1 VSA Series Air Dryer User s Guide Models covered: VSA1 VSA2 VSA3 VSA4
3 1. Welcome & Congratulations Congratulations on your purchase of a new PUREGAS VSA SERIES AIR DRYER! We here at PUREGAS are very proud of our products and we are committed to providing you with the best value and service possible. We are sure that you will be satisfied with your new air dryer and would like to thank you for choosing PUREGAS for your air dryer requirements. We also hope that you will continue to choose us for your future air pressure and related products purchases. For information about this and other PUREGAS products, please visit us on the web at 2. Introduction PLEASE READ THIS USER S GUIDE THOROUGHLY AND SAVE FOR FUTURE REFERENCE. This User s Guide is provided for the benefit of our customers and contains information and direction specific to the PUREGAS VSA SERIES AIR DRYER. It will cover topics including: safety, specifications, installation, testing, maintenance, and troubleshooting issues. Observation and compliance with this User s Guide will ensure the maximum life and efficiency of your air dryer. This User s Guide should be read thoroughly prior to installing, operating, or servicing the air dryer in order to become familiar with the recommended procedures. This will minimize the possibility of personal injury or damage to the dryer due to improper operation or handling. Page 3 of 35
4 3. Table of Contents 1. Welcome & Congratulations Introduction Table of Contents Safety & Warning Information Overview & Specifications Product Description Key Features VSA Series Air Dryer Models Technical Specifications Installing Your Air Dryer Safety & Warning Information Before You Begin Included Contents Required Tools and Materials Installation Steps Installation Checklist Registering Your VSA Series Air Dryer Testing Your Air Dryer Safety & Warning Information Testing Consistent Dryer Cycling Measuring Incoming Voltage Measuring Solenoid Voltage Testing Air Fittings & Hoses for Leaks Maintaining Your Dryer Safety & Warning Information Maintenance Log Sheet Parts Accessories for Your Air Dryer Ordering Parts from PUREGAS Service & Repair Services Offered at Puregas Facility Initiating a Service Transaction Troubleshooting Your Air Dryer Before You Call PUREGAS Safety & Warning Information Restricted Pressure or Flow Excessive Purge Delivers Wet Air Contacting PUREGAS Technical Support Appendix Model Number Coding Wiring Diagram Recommended Dryer Installation Limited Warranty Agreement Registration Reminder Contacting PUREGAS General Sales Service Technical Support Maintenance Log Sheet Notes Replacement Parts & Accessories Page 4 of 35
5 4. Safety & Warning Information This section contains general information about safety and warning points to consider and adhere to during installation and maintenance of your air dryer. PLEASE READ THIS SECTION BEFORE PERFORMING ANY OPERATION OR PROCEDURE ON YOUR AIR DRYER. Additional warnings specific to an operation or procedure will also be presented throughout the following sections. These will include the symbol as well as a label of WARNING!, CAUTION!, or IMPORTANT!. Please be sure to pay close attention for these warnings and read them as you encounter them. IMPORTANT! Performing procedures not described in this User s Guide MAY VOID THE WARRANTY. IMPORTANT! Appropriate inlet filtration is MANDATORY and outlet filtration is recommended for all application. IMPORTANT! Each air dryer is sized for specific operating conditions. For OPTIMUM performance, the maximum available operating pressure should be maintained across the unit. Any pressure reduction or flow control should be done downstream of the unit. Depending on the magnitude of the change, the size of the desiccant chambers or orifice may need to be changed. Page 5 of 35
6 5. Overview & Specifications 5.1 Product Description The VSA SERIES AIR DRYER from PUREGAS is a compact, regenerative desiccant air dryer designed to dry compressed air to a standard pressure dew point (PDP) of -40 F. Optional performance to -100 F atmospheric dew point (ADP) can be achieved. The pressure-swing adbsorption (PSA) process used is fully automatic and will remain consistent with minimal required periodic maintenance 5.2 Key Features Ultra-dry air to better than -100 F ADP Continuous self-regenerative operation Outlet flow capacities of 0.1 to 8.8 SCFM at 100 PSIG Operating pressures of 30 to 150 PSIG Compact, lightweight aluminum construction Low power requirements (20 watts) Ideal for OEM and point-of-use applications 5.3 VSA Series Air Dryer Models Model Inlet Flow Purge Flow Outlet Flow VSA VSA VSA VSA Notes: 1. Flow capacities in SCFM shown are for standard units operated at 100 PSIG and outlet dew point of -40 F PDP. 2. Inlet and outlet flow capacities will be greater at higher pressures and lower at lower pressures. 3. Standard inlet conditions are 100 F saturated. Page 6 of 35
7 5.4 Technical Specifications Dimensions VSA1 VSA2 VSA3 VSA4 Voltage Requirements Power Electrical Rating NEMA D x 8.1 W x 10.1 H 4.9 D x 8.1 W x 13.1 H 4.9 D x 8.1 W x 16.1 H 4.9 D x 8.1 W x 25.1 H VAC, 50/60 Hz OR VAC, 50/60 Hz 20 Watts Solenoid Valve Coil Voltage Operating Ambient Temperature Range Inlet Temperature Maximum Inlet Pressure Cycle Timer Purge Cycle Separation Media Noise Level Inlet / Outlet Connections 53 VDC (115 VAC Dryer) 106 VDC (230 VAC Dryer) 33 to 120 F (5 to 30 C) <120 F Maximum <100 F Recommended 150 PSIG Solid State with memory 30 seconds per side continuous 4A Molecular Sieve <90 dba 1/4 NPT Female Page 7 of 35
8 6. Installing Your Air Dryer 6.1 Safety & Warning Information WARNING! Extreme care should be exercised to avoid contact with live electrical circuits. Many procedures performed during installation, and testing of this air dryer require the equipment to be running, creating a situation for potential electrical shock. It is highly recommended that you remove all jewelry before performing any procedures. CAUTION! Proper Installation & Maintenance as outlined in this User s Guide is extremely important to ensure the reliability and longevity of the equipment as well as prevent damage or personal injury. CAUTION! Incoming power to dryer must be: VAC, 50/60 Hz OR VAC, 50/60 Hz Page 8 of 35
9 6.2 Before You Begin Carefully inspect the unit, including the shipping box as well as the air dryer, for ANY DAMAGE CAUSED BY SHIPPING. If any shipping damage is detected, it is important to file a claim with the shipping company prior to continuing the installation procedures Read the entire Installing Your Air Dryer section to familiarize yourself with the components and procedures before performing the installation Verify the installation location of the air dryer: Ambient temperature is between 33 and 120 F NOTE: Higher temperatures will decrease component lifespan Meets the following power requirements: VAC, 50/60 Hz VAC, 50/60 Hz Page 9 of 35
10 6.3 Included Contents (1) VSA SERIES AIR DRYER (1) User s Guide (not shown) 6.4 Required Tools and Materials 1/4 nut driver Needle nose pliers 1/4" hex head wrench Mounting hardware Drill Drill bit (varies on mounting hardware) Medium adjustable wrench (used only when installing a Complete System) Cup of soapy water 1-inch paint brush (recommended) Page 10 of 35
11 6.5 Installation Steps IMPORTANT! To properly operate the Air Dryer, PUREGAS recommends that all essential elements and certain options be installed. SEE SECTION Remove the VSA Series Air Dryer from packaging With a 1/4 nut driver loosen screws and remove Manifold Cover Check for loose parts or wiring. NOTE: If ANY SHIPPING DAMAGE is detected, file a claim with the shipping company prior to continuing the installation procedures Re-install Manifold Cover. Page 11 of 35
12 6.5.5 Place the VSA Series Air Dryer at the operating location Pre-drill holes in wall, and install wall mount hardware. NOTE: Wall mounting hardware installation instructions may vary With needle nose pliers remove and discard red plugs. With hex head wrench, arrange port plugs for desired flow direction. NOTE: The arrows on the top surface of the manifold indicate the inlet and outlet ports on both sides Install Inlet and Outlet fittings or assemblies to Air Dryer. CAUTION: When installing a typical Complete Air Dryer, or Point-of-Use System, Puregas recommends assembling ALL components before mounting the VSA Series Air Dryer. Page 12 of 35
13 6.5.9 Mount VSA to wall using secure wall mounting hardware Connect the air supply line to the Inlet and Outlet Port Plug in the Power Cord to an outlet: VAC power outlet VAC power outlet NOTE: Customer must supply a 220 VAC plug to match their receptacle. Page 13 of 35
14 Check for air leaks: NOTE: This is a general procedure that can be applied to any fitting or hose that has air pressure in it Listen for any hissing sounds which may indicate a fitting or hose air leak Use a 1-inch paint brush to dab soapy water on the air fitting or hose connection to be tested. If air bubbles appear at the connection, this indicates that air is leaking from the connection. If any leaks are detected, take steps to seal them off (as necessary): Tighten the fitting Re-connect the hose end Replace the fitting / hose / component REGISTER YOUR AIR DRYER. See section 7. for details. 6.6 Installation Checklist No shipping damage was detected. Wall mounted properly. No air leaks are present. Page 14 of 35
15 7. Registering Your VSA Series Air Dryer Please take a moment to register your PUREGAS VSA SERIES AIR DRYER. Registering is necessary to activate the Limited Warranty on your product. Once you register, you are eligible to receive free technical support, as well as updates concerning your PUREGAS products. Register Online at Or by Phone (option 2) Have the following information available: Model #: Serial #: Company Name: Location Name: Shipping Address: City: State: Zip Code: Contact Name: Phone #: ( ) - ext. Page 15 of 35
16 8. Testing Your Air Dryer 8.1 Safety & Warning Information WARNING! Extreme care should be exercised to avoid contact with live electrical circuits. It is highly recommended that you remove all jewelry before performing any procedures. WARNING! Extreme care should be exercised to avoid contact with live electrical circuits. Many procedures performed during installation, testing, and maintenance of this air dryer require the equipment to be running, creating a situation for potential electrical shock. It is highly recommended that you remove all jewelry before performing any procedures. CAUTION! Observe precautions for handling Electrostatic Sensitive Devices. CAUTION! Depressurizing the air dryer may be necessary before performing certain procedures. Page 16 of 35
17 8.2 Testing Consistent Dryer Cycling Remove the Manifold Cover Place your hand beneath the purge fittings to feel for purging air. Air should: Purge from Tower 1 side Purge from Tower 2 side 30 Seconds later Purge from Tower 1 side 30 Seconds later and so on Reinstall the Manifold Cover. Page 17 of 35
18 8.3 Measuring Incoming Voltage Remove the Manifold Cover Locate the Cycle Timer. The timer has three (3) sets of terminals (from left-to-right): VALVE Left solenoid IN Incoming power VALVE Right solenoid Use a Voltmeter to measure the AC voltage across the IN terminals. The voltage should measure: VAC VAC If the incoming voltage measures less than indicated above, it is recommended that steps be taken at your facility to increase the incoming power to the recommended levels. Page 18 of 35
19 8.3.4 Reinstall the Manifold Cover. 8.4 Measuring Solenoid Voltage Remove the Manifold Cover Locate the Cycle Timer. The timer has three (3) sets of terminals (from left-to-right): VALVE Left solenoid IN Incoming power VALVE Right solenoid Page 19 of 35
20 8.4.3 Use a Voltmeter to measure the DC voltage across each set of VALVE terminals. Continue to measure for up to 45 seconds if no voltage is initially measured. The voltage should measure: 53 VDC for the 115 VAC models. 106 VDC for the 230 VAC models Reinstall the Manifold Cover. If the voltage does not measure as indicated above, verify incoming power section 8.3 or is an indication that the Cycle Timer is defective and should be replaced. See sections 10.1 for part detail and 15.2 for ordering information. Page 20 of 35
21 8.5 Testing Air Fittings & Hoses for Leaks NOTE: This is a general procedure that can be applied to any fitting or hose that has air pressure in it Listen for any hissing sounds which may indicate a fitting or hose air leak Use a 1-inch paint brush to dab soapy water on the air fitting or hose connection to be tested. If air bubbles appear at the connection, this indicates that air is leaking from the connection. If any leaks are detected, take steps to seal them off (as necessary): Tighten the fitting Re-connect the hose end Replace the fitting / hose / component Page 21 of 35
22 9. Maintaining Your Dryer In order to ensure that your VSA Air Dryer continues to operate efficiently and reliably, PUREGAS recommends performing the following maintenance procedures at the specified Six Month and Two Year intervals. It is also recommended that you print out the included Maintenance log sheet (section 16. and record all completed maintenance for historical tracking and reference purposes. The log sheet includes a Section reference column which indicates the User s Guide section containing the information about the specific procedure. Please refer to these sections for detailed procedural information. NOTE: When operating at higher ambient temperatures, it is recommended that maintenance be performed more frequently. 9.1 Safety & Warning Information WARNING! Extreme care should be exercised to avoid contact with live electrical circuits. Many procedures performed during installation, operation, testing, and maintenance of this air dryer require the equipment to be running, creating a situation for potential electrical shock. It is highly recommended that you remove all jewelry before performing any procedures. CAUTION! SHUT DOWN IMMEDIATELY FOR REPAIRS if the air dryer shows any evidence of excessive noise. Page 22 of 35
23 CAUTION! Observe precautions for handling Electrostatic Sensitive Devices. IMPORTANT! After performing any maintenance, always soap test pressure fittings to check for air leaks. Also, check for any loose or disconnected wiring. 9.2 Maintenance Log Sheet MODEL: LOCATION NAME: SERIAL NUMBER: ADDRESS: DATE INSTALLED: Maintenance Interval (Months) Procedure Section Visually Inspect VSA for Loose Wiring or Hardware Test Consistent Dryer Cycling 8.2 Measure & Record Incoming Voltage 8.3 Test Cycle Timer Voltage 8.4 Install New Desiccant Towers 10.1 Install air Dryer Maintenance Kit 10.1 Maintenance Performed by: Date of Maintenance: NOTE: COPY OR PRINT THIS PAGE AND KEEP IT WITH THE AIR DRYER Page 23 of 35
24 10. Replacement Parts & Accessories 10.1 Parts Description Part Number Recommend Quantity 115VAC 230VAC Spare VSA1 Desiccant Tower VSA12Desiccant Tower VSA3 Desiccant Tower (2) VSA4 Desiccant Tower *Purge Orifice (specify #) XX 2 Manifold P300495P 1 Solenoid Valve P400589DC1 P400589DC2 2 (2) Manifold Cover P Plug (standard) P07559 Moisture Indicator (optional) Mounting Bracket P Cycle Timer P010530F1 P010530F2 1 (1) Muffler (2) *Notes: The orifice number is located on the serial decal and stamped on the top of the purge orifice. Page 24 of 35
25 10.2 Accessories for Your Air Dryer Description Dryer Maintenance Kit Includes solenoids, check ball, check springs, and o-rings. Filter Kit with Regulator Includes 5 micron pre-filter, 0.01 coalescing pre-filter,.5 micron after filter, gauge, and regulator. Filter Kit Includes 5 micron pre-filter, 0.01 coalescing pre-filter, and.5 micron after-filter. Part Number R Regulator R18-03-F0G0 Moisture Indicator Includes o-ring Surge Tank Includes air tank, pipe plugs, and pressure gauge. Sound Suppression Kit Includes fittings and hardware to connect to the VSA. P07994 P08084 VSA1-3 Enclosure Kit VSA4 Enclosure Kit Page 25 of 35
26 10.3 Ordering Parts from PUREGAS IMPORTANT! Instruction for the replacement of individual listed components goes beyond the scope of this User s Guide and will not be covered. Please refer to the information included with the specific replacement part for this instruction. Once you have identified your required parts and accessories, contact the PUREGAS Inside Sales / Service department to order: (800) Fax (303) Service & Repair 11.1 Services Offered at Puregas Facility Heatless Dryer Rebuild o Replace desiccant, o-rings, check valves, springs, and complete solenoid assembly o Test proper component operation Desiccant Tower Repack o Clean out tower and replace desiccant, filter, and o-ring Complete Dryer Repair Page 26 of 35
27 11.2 Initiating a Service Transaction Contact our Parts & Service Department at (option 3) to obtain a Return Authorization (RA) number. Carefully package the item(s) to be returned. Mark the Return Authorization (RA) number on the outside of the shipping container. Include the main address and phone number of the individual to contact for related inquiry and follow-up information. Include the purchase order number. 12. Troubleshooting Your Air Dryer 12.1 Before You Call PUREGAS PLEASE READ THIS SECTION FIRST. It is important that you use the following sections in order to diagnose and attempt to fix the problem with your air dryer before placing a call to PUREGAS Technical Support. This troubleshooting guide is intended to simplify the isolation of problems, present possible causes, provide test procedures for verification, and suggest corrective actions to restore the air dryer back to normal operation. Each section begins with the most likely cause(s) of the issue. Otherwise, they start from the simplest possibilities and progress to more complicated ones. This troubleshooting guide is designed to be easy to follow and very effective when used properly. It is suggested to always start at the beginning of the specific problem section and continue in sequence, following the procedures indicated. Page 27 of 35
28 12.2 Safety & Warning Information WARNING! For your safety, all the information in this User s Guide must be followed to minimize the risk of electrical shock, and prevent property damage or personal injury. WARNING! Extreme care should be exercised to avoid contact with live electrical circuits. Many procedures performed during installation and testing of this air dryer require the equipment to be running, creating a situation for potential electrical shock. It is highly recommended that you remove all jewelry before performing any procedures. IMPORTANT! Performing procedures not described in this User s Guide or installing components not supplied by PUREGAS is NOT RECOMMENDED AND MAY VOID THE WARRANTY Restricted Pressure or Flow Possible Cause Check Corrective Action No power to unit Verify power is supplied to the unit (section ) Troubleshoot facility power supply to air dryer Dirty or obstructed inlet Verify inlet air filters are Replace filter Inlet and outlet ports reversed clean Verify ports for proper orientation (see section ) Reconnect properly Page 28 of 35
29 12.4 Excessive Purge Possible Cause Check Corrective Action Purge orifice(s) incorrect Measure purge flow with flow meter, contact Install correct purge orifice(s). Puregas for correct flow. Solenoid coil burned out Test for consistent dryer cycle, and verify voltage (see section 8.2 ) Replace coil 12.5 Delivers Wet Air Possible Cause Check Corrective Action High inlet temperature Verify inlet temperature is below 100 F. Reduce inlet air temperature. Air flow through dryer in excess of rated capacity Verify outlet flow does not exceed air dryer s rated flow Reduce air usage downstream. Low inlet pressure Purge orifice plugged. Solenoid coil burned out Contamination of desiccant Defective timer Purge flow restricted Verify inlet pressure meets air dryer s rated pressure, or is not restricted. (section 12.3 ) Measure purge flow with flow meter, contact Puregas for correct flow. Listen for proper purge cycle, and verify voltage (see section 8.2 ) Remove tower and depress perforated disc. Verify timing cycle (section 8.4 ) Verify mufflers for excessive back pressure (section 8.2 ) Increase pressure, or replace filters. Replace orifice (section 10.1 ) Replace coil (section 10.1 ) If disc is depressed more than 1/4 replace towers (section 10.1 ) Replace timer (section 10.1 ) Replace mufflers (section 10.1 ) Page 29 of 35
30 12.6 Contacting PUREGAS Technical Support Please read the Before You Call PUREGAS section (12.1 ) Once you have exhausted all of the potential problems and solutions covered in the Troubleshooting Your Dryer section, and you still require further assistance to correct a problem, contact PUREGAS Technical Support: (800) (option 1) Have the following information available: Trouble Ticket # (if following-up on a previous call): Technician Name: Phone #: Model #: Serial #: Company Name: Location Name: City: State: Page 30 of 35
31 13. Appendix 13.1 Model Number Coding 13.2 Wiring Diagram Page 31 of 35
33 14. Limited Warranty Agreement PUREGAS products carry a one (1) year warranty against defective workmanship and material. This period starts at date of shipment. Not included are the components subject to normal replacement during a year s operating time. No claims for labor in replacing defective parts or for consequential damages will be allowed. Replacement parts will be invoiced in the regular way, with invoices subject to adjustment after the parts claimed defective are examined at our factory. In addition, no material or parts will be accepted at our factory for in-warranty repairs or credit without previous authorization from PUREGAS. Responsibility for damages incurred in transit will be borne by the user and the user in turn should file any damage claim against the carrier. All warranty items are F.O.B. Broomfield, Colorado. Freight charges are the responsibility of the user. This warranty shall not apply to any PUREGAS product which shall have been repaired or altered in any way by anyone other than PUREGAS or authorized personnel so as to affect, in our judgment, its proper functioning or reliability, neither will it apply to any product which has been subject to misuse, negligence, or accident. The installation of unauthorized non PUREGAS parts will void the warranty on those PUREGAS products. Registration Reminder If you haven t already done so, please take a moment to register your PUREGAS VSA SERIES AIR DRYER. Registering is necessary to activate this Limited Warranty on your product. Once you register, you are eligible to receive free technical support, as well as updates concerning your PUREGAS products. See Section 7. for details on Registering Your Air Dryer. Page 33 of 35
34 15. Contacting PUREGAS 15.1 General 226A Commerce Street Broomfield, Colorado (800) (303) Fax (303) Sales (800) Fax (303) Service (800) (option 3) Fax (303) Technical Support (800) (option 1) DON T FORGET TO REGISTER YOUR VSA AIR DRYER! See Section 7. for details on Registering Your Air Dryer. Page 34 of 35
35 16. Maintenance Log Sheet MODEL: LOCATION NAME: SERIAL NUMBER: ADDRESS: DATE INSTALLED: Maintenance Interval (Months) Procedure Section Visually Inspect VSA for Loose Wiring or Hardware Test Consistent Dryer Cycling 8.2 Measure & Record Incoming Voltage 8.3 Test Cycle Timer Voltage 8.4 Install New Desiccant Towers 10.1 Install air Dryer Maintenance Kit 10.1 Maintenance Performed by: Date of Maintenance: NOTE: COPY OR PRINT THIS PAGE AND KEEP IT WITH THE AIR DRYER 17. Notes Page 35 of 35
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