Puregas P4200W2, User Manual

Page 1: ...P012308 Rev E P4200W2 Series Air Dryer User s Guide Models covered P4200W2 P4200W2LP P4202W2 P4202W2LP P4202W2H...

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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: ...Panel 48 8 11 Removing the Top Cover 48 8 12 Depressurizing the Dryer 49 8 13 Connecting to Common Alarm Socket 49 8 14 Setting the System Pressure 50 8 15 Setting the Static Pressure 51 8 16 Setting...

Page 5: ...ning 99 13 5 High Outlet Pressure Alarm 99 13 6 Can t Create a High Pressure Alarm 100 13 7 Low Outlet Pressure Alarm 100 13 8 Can t Create a Low Pressure Alarm 101 13 9 High Flow Rate Alarm 101 13 10...

Page 6: ...tention 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 pr...

Page 7: ...ing Your Dryer section will ensure optimal performance over the lifecycle of your air dryer CAUTION Incoming power to dryer must be 15 amp service recommended 10 amp slow blow fuse 110 125 VAC 50 60 H...

Page 8: ...t be supplied by the user CAUTION Observe precautions for handling Electrostatic Sensitive Devices IMPORTANT Installation of PUREGAS air dryers are intended for network telecommunication facilities no...

Page 9: ...easier access for adjustment and maintenance and ultra quiet compressors with an industry leading maintenance interval of 8 000 hours 5 2 Key Features LCD display of all operating parameters Solid st...

Page 10: ...15 Amp service recommended Outlet Pressure Range 35 138 KPa 2 69 KPa 35 138 KPa 2 69 KPa 35 138 KPa Outlet Air Humidity Less than 2 RH Compressor 2 cylinder 3 4 HP oil less type compressor Drying Met...

Page 11: ...d air 5 Capacity Control Valve Regulates System Pressure at 345 KPa 50 PSI and prevents air from bleeding back through the Heatless Dryer 6 Air Tank Stores dry compressed air 7 Static Pressure Regulat...

Page 12: ...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 13: ...lated 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 Meets the following power req...

Page 14: ...side the dryer 2 Alarm Connector 1 User s Guide not shown 1 Mini CD not shown 1 Allen Wrench 1 Purge Muffler 1 Compressor Connector Tool 1 Power Cord 6 4 Required Tools and Materials Large adjustable...

Page 15: ...NG DAMAGE is detected file a claim with the shipping company prior to continuing the installation procedures 6 5 2 Place the dryer at the operating location 6 5 3 Remove the Front Panel 6 5 4 Check fo...

Page 16: ...nch remove the shipping block from under the Compressor Plate Discard block and bolt 6 5 6 Remove the ship loose contents package On BACK of dryer 6 5 7 Verify that the Red Orifice Plug is still insta...

Page 17: ...outlet 110 125 VAC power outlet for P4200W2 and P4200W2LP model 220 230 VAC 1 phase power outlet for P4202W2 P4202W2LP and P4202W2H models 6 5 12 Power the dryer ON NOTE The Compressor and Heatless D...

Page 18: ...E 6 5 13 2 Turn the knob until the reading on the Pressure Gauge is 345 KPa 50 PSI 6 5 13 3 Push the knob in to lock 6 5 14 Let the dryer run until the Humidity drops below 2 may take up to 15 minutes...

Page 19: ...Be careful when removing plug System may be pressurized 6 5 17 Connect the air supply line to the Outlet Pressure Port PUREGAS recommends using Installation Kit P011752 to connect your air dryer to th...

Page 20: ...sure Gauge is 138 KPa 20 PSI 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 the retaining nut LP models 6 5 20 2 Turn knob...

Page 21: ...NOT running 6 5 21 1 Listen 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 hos...

Page 22: ...Common and N O for CLOSE ON ALARM operation 6 5 24 REGISTER YOUR DRYER See section 7 for details 6 6 Installation Checklist No shipping damage was detected Dryer location meets the following requirem...

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: ...hock 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 with internal components as there is a...

Page 25: ...supply line to the Outlet Pressure Port PUREGAS 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...

Page 26: ...CTION Button Acts as a HOLD button to freeze the current information screen on the display When pressed again it will allow the information screens to begin cycling again Acts as an ENTER button in th...

Page 27: ...Sys Status Screen SYS STATUS Running Status of the system ONLINE System is Online SHUTDOWN System has been shutdown as a result of either a High Humidity or High Cabinet Temperature alarm CAB TEMP Te...

Page 28: ...CLE The percentage of time the Compressor is ON versus time it is OFF during the last Air Tank pressurization cycle TOTAL How many hours the Compressor has run since the last Compressor Total Time Res...

Page 29: ...displayed showing the Date and Time that the alarm occurred 8 5 1 1 Press the Info Button to see the detail of the alarm See section 13 12 for troubleshooting information 8 5 2 High Humidity Alarm Oc...

Page 30: ...ime that the alarm occurred 8 5 3 1 Press the Info Button to see the detail of the alarm See section 13 7 for troubleshooting information 8 5 4 High Outlet Pressure Alarm Occurs when the Outlet Pressu...

Page 31: ...that the alarm occurred 8 5 5 1 Press the Info Button to see the detail of the alarm See section 13 9 for troubleshooting information 8 5 6 High Duty Cycle Alarm Occurs when the Duty Cycle DUTY CYCLE...

Page 32: ...Time Alarm Occurs when the Compressor has reached an 8 000 Hour maintenance interval Perform the required maintenance This screen will be displayed showing the Date and Time that the alarm occurred 8...

Page 33: ...olds is factory programmed with a default value Many of can be modified to levels based upon your specific application Network Setup Used to configure network settings including the IP Address Subnet...

Page 34: ...lay default setting is ON 8 7 3 1 Press the Enter Button to access the edit screen 8 7 3 2 Press the Left Right Arrow Buttons to Select the correct choice On or Off 8 7 3 3 Press the Enter Button to s...

Page 35: ...Buttons to Select the digit to change 8 7 5 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 7 5 4 Press the Enter Button to submit the new setting 8 7 5 5 Press the Left...

Page 36: ...firm the selected choice This will reset the Total Time to zero 0 8 7 8 Press the Up Arrow Button to access the next screen 8 7 9 Reset To Factory Default Values 8 7 9 1 Press the Enter Button to acce...

Page 37: ...the digit to change 8 7 11 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 7 11 4 Press the Enter Button to submit the new setting 8 7 11 5 Press the Left Right Arrow But...

Page 38: ...ress the Enter Button to access the edit screen 8 8 3 2 Press the Left Right Arrow Buttons to select the digit to change 8 8 3 3 Press the Up Down Arrow Buttons to Change the value of the selected dig...

Page 39: ...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 Press the Enter Button when to submit the new setting 8 8 5 5 Press the...

Page 40: ...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 new setting 8 8 7 5 Press the...

Page 41: ...uttons to Select the digit to change 8 8 9 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 8 9 4 Press the Enter Button when to submit the new setting 8 8 9 5 Press the L...

Page 42: ...ttons to Select the digit to change 8 8 11 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 8 11 4 Press the Enter Button when to submit the new setting 8 8 11 5 Press the...

Page 43: ...rrow Buttons to Select the N in Network Setup 8 9 1 1 Press the Enter Button to access Network Setup 8 9 2 Enter Keyword default Keyword is 123456 8 9 2 1 Press the Left Right Arrow Buttons to Select...

Page 44: ...to Select the digit to change 8 9 3 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 9 3 4 Press the Enter Button when to submit the new setting 8 9 3 5 Press the Left Ri...

Page 45: ...ns to Select the digit to change 8 9 5 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 9 5 4 Press the Enter Button when to submit the new setting 8 9 5 5 Press the Left...

Page 46: ...tons to Select the digit to change 8 9 7 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 9 7 4 Press the Enter Button when to submit the new setting 8 9 7 5 Press the Lef...

Page 47: ...e Left Right Arrow Buttons to Select the digit to change 8 9 9 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 9 9 4 Press the Enter Button when to submit the new setting...

Page 48: ...s 8 10 2 Pull the Front Panel away from the dryer 8 11 Removing the Top Cover 8 11 1 Use he included Allen Wrench to unlock the two 2 Trigger Latches 8 11 2 Depress the two 2 Trigger Latches 8 11 3 Li...

Page 49: ...ssure is released NOTE To prevent pressure from building back up power the dryer OFF section 8 3 8 12 3 Reinstall the Front Panel section 8 10 8 13 Connecting to Common Alarm Socket 8 13 1 Insert the...

Page 50: ...the System Pressure 8 14 1 Remove the Front Panel section 8 10 With Compressor running 8 14 2 Pull the Capacity Control Valve knob out 8 14 3 Turn the knob until the reading on the Pressure Gauge is 3...

Page 51: ...E 8 15 Setting the Static Pressure 8 15 1 Remove the Front Panel section 8 10 8 15 2 Pull the Static Pressure Regulator knob out 8 15 3 Turn knob until the reading on the Pressure Gauge is 138 KPa 20...

Page 52: ...16 Setting the Outlet Pressure 8 16 1 Remove the Front Panel section 8 10 8 16 2 Pull the Outlet Pressure Regulator knob out 8 16 3 Turn knob until Outlet Pressure OUTLET reading is at the desired se...

Page 53: ...ox Web Browser 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 m...

Page 54: ...r System Alarms Network and Keyword can be made in this screen Event Screen Displays all events such as alarms changes made and alarm resets registered by the P4200W2 Series Air Dryer This screen is i...

Page 55: ...larms monitored in the P4200W2 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 Alarm...

Page 56: ...uide Page 56 of 113 P012308 Rev E 8 18 1 Resetting an Alarm 8 18 1 1 Click on the ALARM RESET Button to remotely reset Air Dryer alarms displayed on Status Screen 8 18 1 2 Enter Keyword default is 123...

Page 57: ...308 Rev E 8 18 2 Resetting a Compressor Total Run Time 8 18 2 1 Click on the RESET COMPRESSOR TOTAL RUN TIME Button to remotely reset Compressor Total Run Time displayed on Status Screen 8 18 2 2 Ente...

Page 58: ...ns for the System Alarms Network and Keyword can be made in this screen Values in BLUE represent the current setting The ENTER Button is used to change values The CHANGE KEYWORD Button allows you to c...

Page 59: ...8 19 1 Changing a Threshold or Setup value 8 19 1 1 Click on the value to change 8 19 1 2 Type in the new value 8 19 1 3 Click the ENTER Button when done 8 19 1 4 Enter Keyword default is 123456 8 19...

Page 60: ...v E 8 19 2 Changing the Keyword 8 19 2 1 Click on CHANGE KEYWORD Button to change the keyword 8 19 2 2 Type the Old Keyword 8 19 2 3 Type the New Keyword 8 19 2 4 Type the Confirm New Keyword 8 19 2 5...

Page 61: ...e Event Screen Displays all events such as alarms changes made and alarm resets registered by the P4200W2 Series Air Dryer This screen is informational only Click on the column headings to sort data a...

Page 62: ...8 Rev E 8 21 Using the Alarm Screen Displays all the Alarms registered by the P4200W2 Series Air Dryer This screen is informational only Click on the column headings to sort data according to that col...

Page 63: ...date of the P4200W2 Series Air Dryer Current Version Displays the current firmware version of the P4200W2 Series Air Dryer New Version File Displays the new location and new firmware version chosen Th...

Page 64: ...Firmware 8 22 1 1 Click on BROWSE Button to locate the firmware file 8 22 1 2 Navigate and select the correct bin file Press the OK Button 8 22 1 3 Click the ENTER Button 8 22 1 4 Enter Keyword defau...

Page 65: ...ic 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 This file is named PuregasP420...

Page 66: ...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 component...

Page 67: ...ssor running the running amps should measure 8 6 amps or below for the P4200W2 P4200W2LP models 3 9 or below for the P4202W2 P4202W2LP models 4 2 or below for the P4202W2H model If the Compressor meas...

Page 68: ...he voltage between the BLACK and WHITE wires 9 3 3 1 Place the Voltmeter probes in the openings in the power connector The voltage should measure 110 125 VAC for the P4200W2 P4200W2LP models 220 230 V...

Page 69: ...t they touch the metal contacts The voltage should measure 110 125 VAC for the P4200W2 P4200W2LP models 220 230 VAC for the P4202W2 P4202W2LP P4202W2H models If any of the voltage measurements are dif...

Page 70: ...that they touch the metal contacts The voltage should measure 110 125 VAC for the P4200W2 P4200W2LP models 220 230 VAC for the P4202W2 P4202W2LP P4202W2H models If the incoming voltage measures less...

Page 71: ...6 2 Locate the Solid State Relay inside the Top Section of the air dryer With the Compressor running 9 6 3 Use a Voltmeter to measure across the AC terminals The voltage should measure 0 VAC 9 6 4 Us...

Page 72: ...the P4200W2 P4200W2LP models 220 230 VAC for the P4202W2 P4202W2LP P4202W2H models 9 6 6 Use a Voltmeter to measure across the DC terminals The voltage should measure 0 VDC 9 6 7 Reinstall the Top Cov...

Page 73: ...the Heatless Dryer 9 7 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 from Tower 1 side 30 Seco...

Page 74: ...and 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 Compressor shuts off 9 8 4 Re conne...

Page 75: ...LVE Right solenoid 9 9 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 me...

Page 76: ...ce defective fan see sections 11 3 for part detail and 11 7 for ordering information 9 11 Testing Safety Relief Valve 9 11 1 Remove the Front Panel section 8 10 9 11 2 Pull the ring handle on the Safe...

Page 77: ...ure TANK reaches 345 KPa If the Tank Pressure TANK fails to reach 345 KPa see section 13 15 for troubleshooting information With Compressor NOT running 9 12 4 Pull the ring handle on the Safety Relief...

Page 78: ...r run and then turn off 9 13 3 Immediately after the Compressor turns off pull the ring handle on the Safety Relief Valve until the Compressor turns on again A High Duty Cycle Alarm should appear on t...

Page 79: ...13 P012308 Rev E 9 14 Testing Humidity Alarm and System Shutdown 9 14 1 Power the air dryer OFF 9 14 2 Remove the Front Panel section 8 10 9 14 3 Depressurize the air dryer 9 14 4 Unscrew and remove t...

Page 80: ...14 8 Replace the Humitter into the Combo Block 9 14 9 Press the RESET Button to clear the alarm 9 14 10 Reinstall the Front Panel section 8 10 NOTE If the Humitter is disconnected from the Control Bo...

Page 81: ...reading 9 15 2 Remove the Front Panel section 8 10 With Compressor running 9 15 3 Pull the Outlet Pressure Regulator knob out 9 15 4 Turn knob clockwise until Outlet Pressure OUTLET reading climbs ov...

Page 82: ...Panel section 8 10 If you are unable to create a High Outlet Pressure Alarm as described see section 13 6 for troubleshooting information 9 16 Testing Low Outlet Pressure Alarm 9 16 1 Make a note of t...

Page 83: ...6 Press the RESET Button to clear the alarm 9 16 7 Turn Outlet Pressure Regulator knob clockwise until Outlet Pressure OUTLET reading raises to the reading recorded in step 9 16 1 9 16 8 Push knob in...

Page 84: ...R MAY OCCUR With Compressor NOT running 9 17 1 Listen for any hissing sounds which may indicate a fitting or hose air leak With Compressor running 9 17 2 Use a 1 inch paint brush to dab soapy water on...

Page 85: ...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 86: ...s Also check for any loose or disconnected wiring CAUTION SHUT DOWN IMMEDIATELY FOR REPAIRS if the air compressor shows any evidence of overheating or presents excessive noise CAUTION Depressurizing t...

Page 87: ...oltage 9 5 Test High Low Outlet Pressure Alarms 9 15 9 16 Set System Pressure 345 KPa 50 PSI 8 14 Set Static Pressure 138 KPa 20 PSI 8 15 Set Outlet Pressure 8 16 Test Consistent Heatless Dryer Cyclin...

Page 88: ...40 000 Install 8 000 Hour Maintenance Kit P011471 Install P012519 for P4202W2H ONLY 11 6 Read Record Flow Rate FLOW 8 4 5 2 Measure Record Compressor Amp Draw 9 2 Set System Pressure 345 KPa 50 PSI 8...

Page 89: ...ection Parts Description Part Number Quantity Recommend Spare P4200W2 P4200W2LP 120 VAC P4202W2 P4202W2LP P4202W2H 220 VAC Power IEC Connector P012279 1 Power Line Filter P011628 1 Circuit Breaker P06...

Page 90: ...0W2LP 120 VAC P4202W2 P4202W2LP P4202W2H 220 VAC Precooler P4642 1 Heatless Dryer Assembly See section 11 4 for detail Static Pressure Gauge 0 30 PSI P013339 1 Humitter P011380 1 Temperature Sensor P0...

Page 91: ...Section Parts 2 Description Part Number Quantity Recommend Spare P4200W2 P4200W2LP 120 VAC P4202W2 P4202W2LP 220 VAC P4202W2H 220VAC Fan P012366 P012368 1 Static Pressure Regulator P013203 1 1 Flow Bl...

Page 92: ...are P4200W2 P4200W2LP 120 VAC P4202W2 P4202W2LP 220 VAC P4202W2H 220 VAC Heatless Dryer Assembly PHF2C112041 PHF2C212041 PHF2C212045 1 Capacity Control Valve P4634 1 1 Pressure Gauge 0 100 PSI P010695...

Page 93: ...arts Description Part Number Quantity Recommend Spare Front Panel 1 Trigger Latch 6 Air Intake Filter In Kit P012314 See section 11 6 for detail In Kit P012514 for P4202W2H ONLY Top Cover 1 Fan Guard...

Page 94: ...752 Six Month Maintenance Kit Includes air intake filter compressor air intake filter and purge muffler P012314 P4202W2H P012514 2 8 000 Hour Maintenance Kit Includes heatless dryer maintenance kit an...

Page 95: ...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 96: ...eplace 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...

Page 97: ...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 98: ...t you remove all jewelry before performing any procedures CAUTION Depressurizing the air dryer may be necessary before performing certain procedures NEVER remove pressure sensing tubes from the Contro...

Page 99: ...rect go to next possible cause No incoming voltage to air dryer Measure incoming voltage section 9 5 Troubleshoot facility power supply to air dryer 13 4 Display Screen Not Functioning Possible Cause...

Page 100: ...igher than the High Outlet Pressure threshold above Replace Control Board section 11 1 if Outlet Pressure OUTLET reading is over verified High Outlet Pressure threshold for more than 1 minute and fail...

Page 101: ...hreshold section 8 16 Defective Control Board Verify that the Outlet Pressure OUTLET reading is lower than the Low Outlet Pressure threshold above Replace Control Board section 11 1 if Outlet Pressure...

Page 102: ...tion 8 8 3 Over 10 not recommended Heatless Dryer not cycling between towers Verify consistent Heatless Dryer cycling section 9 7 Troubleshoot Inconsistent Heatless Dryer Cycling condition section 13...

Page 103: ...2 Defective Control Board Verify that Humidity reading is over 15 for more than 1 minute Replace Control Board if no alarm is created and system does not shut down section 11 1 13 12 High Cabinet Tem...

Page 104: ...lace Compressor section 11 5 or send it in for repair section 12 No power to Compressor Measure voltage to Compressor section 9 3 If voltage is not present or fluctuates continue to next Possible Caus...

Page 105: ...High Duty Cycle Alarm Possible Cause Check Corrective Action Low System Pressure Verify System Pressure section 8 14 Adjust System Pressure section 8 14 High Flow condition Verify Flow Rate FLOW readi...

Page 106: ...mpressor has run longer than the verified High Duty Cycle threshold above Replace Control Board section 11 1 if the Compressor runs longer than the verified High Duty Cycle Alarm threshold and fails t...

Page 107: ...e 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 Suppor...

Page 108: ...PUREGAS LLC P4200W2 Series Air Dryer User s Guide Page 108 of 113 P012308 Rev E 14 Appendix 14 1 Wiring Diagram...

Page 109: ...e Alarm 2 0 137 0 2 0 KPa High Flow Rate Alarm 0 119 74 SCMD High Duty Cycle Alarm 0 99 70 Compressor Total Run Time Alarm 8000 Hours High Cabinet Temperature Alarm 46 Deg C Shutdown at 50 C 14 2 3 Sy...

Page 110: ...Cabinet Temperature Reading Numeric DEG C Compressor Total Run Time Reading Numeric Hours Duty Cycle Reading Numeric System Status ON SHUTDOWN STANDBY Compressor Status ON OFF Alarm Readings Read Only...

Page 111: ...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 112: ...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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