE PRESSURE RELIEF VALVES
CAUTION
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 check government regulations, i.e., state and local codes.
Connections are provided on the top of the vessels for the installation of pressure relief valves. Reference SECTION 3.2 for location and connection size.
Install the pressure relief valves into the provided connections. If pressure relief valves were not purchased with the dryer, they are available from your local VAN AIR representative under part number 14-0990 quantity 2.
Once the location has been determined, place the dryer into position. Lift the dryer by the lifting lugs only. Reference SECTION 1 for
handling instructions.
When the dryer is in place, it can be fastened to the mounting surface.
Reference SECTION 3.2 for dryer dimensions.
4.2-1 BYPASS PIPING (optional)
The installation of bypass piping is not required, but will allow the dryer and filters to be taken off stream without interrupting the air system.
In Figure 4A, several recommended bypass piping layouts and additional components are shown.
PAGE 5
INSTALLING THE DRYER SECTION 4
FIGURE 4A RECOMMENDED PIPING CONFIGURATIONS AND COMPONENTS 3 VALVE BYPASS
9 VALVE BYPASS
11 VALVE BYPASS
MODEL
HL-2500
IN/OUT
4" RF FLG
PREFILTERDRYER
MODEL
F101-3500-C
IN/OUT
6" RF FLG
DRAIN
VALVE
MODEL
EDV-2006
DEL-P
IND.
MODEL
PD-2
AFTERFILTER
MODEL
F101-2000-RB
IN/OUT
4" RF FLG
DEL-P
IND.
MODEL
PD-2
PAGE 6
INSTALLING THE DRYER SECTION 4
4.4 REMOTE PURGE EXHAUST PIPING
To reduce noise during purging and tower depressurization, this dryer was supplied with mufflers for installation on the purge exhaust valves. If the sound or humidity discharged from the dryer is unacceptable, the purge can be piped to a remote location.
Make sure that the piping is as short as possible and does not create back pressure on the dryer. To prevent liquid accumula­tion in the piping and purge valves, the piping must be at the same level or lower than the purge valves.
The purge line must be vented to atmospheric pressure. If the ambient temperature at the venting end of the piping is subject to temperatures below 40
The purge valves have threaded pipe connections. Reference Section 3.2 for location. Use adequate pipe supports to prevent stress on valves.
The distance will determine the size of piping that is recommended. For distances of 10 feet or less, use piping of the same size as the purge valves. For distances up to 20 feet, use piping one size larger than the purge valves.
IMPORTANT
o
F, freeze protection must be installed.
4.6-1 STANDARD CONTROL BOX (115V & 230V)
The power supply to the dryer is to be connected to the dryer control box. A 7/8" dia hole was provided in the bottom of the box for the connection of conduit or a cord grip connector.
Check the electrical rating of the dryer as listed on the dryer data tag. Make sure that the power source is correct for the dryer rating.
Remove the box cover to access the power and alarm terminals. Wire the power supply as shown in Figure 4C (Standard Control Box). Connect the wiring to the dryer box. Comply with all codes applicable for this installation.
FIGURE 4C ELECTRICAL CONNECTIONS
(STANDARD CONTROL BOX)
4.5 INSTALLING THE PURGE MUFFLERS
To reduce the sound level during purge and tower depressurization, this dryer was supplied with mufflers for installation on the purge exhaust valves.
Mufflers were shipped separately. They should NOT be installed until the dryer has been operated for several hours. From desiccant installation, some dust may be present in the desiccant towers. Operating the dryer with the mufflers installed immediately after the towers have been filled with the desiccant or during initial start up may cause the mufflers to clog.
The dryer must be operated for several hours without the mufflers after the towers have been filled with desiccant. This will prevent the mufflers from becoming clogged.
IMPORTANT
FIGURE 4B PURGE MUFFLER INSTALLATION
NOTE Dryer Model HL-2500 Has flanged muffler connections.
Control Power: 115V /1PH/50-60Hz; 230V/1PH/50-60Hz Max amp draw: 0.3 AMPS; 0.15 AMPS General Alarm Contacts: 115V-230V/1PH/60Hz, 0.25 amps
4.6-2 CYCLE SAVER / FAILURE TO SWITCH (115V & 230V)
Same instructions as Standard Control Box except wire the power supply as shown in Figure 4D (Cycle Saver / Failure To Switch).
FIGURE 4D ELECTRICAL CONNECTIONS
(CYCLE SAVER / FAILURE TO SWITCH)
4.6 ELECTRICAL CONNECTIONS
WARNING
SERIOUS PERSONAL INJURY AND DAMAGE TO THE DRYER WILL OCCUR IF THE DRYER IS CONNECTED TO A POWER SOURCE OTHER THAN THE VOLTAGE LISTED ON THE DATA TAG.
WHEN INSTALLING THE ELECTRICAL CONNECTIONS FOR THIS DRYER, COMPLY WITH NATIONAL ELECTRICAL CODE AND ALL APPLICABLE FEDERAL, STATE AND LOCAL CODES
Control Power: 115V /1PH/50-60Hz; 230V/1PH/50-60Hz Max amp draw: 1 AMPS; 0.5 AMPS General Alarm Contacts: 115V-230V/1Ph/60Hz, 3 amps
PAGE 7
INSTALLING THE DRYER SECTION 4
4.6-3 EMCON II (115 VOLT)
The electrical controls for the Emcon II dryers are housed in a NEMA 4 rated fiberglass enclosure.
Reference Figure 4E to locate the power input terminals. Access into the enclosure for wiring and conduit can be made by carefully drilling a hole in the bottom of the enclosure.
FIGURE 4E ELECTRICAL CONNECTIONS EMCON II (115 VOLT)
Do NOT wire the power supply directly to the
IMPORTANT
PLC. Wire the power supply to the input terminals as shown in Figure 4E.
Connect the proper conduit and wiring as required for this installation by all applicable codes.
Make the necessary connections to the power input terminals.
4.6-4 EMCON II (230 VOLT)
The main electrical controls for the Emcon II dryers are housed in a NEMA 4 rated fiberglass enclosure.
Dryers rated for 230V/1PH/60Hz are equipped with a power transformer located in a separate enclosure on the dryer. All main power supply (230V) connections will be made in the transformer enclosure.
Reference Figure 4F for connection details. Connect to the enclosure using the proper conduit and wiring as required for this installation by all applicable codes.
Control Power: 115V/1PH/60Hz Max amp draw: 2 AMPS General Alarm Contacts: 115V-230V/1PH/60Hz, 2 amps
FIGURE 4F ELECTRICAL CONNECTIONS EMCON II (230 VOLT)
General Alarm Contacts: 115V-230V/1PH/60Hz, 2 amps
PAGE 8
START UP SECTION 5
5.1 START UP
WARNING
BEFORE STARTING THIS DRYER, 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 WHILE IT IS PRESSURIZED.
For the Standard Control Box, make sure the Stop button is pressed. For the Cycle Saver and Emcon II Control Boxes, make sure that the Power switch is in the OFF position.
If the dryer is being started up for the first time or after the desiccant has been changed, the purge mufflers must be removed. The dryer should be operated until no desiccant dust is visible at the purge valves. Then the mufflers can be reinstalled. See Section 2.2 for safety precautions concerning the desiccant dust.
WARNING
WHEN OPERATING THIS DRYER WITHOUT THE MUFFLERS INSTALLED, USE HEARING PROTECTION.
If bypass piping was installed on this dryer as outlined in SECTION 4.2, close the inlet and outlet isolation valves. Open the bypass valve.
Pressurize the air system. Once the air system is pressurized, slowly open the inlet isolation valve. DO NOT open the outlet isolation valve.
To start the dryer with a Standard Control Box, press the Run button which will light the Run LED. For Cycle Saver and Emcon II Control Boxes, 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 muffler.
Dryers equipped with CYCLE SAVER or EMCON II controls will begin a 20 minute start up cycle. While in the start up cycle the dryer will operate for 5 minutes on each tower to allow the humistat(s) to reach equilibrium. Any time the dryer is restarted after a loss of power or pressure in both towers, it will restart in the start up cycle.
The dryer is equipped with a purge metering valve. The setting should be checked before placing the dryer on stream.
5.2 ADJUSTING THE PURGE FLOW
IMPORTANT
NEVER OPERATE THE DRYER WITH THE PURGE METERING VALVE CLOSED. IF THE VALVE IS CLOSED, THE TOWERS WILL NOT REPRESSURIZE AND SWITCHING FAILURE WILL OCCUR.
conditions, the purge metering valve must be adjusted to maintain the required purge flow rate listed in Figure 5B.
Determine the dryer minimum operating pressure. Using the chart in Figure 5A, find the valve setting for that pressure. The valve is equipped with a set screw which must be loosened before the valve is adjusted. Adjust the needle valve to the desired setting. Tighten the set screw to prevent tampering.
FIGURE 5A PURGE METERING VALVE SETTINGS
FACTORY
SETTING
PURGE
FLOW
100 PSIG
4.0 turns
120 PSIG
3.5 turns
150 PSIG
3.2 turns
MODEL
HL-2500
FIGURE 5B REQUIRED PURGE FLOW
4.5 turns
DRYER MODEL
HL-2500
60 PSIG
80 PSIG
4.2 turns
450 SCFM
5.3 CONDITIONING THE DESICCANT BED
To condition the desiccant bed, the dryer is operated without any outlet flow, while the towers regenerate with purge air.
To start the dryer with a Standard Control Box, press the Run button, which will light the Run LED. For Cycle Saver and Emcon II Control Boxes, place the Power switch to the ON position.
Dryers equipped with the Standard Contol Box should be set on the 10 minute time cycle. Dryers equipped with Emcon II and Cycle Saver should be set in the Fixed Mode. Observe the dryer for several cycles. Make sure that it is operating properly.
At initial start up or after extended shutdowns (over one month), the dryer 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 is placed on stream.
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 PERFORMANCE AND/OR EXCESSIVE USE OF PROCESS AIR.
The purge flow can be adjusted for the operating conditions. Standard dryers are equipped with a micrometer type needle valve. The valve can be adjusted to the desired setting.
This dryer was shipped with the purge flow set for the rated inlet flow at 100 PSIG. Reference Section 3.1 for rated flow. This setting should be correct for most installations. Before placing the dryer on stream, check the purge metering valve setting.
Figure 5B shows the purge flow required for each model. This flow is required to properly regenerate the desiccant beds.
If the dryer is being operated at a pressure other than inlet rated
Once the moisture indicator on the dryer turns blue, the desiccant bed is ready. Place the dryer on stream by opening the outlet isolation valve. Make sure that the by-pass valve is closed.
PAGE 9
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