OCTOBER 2012 REV A 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) 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.
HANDLING SECTION 1 1.1 HANDLING INSTRUCTIONS WARNING 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. 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.
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 fittings: ............ ASME B16.
SPECIFICATIONS 3.
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 sufficient clearance over and around the dryer system for access to desiccant fill and drain ports and controls. Refer to SECTION 3.2 for dryer dimensions.
START UP 5.1 START UP SECTION 5 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.
START UP 5.6 INSTALLING THE PURGE MUFFLERS To reduce the sound level during purge and tower depressurization, this dryer system was supplied with mufflers for installation on the purge exhaust valves. SECTION 5 FIGURE 5A PURGE MUFFLER INSTALLATION Mufflers 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.
OPERATION 6.3 MOISTURE INDICATOR The moisture indicator is in the center of the panel. The moisture indicator is a clear plastic tube filled 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. 6.
OPERATION SECTION 6 FIGURE 6B CONTROL BOX DOOR FIGURE 6C DRYER TIMING CHART = ON PAGE 9
SHUTDOWN SECTION 7 Shut off the air supply to the Prep-40 dryer system. Turn the dryer system off by placing the Power Switch to the OFF position. Manually drain the separator/prefilter by lifting the manual override collar, on the separator/prefilter automatic drain, until no more fluid is discharged. Manually drain the prefilter by lifting the manual override collar, on the prefilter automatic drain, until no more fluid is discharged.
MAINTENANCE 9.1 DAILY INSPECTION The following procedures should be performed daily: • Check the dryer system operating conditions, ambient temperature and inlet pressure. • Monitor the dryer system for one complete cycle. Make sure it is operating properly. • Check the purge mufflers. Purge air should be exhausting from one of the valves. If oil is present, the dryer and air system may be contaminated with lubricants. • Inspect separator/prefilter and prefilter drains for proper draining.
MAINTENANCE 9.6 CLEANING THE INTERIOR OF THE PRE-COOLER The inside of the pre-cooler core should be cleaned periodically if the process air has an excessive amount of lubricating fluids. Excess lubricating fluids can build up on the inside of the core and greatly reduce the efficiency of the pre-cooler. Shut down the dryer system per SECTION 7 and completely depressurize the dryer system. Disconnect the core from the air system.
TROUBLESHOOTING SECTION 10 10.1 TROUBLESHOOTING The following check list should be used as a guideline for troubleshooting problems. Each of the topics will reference other sections in this manual for further information. IS THE POWER ON? Check the main power source. Make sure the Power switch is in the ON position. IS THE SYSTEM PRESSURIZED? The dryer system is designed to operate at 60 to 175 psig. Check to make sure the air supply was connected to the dryer system inlet.
TROUBLESHOOTING SECTION 10 10-2 CHECKING THE SMARTRELAY The control system consists of three different control systems: 1. The SmartRelay 2. Input devices (120VAC components) a. Pressure switches b. Alarm Reset push-button d. Power switch 3. Output components a. Pilot valves b. Lights c. General alarm contact The SmartRelay controls the cycling of the dryer system. The program logic is stored on an electrically erasable non-volatile EEPROM. Loss of power will not cause loss of the program.
TROUBLESHOOTING SECTION 10 10.4 CHECKING THE INLET TRANSFER VALVE The inlet transfer valve should not change position until both towers are at equal pressure. At tower changeover, the regenerating tower should approach full line pressure before the inlet valve will switch. Make sure that there are no leaks in the piping or fittings. Make sure that the purge exhaust valves are closing and that the purge metering valve is properly set.
TROUBLESHOOTING FIGURE 10D WIRING DIAGRAM PAGE 16 SECTION 10
PARTS SECTION 11 11.1 GAUGE PANEL REPLACEMENT PARTS ITEM QTY DESCRIPTION 1 Panel 1 2 2-1/2" Pressure Gauge, 0-300 PSIG 2 3 1/4" Coupling 2 4 1/4" NPT Anchor Tube Fitting 2 5 1/4" NPT x 10-32 Reducer Bushing 1 6 10-32 Short Coupling 1 7 10-32 Choke Fitting 1 8 10-32 Sintered Filter 1 9 Visible Moisture Indicator Assembly 1 10 1/4" Tube x 1/4" NPT Branch Tee Fitting 3 PART NO. 27-1235 29-0394 12-0223 26-1497 26-0296 26-0657 26-0490 26-0623 46-2300 26-7532 11.
PARTS SECTION 11 11.3 DRYER REPLACEMENT PARTS ITEM DESCRIPTION 1 1a 1b 1c 2 3 3a 4 5 6 7 8 8a 9 9a 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Inlet Transfer Valve Seat & Seal Kit for Inlet Transfer Valve Position Indicator Kit for Inlet Transfer Valve Shuttle Assembly Kit for Inlet Transfer Valve Outlet Check Valve Purge Exhaust Valve Seal Kit for One Purge Valve Diffuser basket Fill/Drain Plug Stud Gasket for R.F.
SAFETY PRECAUTIONS Safety is everybody's business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. DANGER DISCHARGE AIR USED FOR BREATHING WILL CAUSE SEVERE INJURY OR DEATH. CONSULT FILTRATION SPECIALIST FOR ADDITIONAL FILTRATION AND TREATMENT EQUIPMENT TO MEET HEALTH AND SAFETY REGULATIONS.
