Puregas P1500W Series, User Manual

Page 1: ...P011787 Rev S P1500W Series Air Dryers User s Guide Models covered P1500W P1500WLP P1500WHP P1502W P1502WLP P1502WHP...

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Page 3: ...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...

Page 4: ...8 9 Connecting to Power Fail Alarm Terminals 45 8 10 Connecting via Web Browser 45 8 11 Using the Status Screen 47 8 12 Using the Configuration Screen 50 8 13 Using the Event Screen 51 8 14 Using the...

Page 5: ...3 8 Can t Create a Low Pressure Alarm 87 13 9 High Humidity 88 13 10 Can t Create a High Humidity Alarm Shutdown 89 13 11 High Flow Rate Alarm 89 13 12 High Cabinet Temperature Alarm 90 13 13 Inconsis...

Page 6: ...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 property damage or personal injury WARNING Ex...

Page 7: ...MMENDED AND MAY VOID THE WARRANTY IMPORTANT Performing routine maintenance as outlined in the Maintaining Your Dryer section will ensure optimal performance over the lifecycle of your air dryer CAUTIO...

Page 8: ...s of dryer variables removable access panel allowing easier access for adjustment and maintenance and ultra quiet Compressor with an industry leading maintenance interval of 8 000 hours 5 2 Key Featur...

Page 9: ...60 PSI 13 8 413 6 KPa 2 15 PSI 13 8 103 4 KPa 0 30 7 50 PSI 2 52 7 KPa 2 60 PSI 13 8 103 4 KPa Outlet Air Humidity Less than 2 RH Compressor Type Two cylinder 3 4 HP oil less type Drying Method Heatle...

Page 10: ...ture from compressed air 6 Capacity Control Valve Regulates System Pressure and prevents air from bleeding back through the Heatless Dryer 7 Humidity Sensor Measures the Humidity of the compressed air...

Page 11: ...at 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 potential for some of these com...

Page 12: ...n of the air dryer 6 2 3 1 Well ventilated 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...

Page 13: ...llation Guide not shown Package located inside the dryer 1 120 VAC Power Cord for P1500W P1500WLP P1500WHP models 1 220 VAC Power Cord for P1502W P1502WLP P1502WHP models 1 Precision Bleed Orifice Fit...

Page 14: ...aterials NOTE If ANY SHIPPING DAMAGE is detected file a claim with the shipping company prior to continuing the installation procedures 6 5 2 Open Front Panel locking latches and remove the Front Pane...

Page 15: ...se contents package 6 5 5 Remove and discard the packing foam blocks from around the Compressor 6 5 6 Remove the Plug from the Outlet Port by pressing the ferrule down then pulling the plug upward 6 5...

Page 16: ...011773 section 11 4 6 5 9 Verify that the dryer is powered OFF 6 5 10 Plug AC Power Cord to dryer 6 5 11 Wire or plug the power cord into 110 125 VAC power outlet for P1500W P1500WLP P1500WHP models 2...

Page 17: ...b until the reading on the pressure gauge is 80 PSI for W WLP 90 PSI for WHP NOTE 90 PSI may be used on W WLP dryers in low flow applications to maintain low humidity 6 5 13 3 Push the knob in to lock...

Page 18: ...the Outlet Port by pressing the ferrule down then pulling the fitting upward NOTE Save this fitting for use in low flow applications 6 5 17 Connect the air supply line to the Outlet Port NOTE For all...

Page 19: ...b until the reading on the pressure gauge is 17 PSI for W WLP 60 PSI for WHP 6 5 19 3 Push knob in to lock 6 5 20 Set the Outlet Pressure 6 5 20 1 Pull the Outlet Pressure Regulator knob out or loosen...

Page 20: ...sten for any hissing sounds which may indicate a fitting or hose air leak With Compressor running 6 5 21 2 Use a 1 inch paint brush to dab soapy water on the air fitting or hose connection to be teste...

Page 21: ...nts o Well ventilated o Free from abrasive dust or chemicals o Ambient temperature is between 40 and 85 F optimal Shipping foam blocks removed from Compressor System Pressure is set to 80 PSI for W WL...

Page 22: ...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 ALTEC AIR products Register Online at www Altec...

Page 23: ...ituation 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 coming into contact wit...

Page 24: ...ent information screen on the display When pressed again it will allow the information screens to begin cycling again 8 2 4 Arrow Buttons Used to navigate screens and set values 8 2 5 Display Screen S...

Page 25: ...and older 60 90 PSI for P1500WHP P1502WHP models OUTLET Outlet Pressure regulated by the Outlet Pressure Regulator Flow Air flow out of the system CABINET Temperature of the dryer cabinet compartment...

Page 26: ...when the Outlet Pressure OUTP rises above the alarm set point for more than one 1 minute Default setting is 12 0 PSI for W models 7 50 PSI for WLP models 35 0 PSI for WHP models See section 13 5 for...

Page 27: ...for one 1 minute or more the air Dryer will go into SHUTDOWN mode to prevent saturated air from being delivered to the supply line See section 13 9 for troubleshooting information 8 2 10 High Cabinet...

Page 28: ...the required maintenance See section 10 3 for maintenance information 8 3 Accessing the Setup Menu The P1500W has three 3 Setup sections System Setup Used to set specific values for the system Alarm S...

Page 29: ...ccess the menu selected or press the Left Arrow Button to Escape to the information screens 8 4 Using the System Setup Menu In the Setup Menu 8 4 1 Press the Up Down Arrow Buttons to Select the S in S...

Page 30: ...on to confirm the selected choice This will lock in the new setting 8 4 4 Press the Up Arrow Button to access the next screen 8 4 5 Set Start Up Delay default setting is 0 seconds 8 4 5 1 Press the En...

Page 31: ...Up Arrow Button to access the next screen 8 4 7 Reset Compressor Total Time 8 4 7 1 Press the Enter Button to access the reset screen 8 4 7 2 Press the Left Right Arrow Buttons to Select the correct...

Page 32: ...o Factory Default Values 8 4 10 Press the Up Arrow Button to access the next screen 8 4 11 Set Date 8 4 11 1 Press the Enter Button to access the edit screen 8 4 11 2 Press the Left Right Arrow Button...

Page 33: ...Right Arrow Buttons to Select the digit to change 8 4 12 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 4 12 4 Press the Enter Button to submit the new setting 8 4 12 5...

Page 34: ...ttons 8 4 1 5 Press the Enter button to select the file 8 4 1 6 Press the Left Right Arrow Buttons to Select the correct choice Yes or No and begin the update 8 4 2 System Units 8 4 2 1 Press the Ente...

Page 35: ...he new setting 8 4 3 5 Press the Left Right Arrow Buttons to Select the correct choice Yes or No 8 4 3 6 Press the Enter Button to confirm the selected choice This will reset the device and lock in th...

Page 36: ...o confirm the selected choice This will lock in the new setting 8 5 4 Press the Up Arrow Button to access the next screen 8 5 5 Set High Outlet Threshold default setting is 20 00 PSI 8 5 5 1 Press the...

Page 37: ...Press the Left Right Arrow Buttons to Select the digit to change 8 5 7 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 5 7 4 Press the Enter Button when to submit the new...

Page 38: ...s or No 8 5 9 6 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 5 10 Press the Up Arrow Button to access the next screen 8 5 11 Set High Duty Cycle default se...

Page 39: ...8 5 13 1 Press the Left Right Arrow Buttons to Select the digit to change 8 5 13 2 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 5 13 3 Press the Enter Button to submit...

Page 40: ...setting 8 5 15 Set Subnet Mask default is 255 255 255 000 8 5 15 1 Press the Enter Button to access the edit screen 8 5 15 2 Press the Left Right Arrow Buttons to Select the digit to change 8 5 15 3 P...

Page 41: ...git to change 8 5 16 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 5 16 4 Press the Enter Button when to submit the new setting 8 5 16 5 Press the Left Right Arrow Butt...

Page 42: ...n when to submit the new setting 8 5 17 5 Press the Left Right Arrow Buttons to Select the correct choice Yes or No 8 5 17 6 Press the Enter Button to confirm the selected choice This will lock in the...

Page 43: ...m the selected choice This will lock in the new settings 8 5 19 Set Monitoring System Address default is 0 8 5 19 1 Press the Enter Button to access the edit screen 8 5 19 2 Press the Up Down Arrow Bu...

Page 44: ...he network setup menu 8 6 Open Front Panel 8 6 1 Open Front Panel locking latches and remove the Front Panel 8 7 Depressurizing the Dryer 8 7 1 Open Front Panel section 8 6 8 7 2 Pull the ring handle...

Page 45: ...e Panel 8 9 Connecting to Power Fail Alarm Terminals 8 9 1 Open Panel 8 9 2 Locate the external Power Fail pins on the Control Board 8 9 3 Wire the Power Fail Alarm wire pair to the Control Board as r...

Page 46: ...o use the IP Address 192 168 1 101 This will make the Laptop PC compatible with the Air Dryer Use Internet Explorer 6 0 or newer or Mozilla Firefox Web Browser 8 10 1 Type the IP Address of the P1500W...

Page 47: ...0 P011787 Rev S 8 11 Using the Status Screen Displays the readings and alarms monitored in the P1500W Series Air Dryer Provides remote ALARM RESET Readings are displayed in BLACK unless an alarm is pr...

Page 48: ...m if any alarms are present Keyword validation is required for ALARM RESET and RESET TOTAL RUN TIME 8 11 1 Resetting an Alarm 8 11 1 1 Click on the ALARM RESET Button to remotely reset Air Dryer alarm...

Page 49: ...00 P011787 Rev S 8 11 2 Resetting Compressor Total Run Time 8 11 2 1 Click on the RESET TOTAL RUN TIME Button to remotely reset Compressor Total Run Time displayed on Status Screen 8 11 2 2 Enter Keyw...

Page 50: ...s and Keyword can be made in this screen NOTE Reference Appendix section 14 2 for Limits Defaults and Formats Values in BLUE represent the current setting The Enter Key is used to change values Clicki...

Page 51: ...es Air Dryers User s Guide Page 51 of 100 P011787 Rev S 8 13 Using the Event Screen Displays all events such as alarms changes made and alarm resets registered by the P1500W Series Air Dryers This scr...

Page 52: ...ALTEC AIR LLC P1500W Series Air Dryers User s Guide Page 52 of 100 P011787 Rev S 8 14 Using the Firmware Screen Displays the current firmware version and date of the P1500W Series Air Dryers...

Page 53: ...ting via SNMP Using SNMP to connect and communicate with the P1500W Series Air Dryer is dependent upon the specific SNMP Management software used on your network This software requires a SNMP Definiti...

Page 54: ...ing 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 coming into cont...

Page 55: ...the Compressor running the running amps should measure 6 3 amps or below for the P1500W P1500WLP P1500WHP models 3 2 or below for the P1502W P1502WLP P1502WHP models If the Compressor measures over ru...

Page 56: ...ard over wire 6 9 3 6 Power the air dryer ON 9 3 7 Use a Voltmeter to measure the voltage 9 3 7 1 Place the probes over terminals for wire 5 and wire 6 The voltage should measure 110 125 VAC for the P...

Page 57: ...the metal contacts for BLACK BROWN wire and WHITE BLUE wire The voltage should measure 110 125 VAC for the P1500W P1500WLP P1500WHP models 208 230 VAC for the P1502W P1502WLP P1502WHP models If the i...

Page 58: ...f back wall When the Compressor should be running 9 5 3 Use a Voltmeter to measure across the AC terminals Should measure 0 VAC 9 5 4 Use a Voltmeter to measure across the DC terminals Should measure...

Page 59: ...placed If any of the DC voltage measurements are different that indicated above the Control Board may be defective and should be replaced See sections 11 1 for part detail and 11 5 for ordering inform...

Page 60: ...ver the Compressor for this test i e piece of cardboard 9 6 3 Locate the heatless dryer purge solenoids inside the air dryer 9 6 4 Place your hand beneath the purge solenoids to feel for purging air A...

Page 61: ...hooting information 9 7 Testing Unloader Valve With the Compressor running 9 7 1 Open Front Panel section 8 6 9 7 2 Locate the Unloader Valve on the left side of the Dryer 9 7 3 With a 9 16 wrench dis...

Page 62: ...part detail and 11 5 for ordering information 9 7 5 With a 9 16 wrench connect hose to the Unloader Valve 9 7 6 Close Front Panel 9 8 Measuring Heatless Dryer Solenoid Voltage With the Compressor runn...

Page 63: ...els 9 8 4 Close Front Panel If the voltage does not measure as indicated above this is an indication that the Cycle Timer is defective and should be replaced See sections 11 3 for part detail and 11 5...

Page 64: ...Testing Safety Relief Valve 9 10 1 Open Front Panel section 8 6 9 10 2 Pull the ring handle on the Safety Relief Valve to verify air pressure is released 9 10 3 Release ring handle and verify that no...

Page 65: ...ring handle on the Safety Relief Valve to release air pressure from the air tank 9 11 5 Verify the Compressor turns on when the tank pressure TANK falls to 25 0 PSI for the P1500W P1500WLP P1502W P150...

Page 66: ...ing handle on the Safety Relief Valve when necessary to keep the Tank Pressure TANK from reaching 90 PSI This prevents the Compressor from shutting down When the Compressor runs for 3 00 minutes unles...

Page 67: ...e Page 67 of 100 P011787 Rev S 9 13 Testing Humidity Alarm and System Shutdown 9 13 1 Power the air dryer OFF 9 13 2 Open Front Panel section 8 6 9 13 3 Depressurize the air dryer 9 13 4 Unscrew and r...

Page 68: ...0 0 After three 3 minutes verify that a Humidity Alarm appears and the dryer goes into SHUTDOWN mode 9 13 7 Replace the Humidity Sensor into the Humidity Block 9 13 8 Press the RESET Button to clear t...

Page 69: ...egulator knob out or loosen the retaining nut LP Models 9 14 4 Turn knob clockwise until Outlet Pressure OUTP reading climbs over 12 0 PSI for P1500W P1502W models 7 50 PSI for P1500WLP P1502WLP model...

Page 70: ...ting information 9 15 Testing Low Outlet Pressure Alarm 9 15 1 Make a note of the current Outlet Pressure OUTP reading 9 15 2 Open Front Panel section 8 6 9 15 3 Pull the Outlet Pressure Regulator kno...

Page 71: ...ckwise until Outlet Pressure OUTP reading rises to the reading recorded in step 9 15 1 9 15 6 Push knob in to lock or tighten the retaining nut LP Models 9 15 7 Press the RESET Button 9 15 8 Close Fro...

Page 72: ...OR MAY OCCUR With Compressor NOT running 9 16 1 Listen for any hissing sounds which may indicate a fitting or hose air leak With Compressor running 9 16 2 Use a 1 inch paint brush to dab soapy water o...

Page 73: ...record all completed maintenance for historical tracking and reference purposes The log sheets include a Section reference column which indicates the User s Guide section containing the information ab...

Page 74: ...faces may be hot Use care when coming into contact with internal components as there is a potential for some of these components to become hot when in operation or standby IMPORTANT Performing routine...

Page 75: ...rming procedures not described in this User s Guide or installing components not supplied by ALTEC AIR is NOT RECOMMENDED AND MAY VOID THE WARRANTY IMPORTANT After performing any maintenance always so...

Page 76: ...Set System Pressure 80 PSI for P1500W P1500WLP P1502W P1502WLP models 90 PSI for P1500WHP P1502WHP models 0 Set Static Pressure 17 PSI for P1500W P1500WLP P1502W P1502WLP models 60 PSI for P1500WHP P...

Page 77: ...Kit P012252 11 4 Read Record Flow Rate FLOW 8 Measure Record Compressor Amp Draw 9 2 Set System Pressure 80 PSI for P1500W P1500WLP P1502W P1502WLP models 90 PSI for P1500WHP P1502WHP models 6 Set St...

Page 78: ...art Number Quantity Recommen d Spare Precision Bleed Orifice Fitting P013349 1 Power Switch M038428 1 Fan P40801 1 Static Pressure Regulator W WLP models WHP models P010279 P010622 1 Air Tank 1 Solid...

Page 79: ...lator W models WLP models WHP models P010279 P012316 P010622 1 Flow Block 1 Unloader Valve P1500W Series 110 VAC P1502W Series 220 VAC P011022 P010453 1 Safety Relief Valve P011777 1 Control Board P01...

Page 80: ...Parts Description Part Number Quantity Recommend Spare Heatless Dryer P1500W Series 110 VAC P1502W Series 220 VAC PHF2C106023 PHF2C20623 1 Desiccant Chamber P2004036 2 Cycle Timer P1500W Series 110 V...

Page 81: ...ake filter Compressor muffler P018302 2 8 000 Hour Maintenance Kit Includes heatless dryer maintenance kit and Compressor maintenance kit P012252 1 Universal Rack Mounting Kit Includes mounting bracke...

Page 82: ...ponents 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 you...

Page 83: ...d 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 Cir...

Page 84: ...ection 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...

Page 85: ...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 proced...

Page 86: ...re Alarm set point Raise High Outlet Pressure Alarm set point 13 6 Can t Create a High Pressure Alarm Possible Cause Check Corrective Action Defective Outlet Pressure Regulator Verify that the Outlet...

Page 87: ...Tighten any loose connections as required 13 8 Can t Create a Low Pressure Alarm Possible Cause Check Corrective Action Defective Outlet Pressure Regulator Verify that the Outlet Pressure Regulator c...

Page 88: ...thin acceptable levels Raise High Humidity Alarm set point Over 10 not recommended Defective Humidity Sensor Perform the Testing Humidity Alarm and System Shutdown test section 9 13 Troubleshoot Can t...

Page 89: ...Verify that Humidity reading fails to climb higher than 15 or creates sporadic readings Replace Humidity Sensor section 11 1 Defective Control Board Verify that Humidity reading is over 15 for more t...

Page 90: ...section 11 4 Defective Cycle Timer Measure voltage going to the Heatless Dryer Solenoid Valves section 9 8 If voltage IS NOT present replace the Cycle Timer section 11 3 13 14 Compressor Doesn t Opera...

Page 91: ...essor and Air Tank for air leaks section 9 16 Connect tighten or replace leaking component 13 16 Compressor Excessive AMP Draw Possible Cause Check Corrective Action Restriction in air line Remove Dis...

Page 92: ...lowing high amounts of air the Unloader Valve is defective Replace Unloader Valve section 11 2 Defective Heatless Dryer Solenoid Valve Verify consistent Heatless Dryer cycling section 9 6 If either si...

Page 93: ...mpressor has run longer than the verified High Compressor Last Run Time Alarm Set Point above Replace Control Board section 11 2 if the Compressor runs longer than the verified High Compressor Last Ru...

Page 94: ...ave 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 ALTEC AIR Technical Su...

Page 95: ...ALTEC AIR LLC P1500W Series Air Dryers User s Guide Page 95 of 100 P011787 Rev S 14 Appendix 14 1 Wiring Diagram...

Page 96: ...5 0 30 25 0 PSI High Humidity Alarm 3 15 10 YES High Compressor Last Run Time Alarm 2 00 5 00 3 00 Minutes High Cabinet Temperature Alarm 120 Deg F YES Compressor Total Run Time Alarm 8000 Hours 14 2...

Page 97: ...Time Reading Numeric Hours Compressor Last Run Time Reading Numeric Seconds System Status ON SHUTDOWN Compressor Status ON OFF Fan Status ON OFF Heater Status Outdoor Unit Only ON OFF Alarm Readings...

Page 98: ...y 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...

Page 99: ...olorado 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...

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