Van Air Systems HLS-50, HLS-150 User Manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL

FOR

HEATLESS REGENERATIVE

COMPRESSED AIR DRYER

models

HLS-55 through HLS-150

SEPTEMBER 2004

P/N 32-0266-C

2950 MECHANIC STREET

LAKE CITY, PA 16423

PHONE:[phone]

FAX: [phone]

HLS-55/80

HLS-120/150

WARNING

READ ALL INFORMATION IN THIS MANUAL BEFORE BEGINNING INSTALLATION 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 REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS DRYER WHILE IT IS UNDER PRESSURE.

NEVER OPERATE THIS DRYER ABOVE THE RATED OPERATING CONDITIONS. OPERATION 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

PRINTED IN THE U.S.A. PAGE 1

HANDLING THE DRYER SECTION 1

1.1 HANDLING INSTRUCTIONS

DO NOT LIFT THE DRYER BY THE INLET PIPING OR CONTROL

WARNING

BOX. THESE COMPONENTS ARE NOT DESIGNED TO HOLD
THE WEIGHT OF THE DRYER. PERSONAL INJURY AND/OR
EQUIPMENT DAMAGE MAY RESULT.

If the unit is to be stored outdoors, it MUST BE covered completely.
The cover must be adequate enough to prevent rain or snow from
accumulating on the dryer. The location must be free of standing
water and mud. The preferred location if outdoors, is on a paved
surface.

Lift the dryer by the outlet (top) piping or vessel center connector bar.

When lifting the unit make sure that the chains or cables are clear of
all tubing and fragile components.

1.2 STORAGE INSTRUCTIONS

The ideal place to store the unit is indoors. The location should be
free from corrosive gasses and extreme humidity. These conditions
will cause damage to the unit. The unit should be covered with a
tarpaulin to keep the unit clean.

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 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 INLET (BOTTOM) PIPING OR
CONTROL BOX. THESE COMPONENTS ARE NOT DESIGNED TO
HOLD THE WEIGHT OF THE DRYER. PERSONAL INJURY AND/
OR EQUIPMENT DAMAGE MAY RESULT.

MAKE SURE THAT ALL EQUIPMENT BEING USED TO LIFT THE
DRYER IS CAPABLE OF LIFTING THE WEIGHT OF THE DRYER.

IF THE DRYER IS TO BE TRANSPORTED OVERHEAD, MAKE
SURE THAT ALL PERSONNEL ARE ALERTED AND SAFETY
PROCEDURES ARE FOLLOWED.

2.2 INSTALLATION

BEFORE STARTING INSTALLATION AND/OR MAINTENANCE
PROCEDURES, TURN OFF POWER AND DEPRESSURIZE UNIT TO
PREVENT INJURY. SERIOUS PERSONAL INJURY MAY RESULT IF
THESE SAFETY RULES ARE NOT FOLLOWED.

DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON DRYER
WHILE IT IS UNDER PRESSURE. TURN OFF MAIN POWER TO THE
DRYER AND DEPRESSURIZE THE DRYER COMPLETELY BEFORE
STARTING INSTALLATION AND/OR MAINTENANCE PROCEDURES.

WHEN INSTALLING AND OPERATING THIS EQUIPMENT, COMPLY
WITH THE NATIONAL ELECTRICAL CODE AND ANY 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.

2.3 OPERATION

DO NOT OPERATE DRYER IF THERE IS A LEAK IN EITHER VESSEL.
IMMEDIATELY TAKE THE DRYER OUT OF SERVICE.

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.

DO NOT OPERATE THIS DRYER ABOVE THE MAXIMUM RATED
WORKING PRESSURE.

OPERATING CONDITIONS FOR PROPER PERFORMANCE OF THIS
DRYER ARE DIFFERENT THAN 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.

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.

2.4 MAINTENANCE

DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THE
DRYER WHILE IT IS UNDER PRESSURE. TURN OFF MAIN
POWER TO THE DRYER AND DEPRESSURIZE THE DRYER
COMPLETELY BEFORE STARTING MAINTENANCE PROCE­DURES.

DO NOT WELD OR GRIND ON EITHER VESSEL. IT WILL NOT BE
SAFE TO OPERATE.

ALWAYS WEAR EYE PROTECTION, GLOVES AND A RESPIRATORY
PROTECTIVE DEVICE WHEN HANDLING THE DESICCANT. THE
DUST FROM THE DESICCANT 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.

PAGE 2 PRINTED IN THE U.S.A.

DIMENSIONS AND SPECIFICATIONS SECTION 3

3.1 DRYER SPECIFICATIONS

WEIGHT (with desiccant installed)

HLS-55 .... 230 lbs HLS-80.... 280 lbs HLS-120.... 385 lbs

HLS-150.... 445 lbs

DIMENSIONS See SECTION 3.2

IN/OUT CONNECTION

HLS-55....1/2"NPT HLS-80....1"NPT HLS-120....1" NPT

HLS-150....1"NPT

VESSELS (desiccant towers)

Design Pressure ............ 150 PSIG

Design Temperature ...... -20OF TO 200OF

PIPING

Threaded pipe fittings: ANSI B16.3
Threaded union fittings: ANSI B16.39
Pipe: Carbon Steel, Schedule 40

VALVES

Inlet ............... 4-Way, solenoid piloted

Outlet ............. Shuttle valve

Purge .............. 3-Way Valve (run as a 2-Way Valve), solenoid piloted

CONTROL AIR FILTER

Construction ... Zinc housing

ELECTRICAL

Nema 4 Electrical enclosure

Standard 115V ...... 115V/1PH/50-60Hz

Optional 230V: ....... 230V/1PH/50-60Hz

DESICCANT

Material .............. Activated Alumina, 1/8" (2-5 MM) Bead type

Quantity Per Tower (LBS)

HLS-55....30.5 lbs HLS-80....43.5 lbs HLS-120....67.5 lbs

HLS-150....82.5 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

3.2 DIMENSIONS Models HLS-55 through HLS-150

HLS-55
HLS-80

HLS-55
HLS-80

HLS-55

HLS-80

HLS-55

HLS-80

HLS-120

HLS-150

HLS-120

HLS-55

HLS-150

HLS-80

HLS-55
HLS-80

HLS-55 & HLS-80

PRINTED IN THE U.S.A. PAGE 3

HLS-120 & HLS-150

* (ROTATED TO BACK ON HLS-150)

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.

Locate dryer in a protected, well vented area where ambient
temperatures are between 40oF and 120oF. If this dryer must be
installed where ambient temperatures are below 40
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. Allow sufficient
clearance over and around the dryer. Refer to SECTION 3.2 for dryer

dimensions.

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.

o

F, insulation and

4.2 PIPING AND ANCILLARY EQUIPMENT

IMPORTANT
Make sure that the inlet air piping is connected to the bottom and the
outlet air piping is connected to 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.

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.

Once the location has been determined, place the dryer into position.

Reference SECTION 1 for handling instructions.

4.2-1 BYPASS PIPING (optional)

The installation of bypass piping is not required, but will allow the
dryer and filter(s) to be taken off stream without interrupting the air
system.

In Figure 4A, a recommended bypass piping layout and additional
components are shown. 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

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.

CAUTION

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.
The afterfilter will remove any desiccant dust. The afterfilter 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 REMOTE PURGE EXHAUST PIPING

To reduce the noise during purging and tower depressurization, this
dryer was supplied with a muffler for installation on the purge exhaust
valve. If the sound or humidity discharged from this dryer is unaccept­able, the purge of this dryer can be piped remotely away.

IMPORTANT
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 valve, the piping must be at the
same level or lower than the purge valve.

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 32oF, freeze protection must be installed.

The purge valve has threaded pipe connections. Reference Section

3.2 for location. Use adequate pipe supports on the piping to prevent
stress on the valve.

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 valve. For distances up to 20 feet, use piping one size larger
than the purge valve.

4.4 INSTALLING PRESSURE RELIEF VALVES

CAUTION

THESE 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-1 25
through UG-136. Also check government regulations, i.e., state
and local codes.

Relief valve connection ports were NOT provided on this dryer. It is
recommended that relief valves be installed to comply with all
applicable codes. The relief valves should be full flow type, rated for
the dryer operating conditions. For recommended location see Figure
4A.

4.5 INSTALLING THE PURGE MUFFLER

To reduce the sound level during purge and tower depressurization,
this dryer was supplied with a muffler for installation on the purge
exhaust valve. For muffler location Reference SECTION 3.2.

The muffler was shipped separately. It 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 muffler installed immediately after the
towers have been filled with desiccant or at initial start up may cause
the muffler to clog.

IMPORTANT
The dryer must be operated for several hours without the
muffler after the towers have been filled with desiccant. This
will prevent the muffler from becoming clogged.

Make sure that the elements are installed in all filter housings
prior to start up.

PAGE 4 PRINTED IN THE U.S.A.