Puregas P1500W2, User Manual

Page 1: ...P012253 Rev H P1500W2 Series Air Dryers User s Guide Models covered P1500W2 P1500W2LP P1500W2HP P1502W2 P1502W2LP P1502W2HP...

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Page 3: ...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 information and direction specific...

Page 4: ...Dryer 38 8 9 Setting the System Pressure 39 8 10 Setting the Static Pressure 39 8 11 Setting the Outlet Pressure 40 8 12 Connecting to Common Alarm Terminals 41 8 13 Connecting to Power Fail Alarm Te...

Page 5: ...essure Alarm 87 13 6 Can t Create a High Pressure Alarm 87 13 7 Low Outlet Pressure Alarm 88 13 8 Can t Create a Low Pressure Alarm 88 13 9 High Humidity 89 13 10 Can t Create a High Humidity Alarm Sh...

Page 6: ...s 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 E...

Page 7: ...EGAS is NOT RECOMMENDED 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...

Page 8: ...not contain an internal Surge Protection Device SPD If an SPD is required it must be supplied by the user CAUTION Observe precautions for handling Electrostatic Sensitive Devices IMPORTANT Installati...

Page 9: ...les 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 Features LCD display of...

Page 10: ...51 71 kPa 13 8 414 0 kPa 13 8 103 4 kPa 2 07 51 71 kPa 13 8 414 0 kPa Outlet Air Humidity Less than 2 RH Compressor Type Two cylinder 3 4 HP oil less type Drying Method Heatless Desiccant Operating Te...

Page 11: ...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 8 A...

Page 12: ...ll 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 beco...

Page 13: ...dryer 6 2 3 1 Well ventilated and free from abrasive dust or chemicals 6 2 3 2 Ambient temperature is between 5 and 30 C optimal NOTE Higher temperatures will decrease component lifespan 6 2 3 3 Meet...

Page 14: ...tion Guide not shown Package located inside the dryer 1 120 VAC Power Cord for P1500W2 P1500W2LP P1500W2HP models 1 220 VAC Power Cord for P1502W2 P1502W2LP P1502W2HP models 1 Precision Bleed Orifice...

Page 15: ...ng materials 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 latches and remove the Front Panel 6...

Page 16: ...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 17: ...nting Kit P011674 section 11 4 For wall install use Wall Mounting Kit P011773 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 c...

Page 18: ...ort 6 5 13 Set the System Pressure With Compressor running 6 5 13 1 Pull the Capacity Control Valve knob out 6 5 13 2 Turn the knob until the reading on the pressure gauge is 552 kPa for W2 W2LP 621 k...

Page 19: ...leed Orifice fitting from 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...

Page 20: ...he Static Pressure 6 5 19 1 Pull Static Pressure Regulator knob out 6 5 19 2 Turn knob until the reading on the pressure gauge is 117 kPa for W2 W2LP 414 kPa for W2HP 6 5 19 3 Push knob in to lock 6 5...

Page 21: ...t DO NOT SOAP TEST THE HUMIDITY SENSOR FITTING DAMAGE TO THE SENSOR MAY OCCUR With Compressor NOT running 6 5 21 1 Listen for any hissing sounds which may indicate a fitting or hose air leak With Comp...

Page 22: ...shipping damage was detected Dryer location meets the following requirements o Well ventilated o Free from abrasive dust or chemicals o Ambient temperature is between 5 and 30 C optimal Shipping foam...

Page 23: ...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 www puregas...

Page 24: ...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 contact w...

Page 25: ...g Air Supply Line to the Dryer 8 2 1 Connect the air supply line to the Outlet Port NOTE For all dryers with minimal FLOW Install the included Precision Bleed Orifice fitting to maintain a constant ai...

Page 26: ...stem to continue operating 8 4 3 HOLD Button Freezes the current information screen on the display When pressed again it will allow the information screens to begin cycling again 8 4 4 Arrow Buttons U...

Page 27: ...P1500W2HP P1502W2HP models OUTP Outlet Pressure regulated by the Outlet Pressure Regulator HUMIDITY Humidity level of the system CABINET Temperature of the dryer cabinet compartment 8 4 5 2 System Sta...

Page 28: ...t Pressure Alarm Occurs when the Outlet Pressure OUTP drops below the alarm set point for more than one 1 minute Default setting is 45 0 kPa for W models 2 07 kPa for WLP models 172 0 kPa for WHP mode...

Page 29: ...roubleshooting information 8 5 5 High Duty Cycle Alarm Occurs when the Duty Cycle rises above the alarm set point for more than one 1 minute Default setting is 70 See section 13 17 for troubleshooting...

Page 30: ...rrow Button to access the Set Point Adjust screens Press the Up Down Arrow Buttons to navigate through the available Set Point Adjust screens To change a specific Set Point 8 6 1 High Flow Rate Alarm...

Page 31: ...ss the Change Value Screen 8 6 2 2 Press the Right Left Arrow Buttons to move the underscore beneath the digit to change 8 6 2 3 Press the Up Down Arrow Buttons to change the value of the selected dig...

Page 32: ...cess the Change Value Screen 8 6 3 2 Press the Right Left Arrow Buttons to move the underscore beneath the digit to change 8 6 3 3 Press the Up Down Arrow Buttons to change the value of the selected d...

Page 33: ...Press the Right Left Arrow Buttons to move the underscore beneath the digit to change 8 6 4 3 Press the Up Down Arrow Buttons to change the value of the selected digit 8 6 4 4 Press the Right Arrow B...

Page 34: ...2 Press the Right Left Arrow Buttons to move the underscore beneath the digit to change 8 6 5 3 Press the Up Down Arrow Buttons to change the value of the selected digit 8 6 5 4 Press the Right Arrow...

Page 35: ...is it time for maintenance 8 6 6 1 Press the Right Arrow Button to access the Change Value Screen 8 6 6 2 Press the Right Left Arrow Buttons to move the underscore beneath the digits to change to zer...

Page 36: ...irm This will lock in the factory default values 8 6 8 Alarm Delays Set Point The Alarm Delay allows the dryer to come out of the alarm condition on its own without signaling an alarm ON default waits...

Page 37: ...case of a power loss 8 6 9 1 Press the Right Arrow Button to access the Change Value Screen 8 6 9 2 Press the Right Left Arrow Buttons to move the underscore beneath the digit to change 8 6 9 3 Press...

Page 38: ...arms while in use This screen can be used during air dryer troubleshooting 8 7 Open Front Panel 8 7 1 Open Front Panel latches and remove the Front Panel 8 8 Depressurizing the Dryer 8 8 1 Open Front...

Page 39: ...Front Panel section 8 7 8 9 2 Pull the Capacity Control Valve knob out 8 9 3 Turn the knob until the reading on the Pressure Gauge is 552 kPa for W and WLP 621 kPa for WHP 8 9 4 Push the knob in to lo...

Page 40: ...10 4 Push knob in to lock 8 10 5 Close Front Panel 8 11 Setting the Outlet Pressure 8 11 1 Open Front Panel section 8 7 8 11 2 Pull the Outlet Pressure Regulator knob out or loosen the retaining nut...

Page 41: ...Common Alarm Terminals 8 12 1 Open Front Panel section 8 7 8 12 2 Locate the external Common Alarm pins on the Control Board 8 12 3 Wire the Common Alarm wire pair to the Control Board as required COM...

Page 42: ...Fail Alarm Terminals 8 13 1 Open Front Panel section 8 7 8 13 2 Locate the external Power Fail pins on the Control Board 8 13 3 Wire the Power Fail Alarm wire pair to the Control Board as required PW...

Page 43: ...wser If the Air Dryer IS NOT connected to an IP network and has not been configured with IP information Use the default IP Address 192 168 1 100 of the air dryer to connect Use an IP Cable may require...

Page 44: ...s of Set Points Setups and Keyword can be made in this screen Event Screen Displays all events such as alarms changes made and alarm resets registered by the P1500W2 Series Air Dryer This screen is in...

Page 45: ...and alarms monitored in the P1500W2 Series Air Dryer Provides remote ALARM RESET Readings are displayed in BLACK unless an alarm is present Alarms are displayed in RED next to the parameter in alarm...

Page 46: ...uide Page 46 of 100 P012253 Rev H 8 15 1 Resetting an Alarm 8 15 1 1 Click on the ALARM RESET Button to remotely reset Air Dryer alarms displayed on Status Screen 8 15 1 2 Enter Keyword default is 123...

Page 47: ...00 P012253 Rev H 8 15 2 Resetting Compressor Total Run Time 8 15 2 1 Click on the RESET TOTAL RUN TIME Button to remotely reset Compressor Total Run Time displayed on Status Screen 8 15 2 2 Enter Keyw...

Page 48: ...yword 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 ACCEPT Button is used to change values The CHANGE...

Page 49: ...8 16 1 Changing a Set Point or Setup value 8 16 1 1 Click on the value to change 8 16 1 2 Type in the new value 8 16 1 3 Click the ACCEPT Button when done 8 16 1 4 Enter Keyword default is 123456 8 1...

Page 50: ...ev H 8 16 2 Changing the Keyword 8 16 2 1 Click on CHANGE KEYWORD Button to change the keyword 8 16 2 2 Type the Old Keyword 8 16 2 3 Type the New Keyword 8 16 2 4 Type the Confirm New Keyword 8 16 2...

Page 51: ...e Event Screen Displays all events such as alarms changes made and alarm resets registered by the P1500W2 Series Air Dryers This screen is informational only Click on the column headings to sort data...

Page 52: ...3 Rev H 8 18 Using the Alarm Screen Displays all the Alarms registered by the P1500W2 Series Air Dryers This screen is informational only Click on the column headings to sort data according to that co...

Page 53: ...and date of the P1500W2 Series Air Dryers Current Version Displays the current firmware version of the P1500W2 Air Dryer New Version File Displays the new location and new firmware version chosen The...

Page 54: ...Firmware 8 19 1 1 Click on BROWSE Button to locate the firmware file 8 19 1 2 Navigate and select the correct bin file Press the OK Button 8 19 1 3 Click the ACCEPT Button 8 19 1 4 Enter Keyword defa...

Page 55: ...network This software requires a SNMP Definition Configuration File MIB file in order to properly communicate with the Air Dryer The files for the P1500W Series Air Dryers can be downloaded from our...

Page 56: ...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 57: ...Compressor running the running amps should measure 6 3 amps or below for the P1500W2 P1500W2LP P1500W2HP models 3 2 or below for the P1502W2 P1502W2LP P1502W2HP models 9 2 4 Close Front Panel If the...

Page 58: ...over wire 6 9 3 6 Power the air dryer ON section 8 3 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 f...

Page 59: ...e metal contacts for BLACK BROWN wire and WHITE BLUE wire The voltage should measure 110 125 VAC for the P1500W2 P1500W2LP P1500W2HP models 208 230 VAC for the P1502W2 P1502W2LP P1502W2HP models 9 4 4...

Page 60: ...7 9 5 2 Locate the Solid State Relay inside the Dryer at the top of back wall With the Compressor running 9 5 3 Use a Voltmeter to measure across the AC terminals Should measure 0 VAC 9 5 4 Use a Vol...

Page 61: ...2W2 P1502W2LP P1502W2HP models 9 5 6 Use a Voltmeter to measure across the DC terminals Should measure 0 VDC 9 5 7 Close Front Panel If any of the AC voltage measurements are different than indicated...

Page 62: ...l section 8 7 9 6 2 Place a piece of insulating material over the Compressor for this test i e piece of cardboard 9 6 3 Locate the heatless dryer purge solenoids inside the air dryer WARNING Internal...

Page 63: ...or 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 9 6 5 Remove insulating material from top of the Compresso...

Page 64: ...loader Valve 9 7 4 Place your hand under the Unloader Valve to verify for air flow The Unloader Valve should purge all the head pressure when the Compressor turns off and for approximately 2 seconds w...

Page 65: ...VALVE Right solenoid 9 8 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...

Page 66: ...m section 14 1 Replace defective fan see sections 11 1 for part detail and 11 5 for ordering information Replace defective Control Board if fan does not respond properly to temperature changes see sec...

Page 67: ...the Compressor shuts down when the tank pressure TANK reaches 620 kPa If the tank pressure TANK fails to reach 620 kPa see section 13 15 for troubleshooting information With Compressor NOT running 9...

Page 68: ...ation 9 12 Testing High Duty Cycle Alarm 9 12 1 Open Front Panel section 8 7 9 12 2 Allow the Compressor to run and then turn off 9 12 3 Immediately after the Compressor turns off pull the ring handle...

Page 69: ...0 P012253 Rev H 9 13 Testing Humidity Alarm and System Shutdown 9 13 1 Power the air dryer OFF 9 13 2 Open Front Panel section 8 7 9 13 3 Depressurize the air dryer 9 13 4 Unscrew and remove the Humid...

Page 70: ...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 the Humidity alar...

Page 71: ...ulator knob out or loosen the retaining nut LP Models 9 14 4 Turn knob clockwise until Outlet Pressure OUTP reading climbs over 83 kPa for P1500W2 P1502W2 models 51 71 kPa for P1500W2LP P1502W2LP mode...

Page 72: ...ng 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 7 9 15 3 Pull the Outlet Pressure Regulator knob...

Page 73: ...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 74: ...R 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 on...

Page 75: ...on 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 mo...

Page 76: ...ng routine maintenance as outlined in the Maintaining Your Dryer section will ensure optimal performance over the lifecycle of your air dryer IMPORTANT After performing any maintenance always soap tes...

Page 77: ...Set System Pressure 552 kPa for P1500W2 P1500W2LP P1502W2 P1502W2LP models 621 kPa for P1500W2HP P1502W2HP models 8 9 Set Static Pressure 117 kPa for P1500W2 P1500W2LP P1502W2 P1502W2LP models 414 kP...

Page 78: ...Read Record Flow Rate FLOW 8 4 5 2 Measure Record Compressor Amp Draw 9 2 Set System Pressure 552 kPa for P1500W2 P1500W2LP P1502W2 P1502W2LP models 621 kPa for P1500W2HP P1502W2HP models 8 9 Set Stat...

Page 79: ...ision Bleed Orifice Fitting P013349 1 Power Switch M038428 1 Fan P1500W2 Series 1120VAC P1502W2 Series 220 VAC P4080 P040801 1 Static Pressure Regulator W2 W2LP models W2HP models P010279 P010622 1 Ai...

Page 80: ...2HP models P010279 P012316 P010622 1 Flow Block 1 Unloader Valve P1500W2 Series 110 VAC P1502W2 Series 220 VAC P011022 P010453 1 Safety Relief Valve P011777 1 Control Board W2 models W2LP models W2HP...

Page 81: ...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 82: ...Compressor muffler and humidity sensor P011910 2 8 000 Hour Maintenance Kit Includes heatless dryer maintenance kit and Compressor maintenance kit P012252 1 Universal Rack Mounting Kit Includes mount...

Page 83: ...contact the PUREGAS Inside Sales Service department to order 800 521 5351 option 2 Fax 303 657 2205 sales puregas com parts puregas com IMPORTANT Instruction for the replacement of individual listed c...

Page 84: ...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 Circ...

Page 85: ...ion 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 fol...

Page 86: ...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 performin...

Page 87: ...ion 8 6 2 Raise High Outlet Pressure Alarm set point section 8 6 2 13 6 Can t Create a High Pressure Alarm Possible Cause Check Corrective Action Defective Outlet Pressure Regulator Verify that the Ou...

Page 88: ...section 9 16 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 Pressur...

Page 89: ...in acceptable levels Raise High Humidity Alarm set point section 8 6 4 Over 10 not recommended Defective Humidity Sensor Perform the Testing Humidity Alarm and System Shutdown test section 9 13 Troubl...

Page 90: ...te Replace Control Board if no alarm is created and system does not shut down section 11 2 13 11 High Flow Rate Alarm Possible Cause Check Corrective Action Air leak in downstream cable outside of dry...

Page 91: ...esn t Operate Possible Cause Check Corrective Action System is in Shutdown state On the Display Panel verify that the system is in SHUTDOWN state Press the RESET Button Defective Compressor Measure Co...

Page 92: ...tween Compressor 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...

Page 93: ...d Valve is defective Replace Solenoid Valves included in the 8 000 Hour Maintenance Kit section 11 4 Defective Solid State Relay Measure AC voltages at Solid State Relay section 9 5 If measurements ar...

Page 94: ...asurements are incorrect replace Control Board section Error Reference source not found 13 20 Contacting PUREGAS Technical Support Please read the Before You Call PUREGAS section 13 1 Once you have ex...

Page 95: ...PUREGAS LLC P1500W2 Series Air Dryers User s Guide Page 95 of 100 P012253 Rev H 14 Appendix 14 1 Wiring Diagram...

Page 96: ...45 0 2 07 172 0 kPa High Humidity Alarm 3 15 10 YES High Duty Cycle Alarm 0 99 70 High Cabinet Temperature Alarm 48 8 Deg C YES Compressor Total Run Time Alarm 8000 Hours 14 2 3 System Operations Desc...

Page 97: ...umeric DEG C Compressor Total Run Time Reading Numeric Hours Duty Cycle Reading Numeric System Status ON SHUTDOWN Compressor Status ON OFF Fan Status ON OFF Heater Status Outdoor Unit Only ON OFF Alar...

Page 98: ...e 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 sh...

Page 99: ...olorado 80020 800 521 5351 303 427 3700 Fax 303 657 2233 info puregas com www puregas com 16 2 Sales 800 521 5351 option 2 Fax 303 657 2205 sales puregas com parts puregas com 16 3 Service 800 521 535...

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