Puregas Altec AIR P8400W, User Manual

Page 1: ...P017585 Rev A P8400W Air dryer User s Guide...

Page 2: ......

Page 3: ...t us on the web at www AltecAIR com 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 in...

Page 4: ...tting the System Pressure 54 8 13 Setting the Static Pressure 55 8 14 Setting the Outlet Pressure 55 8 15 Engaging the Boost Transformer 56 8 16 Connecting via Web Browser 56 8 17 Using the Status Scr...

Page 5: ...w Outlet Pressure Alarm 97 13 8 Can t Create a Low Pressure Alarm 98 13 9 High Flow Rate Alarm 98 13 10 High Cabinet Temperature Alarm 98 13 11 High Humidity 99 13 12 Can t Create a High Humidity Alar...

Page 6: ...attention for these warnings and read them as you encounter them WARNING For your safety all the information in this User s Guide must be followed to minimize the risk of electrical shock and prevent...

Page 7: ...g routine maintenance as outlined in the Maintaining Your Dryer section will ensure optimal performance over the lifecycle of your air dryer CAUTION Incoming power to dryer must be 190 230 VAC 1 Phase...

Page 8: ...dependently interchangeably or simultaneously depending on your pressurized air requirement Other features of the P8400W Air dryer include a fully digital operating platform offering the most accurate...

Page 9: ...imum 8 400 SCFD both systems 4 200 SCFD single system Power Requirements 190 230 VAC 1 Phase 50 60 Hz Electrical Characteristics Running Amps 15 20 Amp service recommended Outlet Pressure Range 0 15 P...

Page 10: ...Humidity Sensor Measures the humidity of the compressed air 6 Capacity Control Valve Regulates system pressure and prevents air from bleeding back through the heatless dryer 7 Air Tank Stores dry com...

Page 11: ...jewelry before performing any procedures WARNING Internal surfaces may be hot Use care when coming into contact with internal components as there is a potential for some of these components to become...

Page 12: ...entilated and free from abrasive dust or chemicals 6 2 3 2 Ambient temperature is between 40 and 85 F optimal NOTE Higher temperatures will decrease component lifespan 6 2 3 3 Meets the following powe...

Page 13: ...terials Large adjustable wrench Medium adjustable wrench 7 16 wrench Band cutters or snips Lifting Straps Pipe dope or pipe thread tape Cup of soapy water 1 inch paint brush recommended 6 5 Installati...

Page 14: ...latches if a higher level of security is required 6 5 4 Check for loose parts hoses or wiring NOTE If ANY SHIPPING DAMAGE is detected file a claim with the shipping company prior to continuing the ins...

Page 15: ...ify that the red orifice plug is still installed where shown 6 5 8 Install the two 2 purge mufflers shipped loose 6 5 9 Verify that the dryer is powered OFF 6 5 10 Plug the power cord into a 190 230 V...

Page 16: ...measure the voltage by placing the probes between the Circuit Breaker and terminal insulation so that they touch the metal contacts If the voltage measures between 210 230 VAC skip to step 6 5 14 If...

Page 17: ...2 Locate the Main Power Lead quick disconnects in the top section of the dryer 6 5 13 3 Unplug the Main Power Lead quick disconnects 6 5 13 4 Plug both Boost Transformer Lead connectors into the Main...

Page 18: ...the dryer power ON NOTE Both system compressors and heatless dryers will start creating air flow through the red outlet pressure orifice 6 5 16 Set the System Pressures System 1 System 2 are adjusted...

Page 19: ...he knob until the reading on the pressure gauge is 50 PSI 6 5 16 3 Push the knob in to lock 6 5 17 Let the dryer run until the Humidity drops under 2 on both System 1 and System 2 may take up to 15 mi...

Page 20: ...lug System may be pressurized ALTEC AIR recommends using Installation Kit P011752 to connect your dryer to the air supply line See section 11 6 for detail 6 5 20 Turn the dryer ON 6 5 21 Set the Stati...

Page 21: ...ssure Regulator knob out 6 5 22 3 Turn knob until Outlet Pressure OUTP reading is at the desired setting 6 5 22 4 Push knob in to lock 6 5 23 Check for air leaks NOTE This is a general procedure that...

Page 22: ...ing 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 Ti...

Page 23: ...o Well ventilated o Free from abrasive dust or chemicals o Ambient temperature is between 40 and 85 F optimal o Power outlet easily accessible Operating Power is between 210 230 VAC Shipping block rem...

Page 24: ...he Limited Warranty on your product Once you register you are eligible to receive free technical support as well as updates concerning your ALTEC AIR products Register Online at www AltecAIR com regis...

Page 25: ...is highly recommended that you remove all jewelry before performing any procedures WARNING Internal surfaces may be hot Use care when coming into contact with internal components as there is a potent...

Page 26: ...plugs System may be pressurized ALTEC AIR recommends using Installation Kit P011752 to connect your air dryer to the air supply line See section 11 6 for detail 8 3 Powering the Dryer ON OFF 8 3 1 POW...

Page 27: ...4 2 CENTER Button Freezes the current information screen on the display When pressed again it will allow the information screens to begin cycling again 8 4 3 Arrow Buttons Used to access navigate and...

Page 28: ...o manually cycle through the screens by pressing the left or right arrow buttons 8 4 4 1 Tank Screen TANK Air Tank pressure fluctuates between 20 50 PSI OUTLET Outlet Pressure regulated by the Outlet...

Page 29: ...System DUTY CYCLE The percentage of time that the compressor was on during the last compressor pump up cycle 8 4 4 4 System Runtime Screens LAST Last compressor runtime in minutes TOTAL Total compres...

Page 30: ...et Pressure OUTP rises above the alarm set point for more than one 1 minute Default setting is 12 0 PSI Press the Info Button to see the detail of the alarm See section 13 5 for troubleshooting inform...

Page 31: ...of the alarm See section 13 9 for troubleshooting information 8 5 4 High Compressor Temperature Alarm Occurs when the temperature in the lower compressor compartment rises above 140 F for more than on...

Page 32: ...damage due to overheating Press the Info Button to see the detail of the alarm See section 13 10 for troubleshooting information 8 5 6 High Humidity Alarm Occurs when the Humidity level rises above th...

Page 33: ...e alarm Default setting is 3 00 minutes Press the Info Button to see the detail of the alarm See section 13 17 for troubleshooting information 8 5 8 High Duty Cycle Alarm Occurs when the compressor is...

Page 34: ...stem Setup Used to set system parameters including Cycle Mode Cycle Time Startup Delay Alarm Delay Date Time and Units This menu also allows for firmware updates via USB Alarm Setup Used to set the al...

Page 35: ...to Escape to the setup screen 8 7 Using the System Setup Menu In the Setup Menu 8 7 1 Press the Up Down Arrow Buttons to Select the S in System Setup 8 7 2 Press the Enter Button to access System Setu...

Page 36: ...he Up and Down Arrow Buttons to Change the value of the selected digit 8 7 4 5 Press the Enter Button to confirm the selected choice 8 7 4 6 Press the Left Right Arrow Buttons to Select the correct co...

Page 37: ...fault setting is 0 seconds 8 7 6 1 Press the Enter Button to access the edit screen 8 7 6 2 Press the Left Right Arrow Buttons to Select the digit to change 8 7 6 3 Press the Up Down Arrow Buttons to...

Page 38: ...Press the Enter Button to confirm the selected choice This will reset the Total Time to zero 0 8 7 7 4 The process is similar for resetting System 2 runtime 8 7 8 Reset Factory Default Values 8 7 8 1...

Page 39: ...row Buttons to Select the digit to change 8 7 9 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 7 9 4 Press the Enter Button to submit the new setting 8 7 9 5 Press the L...

Page 40: ...row Buttons to Select the digit to change 8 7 10 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 7 10 4 Press the Enter Button to submit the new setting 8 7 10 5 Press th...

Page 41: ...e keyword and press the Enter Button to access the firmware update screen 8 7 11 4 Select the correct file version using the Up and Down Buttons 8 7 11 5 Press the Enter button to select the file 8 7...

Page 42: ...new setting 8 8 Using the Alarm Setup Menu In the Setup Menu 8 8 1 Press the Up Down Arrow Buttons to Select the A in Alarm Setup 8 8 2 Press the Enter Button to access Alarm Setup 8 8 3 Set High Hum...

Page 43: ...cted choice This will lock in the new setting 8 8 4 Set High Outlet Threshold default setting is 20 00 PSI 8 8 4 1 Press the Enter Button to access the edit screen 8 8 4 2 Press the Left Right Arrow B...

Page 44: ...nter Button to access the edit screen 8 8 5 2 Press the Left Right Arrow Buttons to Select the digit to change 8 8 5 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 8 5 4...

Page 45: ...ss the Left Right Arrow Buttons to Select the digit to change 8 8 6 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 8 6 4 Press the Enter Button when to submit the new se...

Page 46: ...Press the Left Right Arrow Buttons to Select the digit to change 8 8 7 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 8 7 4 Press the Enter Button when to submit the ne...

Page 47: ...the Left Right Arrow Buttons to Select the digit to change 8 8 8 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 8 8 4 Press the Enter Button when to submit the new setti...

Page 48: ...k Setup 8 9 2 Enter Keyword default Keyword is 123456 8 9 2 1 Press the Left Right Arrow Buttons to Select the digit to change 8 9 2 2 Press the Up Down Arrow Buttons to Change the value of the select...

Page 49: ...e Yes or No 8 9 3 6 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 9 4 Set Subnet Mask default is 255 255 255 000 8 9 4 1 Press the Enter Button to access th...

Page 50: ...Press the Enter Button to access the edit screen 8 9 5 2 Press the Left Right Arrow Buttons to Select the digit to change 8 9 5 3 Press the Up Down Arrow Buttons to Change the value of the selected di...

Page 51: ...Arrow Buttons to Change the value of the selected digit 8 9 6 4 Press the Enter Button when to submit the new setting 8 9 6 5 Press the Left Right Arrow Buttons to Select the correct confirmation cho...

Page 52: ...7 5 Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No 8 9 7 6 Press the Enter Button to confirm the selected choice This will lock in the new settings 8 9 8 Set M...

Page 53: ...etting 8 9 9 View MAC address 8 9 9 1 The device MAC address can be viewed from the network setup menu 8 10 Opening Panels 8 10 1 Removing Top Cover Depress the latches and pull the Top Cover off The...

Page 54: ...vent pressure from building back up power the dryer OFF See section 8 3 for detail 8 11 4 Reinstall Front Panel 8 12 Setting the System Pressure System 1 System 2 are adjusted and set independently Wi...

Page 55: ...Static Pressure Regulator knob out 8 13 3 Turn knob until the reading on the pressure gauge is 17 PSI 8 13 4 Push knob in to lock 8 13 5 Reinstall Front Panel 8 14 Setting the Outlet Pressure 8 14 1 R...

Page 56: ...Boost Transformer 8 15 1 See section 6 5 13 8 16 Connecting via Web Browser Warning The intra building port Network LAN Port of the equipment is suitable for connection to intra building or unexposed...

Page 57: ...ctly into a Laptop PC and the other end plugged into the Network Port of the air dryer Configure the network card on the Laptop PC to use the IP Address 192 168 1 102 This will make the Laptop PC comp...

Page 58: ...larm Screen Displays all the Alarms registered by the P8400W Series Air dryer This screen is informational only Firmware Screen Allows the user to upload any software updates or upgrades to the Air dr...

Page 59: ...the P8400W Series Air dryer Provides remote ALARM RESET Readings are displayed in GREEN unless an alarm is present Alarms are displayed in RED next to the parameter in alarm Alarm Status will display...

Page 60: ...et Compressor Total Run Time displayed on Status Screen 8 18 Using the Setup Screen All configurations for the System Alarms Network and Keyword can be made in this screen Values in BLUE represent the...

Page 61: ...ng a Threshold or Setup value 8 18 1 1 Click on the value to change 8 18 1 2 Type in the new value 8 18 1 3 Click the ENTER Button when done 8 18 1 4 Enter Keyword 8 18 2 Changing the Keyword 8 18 2 1...

Page 62: ...rm Screen Displays all events such as alarms changes made and alarm resets registered by the P8400W Series Air dryer This screen is informational only You may download a csv file with all event alarm...

Page 63: ...of the P8400W Series Air dryer Current Version Displays the current firmware version of the P8400W Series Air dryer New Version File Displays the new location and new firmware version chosen The BROW...

Page 64: ...specific SNMP Management software used on your network This software requires a SNMP Definition Configuration File MIB file in order to properly communicate with the Air dryer The files for the P8400...

Page 65: ...be running creating a situation for potential electrical shock It is highly recommended that you remove all jewelry before performing any procedures WARNING Internal surfaces may be hot Use care when...

Page 66: ...e 1 System 2 Wire 8 9 2 3 Use an Amp Meter to measure the running amps With the compressor running the running amps should measure 4 0 amps or below 9 2 4 Reinstall Front Panel If the compressor measu...

Page 67: ...be measured 9 3 3 Use a Voltmeter to measure the voltage between the Hot and Neutral wires by placing the probes in the openings in the power connector System 1 Wires 1 2 System 2 Wires 8 7 The volta...

Page 68: ...hat they touch the metal contacts The voltage should measure 210 230 VAC 9 4 4 Reinstall Top Cover If the incoming voltage measures less than 210 VAC it is necessary to engage the Boost Transformer in...

Page 69: ...e across the AC terminals Should measure 0 VAC 9 5 4 Use a Voltmeter to measure across the DC terminals Should measure 12 VDC With the System Compressor NOT running 9 5 5 Use a Voltmeter to measure ac...

Page 70: ...e purge tubes from the System Heatless Dryer 9 6 3 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...

Page 71: ...lve 9 7 3 Place your hand beneath the Unloader Valve fitting to feel for air flow Air should NOT flow from this fitting continuously Air should only be released in a short burst when the System compre...

Page 72: ...ls from left to right 106VDC Left solenoid IN Incoming power 106VDC Right solenoid 9 8 3 Use a Voltmeter to measure the DC voltage across each set of 106VDC terminals Continue to measure for up to 45...

Page 73: ...the Wiring Diagram section 14 1 Replace defective fan see sections 11 2 for part detail and 11 7 for ordering information 9 10 Testing Safety Relief Valve 9 10 1 Remove Front Panel see section 8 10 2...

Page 74: ...re TANK reaches 50 0 PSI If the tank pressure TANK fails to reach 50 PSI see section 13 14 for troubleshooting information With Compressor s NOT running 9 11 4 Pull the ring handle on the Safety Relie...

Page 75: ...2 9 12 2 Start timing when the compressor s turns on 9 12 3 Pull the ring handle on the Safety Relief Valve when necessary to keep the Tank Pressure TANK from reaching 50 PSI This prevents the compres...

Page 76: ...n BOTH Cycle Mode see section for details on changing Cycle Mode Test one System at a time System System 1 or System 2 9 13 1 Remove Front Panel see section 8 10 2 9 13 2 Turn the System Circuit Break...

Page 77: ...7 After three 3 minutes verify that a Humidity Alarm appears and System goes into SHUTDOWN mode 9 13 8 Replace the Humitter into the Humidity Block 9 13 9 Reinstall Front Panel 9 13 10 Turn the Syste...

Page 78: ...of the current Outlet Pressure OUTP reading With Compressor s running 9 14 4 Pull the Outlet Pressure Regulator knob out 9 14 5 Turn knob clockwise until Outlet Pressure OUTP reading climbs over 12 0...

Page 79: ...8 4 4 1 appears on the display press the HOLD Button on the Front Panel to freeze that screen 9 15 3 Make a note of the current Outlet Pressure OUTP reading With Compressor s running 9 15 4 Pull the O...

Page 80: ...0 of 110 P017585 Rev A 9 15 7 Push knob in to lock 9 15 8 Press the RESET Button to clear the alarm 9 15 9 Reinstall Front Panel If you are unable to create a Low Outlet Pressure Alarm as described se...

Page 81: ...R With Compressor s NOT running 9 16 1 Listen for any hissing sounds which may indicate a fitting or hose air leak With Compressor s running 9 16 2 Use a 1 inch paint brush to dab soapy water on the a...

Page 82: ...n 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 mor...

Page 83: ...check for any loose or disconnected wiring CAUTION SHUT DOWN IMMEDIATELY FOR REPAIRS if the air compressor s shows any evidence of overheating or presents excessive noise CAUTION Depressurizing the a...

Page 84: ...ge must be 210 230 VAC 9 4 Test High Low Outlet Pressure Alarms 9 14 9 15 Set System Pressure 50 PSI 8 12 Set Static Pressure 17 PSI 8 13 Set Outlet Pressure 8 14 Test Consistent Heatless Dryer Cyclin...

Page 85: ...Procedure Section 8 000 16 000 24 000 32 000 40 000 Install 8 000 Hour Maintenance Kit P011813 11 6 Install 16 000 Hour Maintenance Kit P011814 11 6 Read Record Flow Rate FLOW 8 4 4 1 Measure Record...

Page 86: ...cessories 11 1 Top Section Parts Description Part Number Quantity Recommend Spare Solid State Relay P010562 2 1 Terminal Block P010200 1 Front Panel Display Assembly P017578 1 LCD Display Only P012105...

Page 87: ...mmend Spare Boost Transformer P012772 1 Heatless Dryer Assembly See section11 3 for detail Pressure Gauge 0 30 PSI P011339 1 Static Pressure Regulator P013203 1 1 Adapter Plate 2 Flow Block 1 Air Tank...

Page 88: ...Parts Description Part Number Quantity Recommend Spare Heatless Dryer P010196 1 Pressure Gauge P010695 1 Solenoid Valve In Kit P011813 See section 11 6 for detail Unloader Valve P010453 1 Cycle Timer...

Page 89: ...T In Kit P011766 See section 11 6 for detail Air Compressor Assembly Left Side Right Side P013263 P013264 1 1 Compressor ONLY P010444 1 1 Spacer 8 Precooler P05663 2 Discharge Hose P05069 2 Capacitor...

Page 90: ...P017585 Rev A 11 5 Frame Section Parts Description Part Number Quantity Recommend Spare Top Cover 1 Front Panel 1 Air Intake Filter In Kit P011766 See section 11 6 for detail Purge Muffler In Kit P011...

Page 91: ...nth Maintenance Kit Includes air intake filter compressor mufflers and purge mufflers P011766 2 8 000 Hour Maintenance Kit Includes heatless dryer maintenance kits and compressor maintenance kits P011...

Page 92: ...t the ALTEC AIR Inside Sales Service department to order 800 521 5351 option 2 Fax 303 657 2205 sales AltecAIR com parts AltecAIR com IMPORTANT Instruction for the replacement of individual listed com...

Page 93: ...place 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 Circuit B...

Page 94: ...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...

Page 95: ...ng the air dryer may be necessary before performing certain procedures NEVER remove pressure sensing tubes from the Control Board without depressurizing the air dryer first or damage to the Control Bo...

Page 96: ...running from the Control Board to the Display Screen is properly connected at both ends see section 11 1 for Control Board and Display Screen locations Plug in ribbon cable to Control Board and Displa...

Page 97: ...UTP reading is higher than the High Outlet Pressure Alarm set point above Replace Control Board section 11 1 if Outlet Pressure OUTP reading is over verified High Outlet Pressure Alarm set point for m...

Page 98: ...ntrol Board section 11 1 if Outlet Pressure OUTP reading is under verified Low Outlet Pressure Alarm set point for more than 1 minute and fails to create an alarm 13 9 High Flow Rate Alarm Possible Ca...

Page 99: ...h Humidity Alarm set point section 9 13 Over 10 not recommended Heatless Dryer not cycling between towers Verify consistent Heatless Dryer cycling section 9 6 Troubleshoot Inconsistent Heatless Dryer...

Page 100: ...ce Control Board if no alarm is created and system does not shut down section 11 1 13 13 Compressor Doesn t Operate Possible Cause Check Corrective Action Defective compressor Measure voltage to compr...

Page 101: ...s between compressor and Air Tank for air leaks section 9 16 Connect tighten or replace leaking component 13 15 Compressor Excessive AMP Draw Possible Cause Check Corrective Action Restriction in air...

Page 102: ...Alarm Possible Cause Check Corrective Action Low System Pressure Verify System Pressure section 8 12 Adjust System Pressure to 50 PSI section 8 12 High Flow condition Verify Flow Rate FLOW reading is...

Page 103: ...set point by 1 minute or more and fails to create an alarm 13 19 Compressor Rapid ON OFF Cycling Possible Cause Check Corrective Action Defective Solid State Relay Measure voltages at Solid State Rel...

Page 104: ...sted 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 ALTEC AIR Technical Support 800...

Page 105: ...Altec AIR P8400W Air dryer User s Guide Page 105 of 110 P017585 Rev A 14 Appendix 14 1 Wiring Diagram...

Page 106: ...Defined by Customer Device Model Alphanumeric Factory Preset Device Firmware Version Numeric Factory Preset Current Date Time Numeric mm dd yy hh mm IP Address Numeric xxx xxx xxx xxx Subnet Mask Num...

Page 107: ...Flow Alarm OK Alarm High Outlet Pressure Alarm OK Alarm Low Outlet Pressure Alarm OK Alarm High Humidity System 1 Alarm OK Alarm High Humidity System 2 Alarm OK Alarm High Cabinet Temperature Alarm O...

Page 108: ...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 n...

Page 109: ...do 80020 800 521 5351 303 427 3700 Fax 303 657 2233 info AltecAir com www AltecAir com 16 2 Sales 800 521 5351 option 2 Fax 303 657 2205 sales AltecAir com parts AltecAir com 16 3 Service 800 521 5351...

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