Van Air Systems Zero Loss Pneumatic PDV User Manual

INSTALLATION INSTRUCTIONS

FOR PDV-500 Series

32-0277-A 2/09

The PDV-500 is designed for trouble-free and maintenance­free draining of unwanted accumulations of condensation
and other foreign matter from any collection point in a com­pressed air system without the need for electricity.

INSTALLATION

CAUTION: COMPRESSED AIR CAN BE DANGEROUS.

Before attempting to install the drain, be certain that the pres­sure vessel on which the drain will be installed is completely
depressurized.

The drain should not be installed in areas that are exposed to
freezing temperatures (heater option is available). Be certain
the air system pressure does not exceed the 250 PSI working
pressure of the drain and the pressure to the control system
does not exceed 120 psi. The inlet temperature should not
exceed 180 degrees F.

Connecting the drain to the air system should be done by using
one of the recommended installation diagrams shown herein.
The installation of a strainer is not required or recommended.

Install the drain as close to the source to be drained as possible.
Since the PDV-500

drain must be installed below the vessel to be drained when
using the top inlet. If flexible tubing is used on the discharge,
be certain it is properly fastened to prevent it from whipping
when the drain discharges the condensation.

The PDV-500 will accept condensation from either the top or
the bottom of the reservoir. We recommend the use of the
top entry port. If the bottom inlet is used, then a vent line
be used. The vent line should be installed down stream from
the vessel that is being drained. This will insure that the air
in the reservoir will properly exit as the condensation fills the
tank and replaces the air. Remove plastic plug and Install the
vent line in the 1/8" port located on the end plate in the upper
right corner (same endplate the control air/filter connects to).
The other end of the vent line should be run back to the air
system to a point just down stream from the source that is
being drained to a point of equal or lesser pressure. Use non­galling pipe sealant on all joints. The use of shut-off valves,
unions and bypass valves is recommended. A backup wrench
should be used on the discharge ball valve to prevent it from
turning and causing the linkage to bind.

uses gravity to fill the reservoir, the entire

must

The power to operate the PDV-500 comes from compressed air.
ONLY CLEAN DRY AIR SHOULD BE USED. The supply pressure
should be between 80 and 120 psig. The PDV-500 is supplied
with an inlet filter, which should be installed in the PDV-500 head
(See Dwg 2 on back). The use of unfiltered air can cause the drain
to fail.

Once the drain is installed, close the By-Pass drain valve and open
the Shut-Off valve. The pressure vessel can now be repressurized.

CHECKING THE DRAIN'S OPERATION

After installation is complete and the drain is on line, a check should
be made that the condensation is properly entering the reservoir.
This can easily be done by looking through the translucent reservoir.

If condensation is not entering the reservoir, check for the following:

1. Make sure the auxiliary shut-off valve is open.

2. Do not use the bottom inlet on the PDV-500 without
installing a vent line.

3. If a vent line is installed, make sure it is down stream
from the vessel that is being drained.

4. Be certain that the PDV-500 reservoir is not higher than
the vessel that is being drained. This is very important
when using the top inlet on the PDV-500 reservoir.

5. Check to make sure the vessel being drained has
condensation in it.

If the top inlet is being used and no condensation is entering the
PDV-500 reservoir, and all the above items have been checked,
we recommend that the bottom inlet be used with a vent line out
of the top.

If condensate fills the reservoir and the drain does not operate,
check to see if control line air is supplied to control line port. If the
drain is supplied with an optional test button, the supply of control
line air can be checked by pushing the test button. If the unit does

not operate, then no air is being supplied or the inlet filter is plugged.

OPTIONS

zz

z High Level Alarm.

zz

zz

z Heater.

zz

WARRANTY

The inlet port that is not used must be plugged by using a
standard 3/4" npt plug. When using the top inlet, any reduction
in the 3/4"pipe size is not recommended and the PDV-500
reservoir cannot be higher than the bottom of the vessel that
is being drained. It is best to run the drain in a downward pitch
from the bottom of the vessel being drained to the PDV-500
inlet

Van Air Systems, Inc. 2950 Mechanic St. Lake City, PA 16423

Phone: [phone] Toll Free: [phone]

The PDV-500 is warranted to be free from defects in workman­ship and materials for a period of one year from the date of
shipment. The liability of the manufacturer is limited to repair or
replacement of the drain at its option. In no event shall the
manufacturer be liable for special or consequential damages or
for delay in performances of this warranty.

CAUTION: Any attempt to repair the drain without authorization will
void any warranty.

INSTALLATION DIAGRAMS ON REVERSE SIDE

IN GENERAL

32-0277-A 2/09

In order for the condensate to properly enter the PDV-500 reservoir, the
condensate line to the PDV-500 must always be installed below the bottom of
the vessel to be drained. It is equally important to provide a means for the air
that is contained in the reservoir to escape (vent) as the condensate enters
the reservoir. If the air can not escape, the condensate will not enter the
reservoir. Below are suggestions on how to best install the PDV-500 on
typical types of vessels that have to drained of condensate. However, it is
possible to install the PDV-500 without a balance line (Dwg. not shown),
providing the condensate enters the

top inlet and the flow rates are less than
9 GPH (750 cfm for an aftercooler or 1500 cfm drier) for a 1/2" drain line and
19 GPH (1500 cfm for an aftercooler or 3000 cfm drier) for a 3/4" line. The
use of unions and shut-off valves are recommended for both the condensate
line and the balance line.

RECEIVER TANK

The preferred installation for a PDV-500 on a receiver t ank is having the
condensate enter the top inlet port and having the balance line go back to the
tank at a position that is above the level of the condensate (Dwg. 1).

FILTER and AFTERCOOLER MOISTURE SEPARA TOR

If a cyclone separator or filter has pipe plugs located in the top of the head,
the plug closest to the discharge pipe should be removed and the balance
line should be installed (Dwg. 2). If there is no provision on the cyclone
separator or filter for a balance line, install it in the discharge side of the pipe
line and as close to the cyclone separator as possible.

Dwg. 1

Clean Dry Control

Air, 80 to 120psi

Vent Line

Needle Valve

1/8 npt

(Not Supplied)

Dwg. 2

Control Line

Inlet Filter

Clean Dry Control

Air, 80 to 120psi

Discharge Port

1/2" npt

REFRIGERATED DR YER

If a balance line is required, it must be connected to the port located on top of
the separator that is closest to the discharge side (Dwg. 2), or between the
separator and the air-to-air heat exchanger. If a port is not available as
described above, then venting to atmosphere is recommended. When venting
to atmosphere, the condensate should enter through the bottom entry port on
the drain. The bleed or needle valve is installed on the 1/8" NPT vent port and
allows the air in the PDV-500 reservoir to escape to the atmosphere (Dwg 3).
The bleed valve (not included) should be adjusted so that only 3 to 5 bubbles
per second are visible. We do not recommend installing a vent line down
stream from the dryer. The vent line can be a conduit for transferring moisture
from the drain to the previously dried air. This can result in unwanted moisture
being sent down stream.

INTERCOOLERS

Install the condensate drain line into the upper port only . This will prevent the
possibility of condensate being drawn back into the intercooler on some
systems. It is important that the vent line be installed on the same stage that
is being drained or to atmosphere.

BALANCE LINE

As mentioned above, both the use and the placement of a balance line is very
important. Most drain failures are the result of an improper balance line
installation. The balance line should be 1/4" tubing or larger , and installed on
top of a pipe or vessel, not the bottom. A needle valve is recommended for
controlling the air flow. Avoid having any loops or low areas in the balance
line that might allow moisture to collect in the line and prevent the passage of
air from the drains reservoir.

Vent Line

Needle Valve

1/8 npt

(Not Supplied)

Dwg. 3

Venting to

Atmosphere With

Needle Valve

(Not Supplied)

Control Line
Inlet Filter

Discharge
Port 1/2" npt

Clean Dry Control

Air, 80 to 120psi

Control Line

Inlet Filter

Discharge Port

1/2" npt