January 2014 REV C 2950 Mechanic Street Lake City, PA 16423 USA Phone: 800-840-9906 Fax: 814-774-0778 Email: info@vanairsystems.com www.vanairsystems.com INSTALLATION, OPERATION & MAINTENANCE MANUAL FOR PREP-40 PORTABLE COMPRESSED AIR DRYER SYSTEM model FR-1600 (P/N 81-2444) WARNING READ ALL INFORMATION IN THIS MANUAL BEFORE INSTALLING OR OPERATING THE DRYER SYSTEM.
HANDLING 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. SECTION 1 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.
SPECIFICATIONS SECTION 3 3.1 SPECIFICATIONS WEIGHT.............. 3625 Lbs (without desiccant installed). 5485 Lbs (with desiccant installed) DIMENSIONS...................... See SECTIONS 3.2 IN/OUT CONNECTION....... 3" 150# RF FLANGE 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: ............
SPECIFICATIONS 3.
INSTALLATION 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 SECTION 5 5.3 SETTING THE CONTROL PRESSURE REGULATOR 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. CAUTION DO NOT OPERATE THIS DRYER SYSTEM WITH THE CONTROL AIR PRESSURE REGULATOR ABOVE 100 PSIG TO PREVENT DAMAGE TO THE PNEUMATIC CONTROLS.
OPERATION SECTION 6 FIGURE 6A PNEUMATIC SCHEMATIC 6.2-1 REPRESSURIZATION STAGE Repessurization occurs in the off-stream (regenerating) tower. Repessurization must occur before tower changover to reduce shock to the desiccant and the possibility of downstream pressure spikes. Pilot valve SV1 or SV2 de-energizes causing the purge valve on the off-stream (regenerated) tower to close. The purge air, which was vented to atomosphere earlier in the cycle, is now used to repressurize the off-stream tower. 6.
OPERATION SECTION 6 6.4 DRYER CONTROLS The control is housed in a NEMA 4X enclosure and it has the following features: - Power switch - Power On light - Fail to Switch light - Alarm Reset pushbutton - Hour Meter See Figure 6B for control box door. 6.4-1 SMART RELAY: The dryer cycle is controlled by a SmartRelay, two solenoid valves and two pressure switches. The dryer timing chart is shown in FIGURE 6C. The SmartRelay has a battery back-up that will hold the program in memory safely for 2 years. 6.
SHUTDOWN SECTION 7 Shut off the air supply to the Prep-40 dryer system. Allow the dryer to depressurize. Turn the dryer system off by placing the Power Switch to the OFF position. Open the ball valve on the afterfilter and completely depressurize the dryer system. If maintenance is to be preformed on the dryer system, make sure the dryer system is completely depressurized. Tower pressure gauges must read 0 PSIG before removing any item on the dryer system.
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. SECTION 9 CAUTION Make sure that the towers are clean to prevent contamination of new desiccant. Replace plugs securely on desiccant drain ports. Apply pipe thread sealant as necessary. • Check the purge mufflers.
MAINTENANCE 9.5 REPLACING SEPARATOR/PREFILTER, PREFILTER, AND AFTERFILTER ELEMENTS Shutdown and depressurize dryer system per SECTION 7. Disconnect drain line as required. Remove filter bowl by turning it counterclockwise (as viewed from below). Pull element from filter head. Set bowl aside for use later. Remove new element from packaging and make sure o-ring is in place on element end cap. See SECTION 11.3 for replacement element part number. Install new element by pushing element onto filter head.
TROUBLESHOOTING 10.1 TROUBLESHOOTING SECTION 10 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 80 to 175 psig. Check to make sure the air supply was connected to the dryer system inlet.
TROUBLESHOOTING SECTION 10 10.2B TESTING THE OUTPUT DEVICES 10.2 CHECKING THE SMARTRELAY The dryer control is comprised of three different systems: 1. The SmartRelay 2. Input devices (115VAC components) a. Pressure switches b. Alarm Reset push-button d. Power switch 3. Output components (115VAC 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.
TROUBLESHOOTING 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 SECTION 10 FIGURE 10D WIRING DIAGRAM PAGE 15
PARTS 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 SECTION 11 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 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 38 39 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 Diffuser basket Fill/Drain Plug Stud Gasket for 3" R.F.
APPENDIX SECTION 12 12.1 APPENDIX - F200 Series IOM - PDV-500T IOM 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.
April 2012 P/N 432-10016-D INSTALLATION, OPERATION & MAINTENANCE INSTRUCTION F200 SERIES COMPRESSED AIR FILTERS PRODUCT PURPOSE & FUNCTION: Van Air's F200 series filters are designed to remove contaminants from compressed air systems. Available in 1/4" to 3" connection sizes and flow capacities from 15 to 1250 SCFM (at 100 psig) in 15 housings and 9 filtration grades, the F200 series can remove oil aerosols, oil vapors, water and particulates.
FILTER HOUSING DIMENSIONS & WEIGHTS DIMENSIONS FOR: F200-55-1/2 F200-150-1 F200-85-3/4 F200-265-1-1/4 F200-100-1 F200-350-1-1/2 DIMENSIONS FOR: F200-15-1/4 F200-25-3/8 F200-25-1/2 A F200-400-2 F200-500-2 DIMENSIONS FOR: F200-600-3 F200-1250-3 F200-800-3 F200-1000-3 A A B B B C C D ELEMENT REMOVAL CLEARANCE D C ELEMENT REMOVAL CLEARANCE D ELEMENT REMOVAL CLEARANCE FILTER MODEL FLOW** (SCFM) IN/OUT CONN.
INSTALLATION 1. Before installing filter, check operating temperature and pressure conditions to verify that they are within the specified ranges. (See Operating Conditions on page 1). Also verify that system flow rate corresponds to the rated capacity of the filter. Operating at flows above rated capacity will result in increased pressure drop. IMPORTANT INSTALL FILTER HEAD INTO THE PIPING WITH ARROWS POINTING IN THE PROPER DIRECTION TO ENSURE PROPER OPERATION. (SEE FLOW DIRECTION DIAGRAM BELOW). 2.
Finding a part number FIGURE 2A F200-15-1/4 THRU 25-1/2 REPLACEMENT PARTS 5A F200-15-1/4 5B F200-25-3/8 1. Find the figure that references your filter. 2. Find the replacement part you need and the item number of that part. 3. Find the item number in the first column of the Replacement Parts table. 4. Find the part description that best describes the part. 5. See the last column for the part number.
REPLACEMENT ELEMENTS FILTER MODEL ELEMENT MODEL PART NO. FILTER MODEL ELEMENT MODEL PART NO.
ACCESSORIES MOUNTING BRACKET DIMENSIONS A C MOUNTING BRACKET KITS B D E E A A B C D E MB-1 2-15/16" 1-9/16" 13/16" 1-3/4" 1/4" MB-1-2 2-15/16" 1-9/16" 13/16" 1-3/4" 1/4" MB-2 4-15/16" 2-3/8" 1" 2-9/16" 5/16" MB-2-2 4-3/4" 2-3/4" 1" 2-3/4" 5/16" MB-3-2 7-1/8" 4-15/16" 1-3/16" 3-15/16" 3/8" INSTALLED MOUNTING BRACKET KIT DIMENSIONS B F C TYPE HEX NUT (4 EACH) D TYPE USED ON PART NO MB-1 55 84-0720 A B C D E 4-1/2" 1-1/4" 1-3/4" 3-5/16" 5-1/4" MB-
ACCESSORIES CONT'D PD-5 (P/N: 84-10001) PD-6 (P/N: 84-10125) FITS ALL MODELS EXCEPT F200-15-1/4 THRU 25-1/2. FITS ALL MODELS EXCEPT F200-15-1/4 THRU 25-1/2. DIFFERENTIAL PRESSURE INDICATOR KITS 1" 1-11/16" * 3-3/8" 2-1/8" 1-7/8" * 2-5/8" 2-1/8" 2-1/4" KIT INCLUDES (1) PD-6, (2) SCREWS, (4) O-RINGS & INSTRUCTION SHEET. PD-6A-C (P/N: 84-10126) PD-6A-P (P/N: 84-10127) 1-1/2" FITS MODELS F200-15-1/4 THRU 25-1/2 ONLY.
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 WARNING AIR AND OIL UNDER PRESSURE WILL CAUSE SEVERE PERSONAL INJURY OR DEATH. SHUT DOWN COMPRESSOR AND RELIEVE SYSTEM OF ALL PRESSURE BEFORE REMOVING VALVES, CAPS, PLUGS, FITTINGS, BOLTS AND FILTERs.
32-0277-A 2/09 INSTALLATION INSTRUCTIONS FOR PDV-500 Series 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.
32-0277-A 2/09 IN GENERAL 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.
PDV-500 Spare Parts List Qty Part # 1 1 2 2 2 1 1 1 1 1 1 1 1 1 39-0290 26-6870 26-6871 26-6872 26-6873 26-6874 26-6875 26-6876 26-6877 26-6878 26-6879 26-6880 26-6881 26-6882 Description Test Button conversion kit Control Line Filter Vessel to endplate O-ring Large O-ring - trigger block to endplate Small O-ring - trigger block to endplate Float & trigger block assembly Seal holder w/ magnet & seal Float Translucent vessel Nut - ball valve stem support Bushing - ball valve bracket Ball valve - stainles
