Dryer Skid Owner’s Manual DS-1000, DS-1200, DS-1600, DS-1600HD & DS-2500 Models Model # Maximum Air Motor Pressure DS-1000 60 PSI DS-1200 60 PSI DS-1600 100 PSI DS-1600HD 100 PSI DS-2500 90 PSI SUPERIOR PERFORMANCE And Quality In Blast Cleaning Equipment ! WARNING Read Manual Failure to read, understand & follow all safety and operation procedures in this manual can cause injury or death. Manuals that are lost, incomplete, or damaged, must be replaced immediately. Manual # DS1406 www.modublast.com Ph: (780) 425-5510 Fax: (780) 425-5540 Copyright© 2014 Mod-U-Blast®, All Rights Reserved Dryer Skid Owner’s Manual T a b l e o f C o n t e n t s Important Warnings 3 How it Functions 4 Performance 4 Successful Dryer Operation 5 Operating Instructions 6 Maintenance Instructions 7 Parts List 8 Maintenance Checklist 9 Warranty Information 10 Contact Information 10 2 Copyright© 2014 Mod-U-Blast®, All Rights Reserved Dryer Skid Owner’s Manual 123456 Important Warnings • DO NOT OPERATE THIS SYSTEM ABOVE MAXIMUM WORKING PRESSURE (MWP) AND/OR MAXIMUM OPERATING TEMPERATURE (OF) SHOWN ON THE VESSEL ASME DATAPLATE. THIS ASME CODE VESSEL MUST BE PROTECTED BY A PRESSURE RELIEF VALVE. 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 applicable provincial, state and local codes. • DO NOT ATTEMPT TO REMOVE OR REPAIR ANY PART OF THE SYSTEM UNTIL IT IS COMPLETELY DEPRESSURIZED. SERIOUS PERSONAL INJURY OR DEATH MAY RESULT IF THIS RULE IS NOT FOLLOWED. • DO NOT WELD OR GRIND ON VESSEL, THIS WILL MAKE IT UNSAFE TO USE. (Note: Any alteration to the vessel will void the ASME Code Certification and the warranty.) • INSPECT THE VESSEL, INSIDE AND OUT, REGULARLY FOR CORROSION, DENTS, GOUGES OR LEAKS. IF DAMAGED, REMOVE FROM SERVICE IMMEDIATELY. • DO NOT TRY TO TIGHTEN A LEAKING COVER. IMMEDIATELY SHUT OFF THE AIR SUPPLY AND DEPRESSURIZE THE SYSTEM. • DO NOT ATTEMPT TO REMOVE THE FILL COVER UNTIL THE SYSTEM IS COMPLETELY DEPRESSURIZED. WHEN THE VESSEL PRESSURE IS REDUCED TO ZERO, THE FILL COVER CAN BE REMOVED BY HAND. INSTALL A NEW GASKET AT LEAST ONCE PER YEAR. INSPECT THE FILL COVER AND SEALING SURFACE FOR DAMAGE SUCH AS CORROSION, CRACKS, OR DISTORTION. IF THERE IS ANY DAMAGE, REPLACE THE FILL COVER. REPLACE THE FILL COVER EVERY FOUR YEARS REGARDLESS OF CONDITION. • USE MOD-U-BLAST AUTHORIZED PARTS ONLY. • DO NOT USE POWER TOOLS TO TIGHTEN THE NUT ON THE FILL COVER. TOO MUCH FORCE CAN DISTORT THE FILL COVER AND/OR THE GASKET. IF DAM-AGED BY OVER-TIGHTENING, THE FILL COVER CAN BLOW OUT AND CAUSE SERIOUS INJURY OR DEATH. (Note: Tighten the nut until it is snug. When the vessel is pressurized, the pressure on the fill cover will complete the seal.) • THE USE OF PRODUCTS OTHER THAN MOD-U-BLAST® DESICCANT WILL VOID THE WARRANTY. 3 Copyright© 2014 Mod-U-Blast®, All Rights Reserved Vertical Dryer Owner’s Manual How it F u n cti o n s DRY-PRO by MOD-U-BLAST® Single Tower, Deliquescent, Air Dryers are a skid mounted system which includes an aftercooler, a coalescing filter and a single tower dryer filled with desiccant tablets. Wet, warm air enters the aftercooler where it is cooled close to the surrounding temperature, water is then condensed out during this cooling process. The saturated air and the liquid water pass through a coalescing filter where any oil contaminants from the compressor are removed and then proceeds to the inlet of the dryer tank. The water and any solid particles present are separated by gravity and fall to the bottom of the dryer tank. The air moves up through the desiccant tablets which absorb the moisture from the air before it flows through the dryer outlet. The tablets dissolve gradually as they absorb the moisture. The dissolved desiccant and water, falls into the bottom of the vessel. The dryer must be drained periodically to remove the accumulated solution. A manual ball valve is installed for this purpose.__ Performance DRY-PRO by MOD-U-BLAST® Dryer Skids are rated as follows: 1000 CFM (DS-1000) - 1200 CFM (DS-1200) - 1600 CFM (DS-1600) - 1750 CFM (DS-1600HD) -2500 CFM (DS-2500) at 100 PSI. Approach temperatures will vary with changes to the inlet conditions (flow, pressure, temperature) and the ambient temperature. The dew point out of the dryer tower is directly related to the inlet temperature entering the dryer vessel. The lower the inlet temperature, the lower the dew point of the outlet air. The aftercooler maximum inlet temperature is 250° F. When using MOD-U-BLAST® desiccant, the inlet temperature to the dryer tower should not exceed 100° F. CFM SPECIFICATIONS - CFM (Cubic Feet Per Minute) Model 100 PSI 125 PSI DS-1000 1000 PSI 1200 1400 DS-1200 1200 PSI 1400 1600 DS-1600 1600 PSI 1900 2000 DS-1600 HD 1750 2100 2500 DS-2500 2500 3000 3500 4 150 PSI Copyright© 2014 Mod-U-Blast®, All Rights Reserved Dryer Skid Owner’s Manual S u cc e s s f u l D r y e r O p e r a ti o n 1 2 Warm Weather Run the aftercooler fan at maximum rated pressure. Cold Weather After the dryer package has warmed up under load, adjust the fan motor pressure regulator to provide a discharge temperature above freezing. (0 degrees C) 3 Draining 4 Air Motor 5 Filter, Regulator, lubricator (FRL) 6 Ball Valve 7 Drain the air dryer and coalescing filter twice daily or keep drain valves open slightly during operation. Always blow down all drains on shutdown. Use a light grade oil (ATF) and set the lubricator to supply 1—2 drops per minute. Drain the air filter and fill the lubricator as required, checking it twice daily. Open the Inlet ball valve slowly on start-up to avoid collapsing the coalescing element (s). Water Separator (if equipped) Can remove up to 90% of the water in your system prior to the desiccant tank. Make sure the separator is always draining, clean separator bowl and check the drain monthly. Aftercooler 1 Air cooled aftercoolers are built for operation with maximum pressure of 250psi and a maximum temperature of 350 degrees F. (176 degrees C.) 2 Consideration should be given to the location so that fan motors are not subject to extreme temperatures. 3 Aftercoolers can be used in below 0 degrees C temperatures. NOTE: The fan motor should be regulated so that the aftercooler temperature gauge reads above 0 degrees C to avoid freezing the core assembly. The aftercooler has a drain valve installed in cold weather climate areas and should be drained daily. 5 Copyright© 2014 Mod-U-Blast®, All Rights Reserved Dryer Skid Owner’s Manual O p e r a ti o n DESICCANT: See below for desiccant refilling. Return to Table of Contents IMPORTANT ! Our DRY-PRO by MOD-U-BLAST® Dryer Skids are shipped with the desiccant installed. The desiccant will NOT be installed if the unit is being shipped overseas at which point the proper amount of desiccant will be shipped with the dryer and must be installed before using the system. IMPORTANT ! LUBRICATOR OIL: Our DRY-PRO by MOD-U-BLAST® Dryer Skids are Check oil level in lubricator regularly and shipped WITHOUT the lubricator oil installed. Lubricaadd oil as required. tor oil (ATF) MUST BE INSTALLED before using the system. (Automatic Transmission Fluid) FAILURE TO MAINTAIN OIL LEVEL WILL CAUSE THE FAN MOTOR TO SEIZE START UP PROCEDURES: Connect your compressor (fittings not included) to the DRY-PRO Dryer inlet, start compressor, then SLOWLY open the ball valve to pressurize the dryer. Make sure that the DRY-PRO Dryer Skid is not subjected to sudden air surges. Always open the valves slowly to permit gradual air pressure between the Dryer and the compressor. *Check the maximum regulator pressure shown on cover page of this manual to ensure proper aftercooler performance. The DRY-PRO Dryer Skids requires certain procedures to ensure best performance: 1. DAILY DRAINING The desiccant and water solution in the bottom of the dryer should be drained often. The manual drain valve is installed on the dryer, must be opened at least once every 4 to 8 hours to drain the dryer. The dryer will require draining more often on humid days. *If the dryer is not drained regularly, it may become flooded and the accumulated liquid WILL enter the air system.* 2. REFILLING THE DRYER WITH DESICCANT During the drying process, the desiccant tablets dissolve slowly. The desiccant consumption rate is dependent on several factors, such as inlet temperature, flow and pressure. To check the level of the desiccant, look into the sight window, if you can’t see the desiccant tablets then the tank has to be refilled to ensure peak dryer performance. 6 Copyright© 2014 Mod-U-Blast®, All Rights Reserved Dryer Skid Owner’s Manual Maintenance Procedures Danger: Never perform any maintenance Warning: Maintenance procedures are to be performed by experienced qualified personnel only, Failure to perform maintenance procedures correctly at the intervals specified below can lead to performance problems and equipment failure, and will void the equipment warranty. or attempt to open the Dryer Skid in any way while it is pressurized. The violent release of compressed air and propelled objects will cause serious injury or death. Warning: Make sure the desiccant level is below the outlet pipe. Do NOT overfill the vessel. Space must be left to allow for the fill cover to be installed. Maintenance Schedule Procedure to be Performed Maintenance Interval Check Dessicant Level Every 8 Hours of Use Check Oil Level In Lubricator Every 8 Hours of Use Clean Aftercooler Core Every 8 Hours of Use Fan Shroud, Fan & Motor Every 8 Hours of Use Internal Cleaning Yearly Coalescing Filter (if equipped) Every 6 Months Moisture Separator (if equipped) Monthly Fill Cover Inspection Every 4 years Look into the sight window, if the desiccant is not visible then top it off. Check the operation of all equipment installed before and after the DRY-PRO dryer. Verify that there is sufficient amount of oil in the lubricator and add oil as needed. ATF only (Automatic Transmission Fluid) The core should be cleaned regularly. Accumulation of dirt or oils will greatly reduce the efficiency of the aftercooler. Dirt can be removed by blowing the core off with compressed air. If the core becomes coated with oil particles, it can be steam cleaned. Dirt and grease should be removed from these parts using the same directions as the core cleaning. Rusty or corroded surfaces should be sanded clean and repainted. Once a year piping should be disconnected and a degreasing agent circulated through the unit to remove sludge from internal tube surfaces to return the unit to full capacity. Check the condition of the oil removal filter element every 6 months and change annually. Some filters have a differential pressure indicator and when the RED button pops up in the indicator it is time to replace the element. When replacing the element make sure to clean and inspect the drain port. Clean separator bowl and check drain monthly Inspect the fill cover and sealing surface. Should there be damage, replace the cover. Replace the fill cover every 4 years regardless of condition. The gasket should be replaced at least once a year. Check the sealing surface of the opening. If it has dirt or rust on it, then it must be cleaned before installing the fill cover. Install the fill cover and gasket. Tighten the nut on the fill cover until it is snug. Over tightening will cause damage gasket. The fill cover will seal when the vessel is pressurized. Adding Desiccant Shut down the air compressor and open the drain valve to allow the dryer to depressurize completely. Loosen the nut on the fill cover. Push on the fill cover. Once the seal is broken, remove the fill cover from the dryer. Add the amount of desiccant needed to restore to the maximum level. 7 Copyright© 2014 Mod-U-Blast®, All Rights Reserved Dryer Skid Owner’s Manual Return to Table of Contents Parts List Description Stock # DS-1000 DS-1200 DS-1600 QTY QTY QTY DS-1600HD DS-2500 QTY QTY Gasket for 4”x6” Fill Cover 22618 1 1 1 1 1 Fill Cover, 4” x 6” 22619 1 1 1 1 1 Sight Glass SP-A-28905 1 1 1 1 1 Manual Drain Valve for Tank 1” NPT 65-800 1 1 1 1 1 1 1 1 Pressure Relief Valve 1” @ 150 PSI 51810-150 Pressure gauge - 160 PSI DESICCANT 55415 1 1 1 1 1 MOD-U-BLAST® Desiccant, 50 LB BAG 79000 24 30 40 48 72 1 1 D r y e r O p ti o n s Model # Coalescer Moisture Separator Desiccant Required DS-1000 DSC-1200 SP-MS1700 1200lbs DS-1200 DSC-1200 SP-MS1700 1500 lbs DS-1600 DSC-1600 SP-MS1700 2000 lbs DS-1600 HD DSC-1600 SP-MS1700 2400lbs DS-2500 TBD TBD 3600lbs Parts Ordering: 1-800-661-3842 8 Copyright© 2014 Mod-U-Blast®, All Rights Reserved Dryer Skid Owner’s Manual Maintenance Checklist DATE Service Completed 9 Copyright© 2014 Mod-U-Blast®, All Rights Reserved Dryer Skid Owner’s Manual Warranty Mod-U-Blast equipment is covered by a one (1) year warranty against defects in material and workmanship starting from the purchase date. This covers the equipment as well as all major components. This warranty does not apply to abnormal use of the equipment or parts. Parts considered consumables are not covered by warranty. Claims will be honored only if the warranty card is returned within a period of two (2) months from the factory shipping date. The card can be returned to your Mod-U-Blast salesperson or mailed to the address on the below. In the event of failure of this equipment please contact a Mod-U-Blast service centre or call (780) 425-5510. 403 - 69 Avenue NW Edmonton, Alberta Canada T6P 0C2 PH: (780) 425-5510 FAX: (780) 425-5540 10 Copyright© 2014 Mod-U-Blast®, All Rights Reserved
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