Van Air Systems FR-1200 - Manual (Page 10)

PAGE 10
MAINTENANCE SECTION 9
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 oil muffler from the air motor for drainage.
• Inspect separator/prefilter and prefilter for proper draining.
• Check the pressure differential indicator on separator/prefilter,
prefilter, and afterfilter. If the differential pressure is unacceptable,
replace the elements.
• Check oil level in lubricator. Fill as required.
• Visually check the dryer system and piping for damage.
• Visually check the dryer system moisture indicator (blue dry or pink
wet)
9.2 SCHEDULED MAINTENANCE
12 MONTHS
• Replace purge muffler elements
• Replace the control air filter element
• Replace the separator/prefilter, prefilter, and afterfilter elements
• Clean the exterior of the pre-cooler
24-60 MONTHS
• The desiccant in the towers should be replaced every two to five
years. The life of the desiccant will vary depending on the inlet air
conditions. Systems with excessive contaminants and/or inad-
equate filtration will decrease the life span of the desiccant drasti-
cally. Once the desiccant is contaminated with lubricants, it must be
replaced.
• Periodically the pre-cooler core should be cleaned internally if the
process air contains excesive amounts of lubricating fluids.
9.3 DESICCANT REPLACEMENT
WARNING
DO NOT ATTEMPT TO REMOVE PLUGS UNTIL ALL AIR
PRESSURE IS OUT OF THE VESSEL. CHECK ALL TOWER
PRESSURE GAUGES, MAKING SURE THAT THEY ARE AT 0
PSIG AND INCOMING PRESSURE HAS BEEN TURNED OFF.
ALWAYS WEAR EYE PROTECTION AND GLOVES WHEN
HANDLING THE DESICCANT. DESICCANT DUST MAY CAUSE
EYE AND SKIN IRRITATION. AVOID BREATHING THE DUST
AND PROLONGED CONTACT WITH THE SKIN.
FIRST AID IN CASE OF EYE CONTACT, IMMEDIATELY FLUSH
EYES WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES.
CONSULT A PHYSICIAN.
Take dryer system off stream following the SHUTDOWN
PROCEDURES IN SECTION 7.
Remove the plugs from the desiccant drain and fill ports; drain old
desiccant from each tower.
Remove any oil, dirt, or scale from the towers and inlet piping. Do
NOT weld, grind or sandblast the vessels as this voids the ASME
Certification. The vessels may be steam cleaned internally and
externally to remove dirt and oil.
Replace plugs securely on desiccant drain ports. Apply pipe thread
sealant as necessary.
Make sure that the desiccant drain plugs are installed before
attempting to fill the towers. Load desiccant through the desiccant
fill ports. REFER TO SECTION 3.1 FOR PROPER DESICCANT
AMOUNTS.
Reinstall the fill plugs. Apply pipe thread sealant as necessary.
Follow START UP PROCEDURES IN SECTION 5.1 to start up and place
dryer in operation.
CAUTION
Make sure that the towers are clean to prevent contamination of
new desiccant.
9.4 CONTROL AIR FILTER ELEMENT REPLACEMENT
Shutdown the dryer per Shut-Down Procedures SECTION 7.
Turn manual valve on bottom of control air filter to ensure that the dryer
is completely depressurized.
WARNING
DO NOT REMOVE THE FILTER BOWL FROM HEAD UNTIL
HOUSING IS COMPLETELY DEPRESSURIZED.
After all pressure is out of the dryer, grasp the filter bowl firmly and
push upward while turning it counter-colckwise (as viewed from the
bottom) to remove it from the filter head. If preferred strap wrenches
can be used to remove bowl. Make sure that the bowl does not drop.
Remove the used element from filter head by pulling down. Discard
used element properly.
Remove new element from the shipping package. Check to make sure
that the o-ring is properly positioned in endcap and has been lightly
greased.
Grasp clean element by bottom endcap and push element onto filter
head firmly, but do not force beyond normal stop.
Check o-ring in filter head. Replace if worn or damaged.
Clean and lubricate threads on bowl with light grease. This will
facilitate removal of bowl at next servicing.
Carefully raise filter bowl over element and screw into head, then
tighten. DO NOT OVERTIGHTEN.
Close manual drain valve.
Following the start up procedures in SECTION 5.1 for the dryer, place
the dryer on stream.