RFS BD4200W Series, User Manual

Page 1: ...100518835 Rev B BD4200W Series Air Dryer User s Guide Models covered BD4200W BD4200WLP BD4202W BD4202WLP ...

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Page 3: ...rld 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 to the RFS BD4200W Series Air Dryer Models covered include BD4200W BD4200WLP BD4202W and BD4202WLP It will cover topics including safety specifications installation registration operation testing...

Page 4: ...ork Setup Menu 45 8 10 Removing the Front Panel 51 8 11 Removing the Top Cover 51 8 12 Depressurizing the Dryer 52 8 13 Connecting to Common Alarm Socket 52 8 14 Setting the System Pressure 53 8 15 Setting the Static Pressure 54 8 16 Setting the Outlet Pressure 55 8 17 Connecting via Web Browser 56 8 18 Using the Status Screen 57 8 19 Using the Setup Screen 60 8 20 Using the Event Screen 62 8 21 U...

Page 5: ...play Screen Not Functioning 100 13 5 High Outlet Pressure Alarm 100 13 6 Can t Create a High Pressure Alarm 101 13 7 Low Outlet Pressure Alarm 101 13 8 Can t Create a Low Pressure Alarm 102 13 9 High Flow Rate Alarm 102 13 10 High Humidity 103 13 11 Can t Create a High Humidity Alarm Shutdown 104 13 12 High Cabinet Temperature Alarm 104 13 13 Inconsistent Heatless Dryer Cycling105 13 14 Compressor...

Page 6: ...ill 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 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 ...

Page 7: ...e pressure sensing tubes from the Control Board without depressurizing the air dryer first or damage to the Control Board will occur CAUTION Incoming power to dryer must be 15 amp service recommended 110 125 VAC 50 60 Hz for BD4200W BD4200WLP models 220 230 VAC 50 60 Hz 1 Phase for BD4202W BD4202WLP models CAUTION Proper Installation Maintenance as outlined in this User s Guide is extremely import...

Page 8: ... Dryer does 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 Installation of RFS air dryers are intended for network telecommunication facilities non customer premises only IMPORTANT Performing procedures not described in this User s Guide or installing compon...

Page 9: ...asier 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 state microprocessor based circuitry eliminates costly maintenance Accurate humidity sensing within 0 1 RH Quietest dryer on the market Pressure Ranges from 5 20 PSIG 35 138 KPa or 0 3 10 PSIG 2 69 KPa LP...

Page 10: ...G 35 138 KPa 0 3 10 PSIG 2 69 KPa 5 20 PSIG 35 138 KPa 0 3 10 PSIG 2 69 KPa Outlet Air Humidity Less than 2 RH Compressor 2 cylinder 3 4 HP oil less type compressor Drying Method Heatless Desiccant Operating Temperature Range 40 to 85 F optimal 5 to 30 C optimal Noise Level 63 dBA 3 Heat Dissipation 3 500 BTU hr 2 900 BTU hr Alarms Standard alarms complete readings of all critical measurement poin...

Page 11: ...m compressed air 5 Capacity Control Valve Regulates System Pressure 50 PSI 345 KPa and prevents air from bleeding back through the Heatless Dryer 6 Air Tank Stores dry compressed air 7 Static Pressure Regulator Regulates the Static Pressure 20 PSI 138 KPa and maintains constant pressure on the Combo Block for accurate Flow measuring 8 Combo Block Measures the Flow of compressed air and houses the ...

Page 12: ...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 components to become hot when in operation or standby CAUTION Proper Installation Maintenance as outlined in this User s Guide is extremely important to ensure the reliability and longevity of the equipment as ...

Page 13: ...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 6 2 3 3 Meets the following power requirements 110 125 VAC for BD4200W and BD4200WLP models 220 230 VAC 1 Phase for BD4202W and BD4202WLP models All models require 50 60 Hz and minimum 15 amp service 6 2 4 No...

Page 14: ...lation Guide not shown Package located inside the dryer 2 Alarm Connector 1 User s Guide not shown 1 Compressor Connector Tool 1 Purge Muffler 1 Power Cord 6 4 Required Tools and Materials Large adjustable wrench Medium adjustable wrench 7 16 wrench Band cutters or snips Pipe dope or pipe thread tape Cup of soapy water 1 inch paint brush recommended ...

Page 15: ...Y SHIPPING 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 for loose parts hoses or wiring NOTE If ANY SHIPPING DAMAGE is detected file a claim with the shipping company prior to continuing the installation procedures ...

Page 16: ...7 16 wrench 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 installed where shown 6 5 8 Install the Purge Muffler optional 6 5 9 Verify that the dryer is powered OFF ...

Page 17: ...wer Cord to an outlet 110 125 VAC power outlet for BD4200W and BD4200WLP model 220 230 VAC 1 phase power outlet for BD4202W BD4202WLP models 6 5 12 Power the dryer ON NOTE The Compressor and Heatless Dryer will start creating air flow through the Red Orifice Plug 6 5 13 Set the System Pressure With Compressor running 6 5 13 1 Pull the Capacity Control Valve knob out ...

Page 18: ...835 Rev B 6 5 13 2 Turn the knob until the reading on the Pressure Gauge is 50 PSI 345 KPa 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 NOTE Press RESET if the dryer goes into SHUTDOWN 6 5 15 Power the dryer OFF ...

Page 19: ...t CAUTION Be careful when removing plug System may be pressurized 6 5 17 Connect the air supply line to the Outlet Pressure Port RFS recommends using Installation Kit P011752 to connect your air dryer to the air supply line See section 11 6 for detail 6 5 18 Power the dryer ON 6 5 19 Set the Static Pressure 6 5 19 1 Pull Static Pressure Regulator knob out ...

Page 20: ...auge is 20 PSI 138 KPa 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 until Outlet Pressure OUTLET reading is at the desired setting 6 5 20 3 Push knob in to lock or tighten retaining nut LP models 6 5 21 Check for air leaks ...

Page 21: ...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 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 fitti...

Page 22: ...peration 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 requirements o Well ventilated o Free from abrasive dust or chemicals o Ambient temperature is between 40 and 85 F optimal Shipping block removed from Compressor Tray System Pressure is set to 50 PSI ...

Page 23: ...cessary 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 RFS products Register Online at www AltecAIRcom registration Or by Phone 1 800 521 5351 option 2 Have the following information available Model Serial Company Name Location Name Shipping Address City State Zip Code Contact Name Phone ext E...

Page 24: ...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 with internal components as there is a potential for some of these components to become hot when in operation or standby IMPORTANT Performing procedures not described in this User s Guide or installing components not supplied ...

Page 25: ...oving plug System may be pressurized 8 2 2 Connect the air supply line to the Outlet Pressure Port RFS recommends using Installation Kit P011752to connect your air dryer to the air supply line See section 11 6 for detail 8 3 Powering the Dryer ON OFF CAUTION Incoming power to dryer must be 15 amp service recommended 110 125 VAC 50 60 Hz for BD4200W BD4200WLP models 220 230 VAC 50 60 Hz 1 Phase for...

Page 26: ...ls the main power to the dryer 8 4 Using the Front Panel Display 8 4 1 ALARM LED Indicates an alarm is present 8 4 2 RESET Button Clears an alarm and allows the system to continue operating CAUTION The Display Screen is covered by a clear protective layer that guards against Electrostatic Discharge ESD DO NOT REMOVE THIS LAYER ...

Page 27: ...ng again Acts as an ENTER button in the Setup Menu screens 8 4 4 Arrow Buttons Used to access navigate and change values in the Setup Menu screens 8 4 5 Contrast Adjust On the back of the LCD there is a knob to ajust the contrast of the display You may adjust this knob if your display is too light or too dark 8 4 6 Display Screen Shows the current dryer readings Will cycle between the following th...

Page 28: ...line SHUTDOWN System has been shutdown as a result of either a High Humidity or High Cabinet Temperature alarm HUMIDITY Humidity level of the system Duty Cycle Percent of time compressor ran during last cycle 8 4 6 2 Outlet Screen OUTLET Outlet Pressure regulated by the Outlet Pressure Regulator FLOW Air Flow Rate TANK Air Tank Pressure fluctuates between 25 50 PSI 172 345 KPa ...

Page 29: ...last Compressor Total Time Reset 8 4 6 4 Unit in Standby Screen Occurs when the dryer is connected to a Cycle Kit and has been switched to Standby Mode 8 5 Identifying Dryer Alarms 8 5 1 High Cabinet Temperature Alarm Occurs when the temperature in the dryer cabinet CAB TEMP rises above 115 F for more than one 1 minute If the temperature rises above 120 F for more than one 1 minute the air dryer w...

Page 30: ...DITY rises above the alarm threshold for more than one 1 minute The air dryer will go into SHUTDOWN mode to prevent saturated air from being delivered to the supply line Default setting is 10 This screen will be displayed showing the Date and Time that the alarm occurred 8 5 2 1 Press the Info Button to see the detail of the alarm See section 13 10 for troubleshooting information 8 5 3 Low Outlet ...

Page 31: ...h Outlet Pressure Alarm Occurs when the Outlet Pressure OUTLET rises above the alarm threshold for more than one 1 minute Default setting is 20 00 PSI 138 KPa This screen will be displayed showing the Date and Time that the alarm occurred 8 5 4 1 Press the Info Button to see the detail of the alarm See section 13 5 for troubleshooting information 8 5 5 High Flow Rate Alarm Occurs when the Flow Rat...

Page 32: ...Last Run Time Alarm Occurs when the Compressor Last Run Time LAST exceeds the alarm threshold during the Air Tank pressurization cycle Default setting is 4 00 minutes This screen will be displayed showing the Date and Time that the alarm occurred 8 5 6 1 Press the Info Button to see the detail of the alarm See section 13 1 for troubleshooting information 8 5 7 Compressor Total Run Time Alarm Occur...

Page 33: ...up Used to set specific values for the system Alarm Setup Used to set the alarm thresholds for specific readings Once the threshold is reached or exceeded this results in an alarm Each of these thresholds 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: ...utton to Escape to the information screens 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 Setup 8 7 3 Set Alarm Delay default setting is ON 8 7 3 1 Press the Enter Button to access the edit screen 8 7 3 2 Press the Up Down Arrow Buttons to Select the correct choice On or Off 8 7 3...

Page 35: ...etting 8 7 4 Press the Up Arrow Button to access the next screen 8 7 5 Set Start Up Delay default setting is 0 seconds 8 7 5 1 Press the Enter Button to access the edit screen 8 7 5 2 Press the Up Down Arrow 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 t...

Page 36: ...ss the Enter Button to access the reset screen 8 7 7 2 Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No 8 7 7 3 Press the Enter Button to confirm 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 access the reset screen 8...

Page 37: ... 8 7 11 Set Date 8 7 11 1 Press the Enter Button to access the edit screen 8 7 11 2 Press the Left Right Arrow Buttons to Select 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 Buttons to Select the correct confirmation choice Yes or No 8 7 11 6 Press...

Page 38: ... 12 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 7 12 4 Press the Enter Button to submit the new setting 8 7 12 5 Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No 8 7 12 6 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 7 1 Firmware Update 8 7 1 1 Insert a USB drive containing an approp...

Page 39: ... Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No and begin the update 8 7 2 System Units 8 7 2 1 Press the Enter Button to access the edit screen 8 7 2 2 Press the Up and Down Arrow Buttons to Change the value 8 7 2 3 Press the Enter Button to submit the new setting 8 7 2 4 Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No...

Page 40: ...change 8 8 3 3 Press the Up Down Arrow Buttons to Change the value of the selected digit 8 8 3 4 Press the Enter Button when to submit the new setting 8 8 3 5 Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No 8 8 3 6 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 8 4 Press the Up Arrow Button to access the next screen ...

Page 41: ... digit 8 8 5 4 Press the Enter Button when to submit the new setting 8 8 5 5 Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No 8 8 5 6 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 8 6 Press the Up Arrow Button to access the next screen 8 8 7 Set Low Pressure Threshold default setting is 0 30 PSI 2 0 KPa 8 8 7 1 Press...

Page 42: ...utton when to submit the new setting 8 8 7 5 Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No 8 8 7 6 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 8 8 Press the Up Arrow Button to access the next screen 8 8 9 Set High Flow Threshold default setting is 2600 SCFD 8 8 9 1 Press the Enter Button to access the edit scree...

Page 43: ...g 8 8 9 5 Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No 8 8 9 6 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 8 10 Press the Up Arrow Button to access the next screen 8 8 11 Set Duty Cycle Threshold default setting is 70 8 8 11 1 Press the Enter Button to access the edit screen 8 8 11 2 Press the Left Right Arrow ...

Page 44: ...lect the correct confirmation choice Yes or No 8 8 11 6 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 8 12 Set Compressor Last Run Threshold default setting is 4 00 min 8 8 12 1 Press the Enter Button to access the edit screen 8 8 12 2 Press the Left Right Arrow Buttons to Select the digit to change 8 8 12 3 Press the Up Down Arrow Buttons to Change the ...

Page 45: ...n to confirm the selected choice This will lock in the new setting 8 8 13 Press the Up Arrow Button to access the next screen 8 9 Using the Network Setup Menu In the Setup Menu 8 9 1 Press the Up Down Arrow 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 Selec...

Page 46: ...nter Button to access the edit screen 8 9 3 2 Press the Left Right Arrow Buttons 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 Right Arrow Buttons to Select the correct confirmation choice Yes or No 8 9 3 6 Press the Enter Button to confirm the sele...

Page 47: ...nge the value of the selected digit 8 9 4 4 Press the Enter Button when to submit the new setting 8 9 4 5 Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No 8 9 4 6 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 9 5 Set Gateway Address default is 000 000 000 000 8 9 5 1 Press the Enter Button to access the edit screen 8...

Page 48: ...ns to Select the correct confirmation choice Yes or No 8 9 5 6 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 9 6 Set SNMP Trap Server default is 000 000 000 000 8 9 6 1 Press the Enter Button to access the edit screen 8 9 6 2 Press the Left Right Arrow Buttons to Select the digit to change 8 9 6 3 Press the Up Down Arrow Buttons to Change the value of th...

Page 49: ...oice This will lock in the new setting 8 9 7 Change Keyword default is 123456 8 9 7 1 Press the Enter Button to access the edit screen 8 9 7 2 Press the Left Right Arrow Buttons 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 Left Right Arrow Buttons to Se...

Page 50: ...s the Enter Button to access the edit screen 8 9 8 2 Press the Up Down Arrow Buttons to Change the value 8 9 8 3 Press the Enter Button when to submit the new setting 8 9 8 4 Press the Left Right Arrow Buttons to Select the correct confirmation choice Yes or No 8 9 8 5 Press the Enter Button to confirm the selected choice This will lock in the new setting 8 9 9 View MAC address 8 9 9 1 The device ...

Page 51: ...g Latches 8 10 2 Pull the Front Panel away from the dryer 8 11 Removing the Top Cover 8 11 1 Use the included Latch Keys to unlock the two 2 Locking Latches 8 11 2 Depress the two 2 Locking Latches 8 11 3 Lift the Top Cover off of the dryer NOTE There is a wire connected between the Top Cover and the dryer s main frame This is used for grounding purposes ...

Page 52: ... air pressure 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 included Alarm Connector into either of the two 2 Alarm Ports 8 13 2 Wire an external alarm wire pair to the Alarm Connector as required Common and N C for OPEN ON ALARM operation Common and N...

Page 53: ...Setting 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 50 PSI 345 KPa 8 14 4 Push the knob in to lock 8 14 5 Reinstall the Front Panel section 8 10 ...

Page 54: ...835 Rev B 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 20 PSI 138 KPa 8 15 4 Push knob in to lock 8 15 5 Reinstall the Front Panel section 8 10 ...

Page 55: ... Rev B 8 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 setting 8 16 4 Push knob in to lock 8 16 5 Reinstall the Front Panel section 8 10 ...

Page 56: ... Cross over cable plugged directly 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 1 101 This will make the Laptop PC compatible with the air dryer Use Internet Explorer 6 0 or newer or Mozilla Firefox Web Browser 8 17 1 Type the IP Address of the BD4200W Series Air Dryer in the Address text...

Page 57: ...B Firmware Screen Allows the user to upload any software updates or upgrades to the Air Dryer 8 17 2 Click on the Menu Bar selection to access a specific screen 8 18 Using the Status Screen Displays the readings and alarms monitored in the BD4200W Series Air Dryer Provides remote ALARM RESET ...

Page 58: ...m is present Alarms are displayed in RED next to the parameter in alarm Alarm Status will display ALARM if any alarms are present Keyword validation is required for ALARM RESET and RESET COMPRESSOR TOTAL RUN TIME 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 ...

Page 59: ...default is 123456 8 18 1 3 Click on SUBMIT Button when done 8 18 2 Resetting 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 Enter Keyword default is 123456 8 18 2 3 Click on SUBMIT Button when done ...

Page 60: ...figurations for the System Alarms Network and Keyword can be made in this screen Values in BLUE represent the current setting The ENTER key is used to change values The CHANGE KEYWORD Button allows you to configure a new Keyword Keyword validation is required for the following o Changing a Threshold value o Changing the Keyword ...

Page 61: ...the ENTER key when done 8 19 1 4 Enter Keyword default is 123456 8 19 1 5 Click on SUBMIT Button when done This will lock in the new setting value 8 19 2 Changing the Keyword 8 19 2 1 Click on the display in the keyword row 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 Click on OK Button to confirm This will lock in...

Page 62: ...r s Guide Page 62 of 114 100518835 Rev B 8 20 Using the Event Screen Displays all events such as alarms changes made and alarm resets registered by the BD4200W Series Air Dryer This screen is informational only Click on the Event Type Header to sort data ...

Page 63: ...lays the current firmware version of the BD4200W Series Air Dryer Current Version Displays the current firmware version of the BD4200W Series Air Dryer New Version File Displays the new location and new firmware version chosen The BROWSE Button allows you to locate the new firmware file The ACCEPT Button is used to change values ...

Page 64: ... This will lock in the new firmware version 8 22 Connecting via SNMP Using SNMP to connect and communicate with the BD4200W Series Air Dryer is dependent upon the 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 BD4200W Series Air Dryers can be downloaded...

Page 65: ...d 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 potential for some of these components to become hot when in operation or standby CAUTION Depressurizing the air dryer may be necessary before performing certain procedures NEVER remove pressure sensing tubes from the control b...

Page 66: ...BLACK wire With the Compressor running the running amps should measure 8 6 amps or below for the BD4200W BD4200WLP models 3 9 or below for the BD4202W BD4202WLP models If the Compressor measures over the recommended running amps see section 13 16 for troubleshooting information 9 2 4 Reinstall the Front Panel section 8 10 WARNING Internal surfaces may be hot Use care when coming into contact with ...

Page 67: ...to measure the 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 BD4200W BD4200WLP models 220 230 VAC for the BD4202W BD4202WLP models 9 3 4 Reinstall the Front Panel section 8 10 WARNING Extreme care should be exercised to avoid contact with live electrical circuits It is highly recomm...

Page 68: ...sulation so that they touch the metal contacts The voltage should measure 110 125 VAC for the BD4200W BD4200WLP models 220 230 VAC for the BD4202W BD4202WLP models If any of the voltage measurements are different than indicated above the Power Line Filter is defective and should be replaced See sections 11 1 for part detail and 0for ordering information 9 4 4 Reinstall the Top Cover section 8 11 W...

Page 69: ...nsulation so that they touch the metal contacts The voltage should measure 110 125 VAC for the BD4200W BD4200WLP models 220 230 VAC for the BD4202W BD4202WLP models 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 9 5 4 Reinstall the Top Cover section 8 11 WARNING Extreme care ...

Page 70: ...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 Use a Voltmeter to measure across the DC terminals The voltage should measure 5 VDC for the BD4200W BD4200WLP models 12 VDC for the BD4202W BD4202WLP models With the Compressor NOT running ...

Page 71: ...ltmeter to measure across the DC terminals The voltage should measure 0 VDC 9 6 7 Reinstall the Top Cover section 8 11 If any of the voltage measurements are different than indicated above the Solid State Relay is defective and should be replaced See sections 11 1 for part detail and 0for ordering information 9 7 Testing Consistent Heatless Dryer Cycling 9 7 1 Remove the Front Panel section 8 10 W...

Page 72: ...conds later Purge from Tower 1 side 30 Seconds later and so on 9 7 4 Re connect the purge tubes to the Heatless Dryer 9 7 5 Reinstall the Front Panel section 8 10 If the Heatless Dryer is not cycling consistently as described see section 13 13 for troubleshooting information 9 8 Testing Unloader Valve 9 8 1 Remove the Front Panel section 8 10 With the Compressor running 9 8 2 Disconnect the unload...

Page 73: ... be released in a short burst when the Compressor shuts off 9 8 4 Re connect the unloader tube to the Unloader Valve 9 8 5 Reinstall the Front Panel section 8 10 If air flows from this valve continuously the Unloader Valve is defective and should be replaced See sections 11 4 for part detail and 0for ordering information 9 9 Measuring Heatless Dryer Solenoid Voltage 9 9 1 Remove the Front Panel se...

Page 74: ...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 BD4200W BD4200WLP models 106 VDC for the BD4202W BD4202WLP models 9 9 4 Reinstall the Front Panel section 8 10 If the voltage does not measure as indicated above this is an indication that the Cycle Timer is defective and s...

Page 75: ...n 14 1 Replace defective fan see sections 11 3 for part detail and 0for 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 Safety Relief Valve to verify air pressure is released 9 11 3 Release ring handle and verify that no air is leaking from the valve 9 11 4 Reinstall the Front Panel section 8 10 If the Safety Relie...

Page 76: ...ssure TANK reaches 50 0 PSI 345 KPa If the Tank Pressure TANK fails to reach 50 PSI see section 13 15 for troubleshooting information With Compressor NOT running 9 12 4 Pull the ring handle on the Safety Relief Valve to release air pressure from the Air Tank 9 12 5 Verify the Compressor turns on when the Tank Pressure TANK falls to 25 0 PSI 345 KPa 9 12 6 Reinstall the Front Panel section 8 10 If ...

Page 77: ...andle on the Safety Relief Valve when necessary to keep the Tank Pressure TANK from reaching 50 PSI 345 KPa This prevents the Compressor from shutting down When the Compressor runs for 4 00 minutes unless adjusted to a different threshold by the user a Compressor Last Run Time Alarm should appear on the System Screen 9 13 4 Press the RESET Button to clear the alarm 9 13 5 Reinstall the Front Panel...

Page 78: ... s Guide Page 78 of 114 100518835 Rev B 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 the Humitter from the Combo Block ...

Page 79: ...ir dryer ON 9 14 6 Allow the Humidity reading to rise over 10 0 9 14 7 After three 3 minutes verify that a Humidity Alarm appears and the dryer goes into SHUTDOWN mode 9 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 ...

Page 80: ...leshooting If you are unable to create a Humidity Shutdown alarm as described see section 13 11 for troubleshooting information 9 15 Testing High Outlet Pressure Alarm 9 15 1 Make a note of the current Outlet Pressure OUTLET 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 ...

Page 81: ...9 15 6 Press the RESET Button to clear the alarm 9 15 7 Turn Outlet Pressure Regulator knob counter clockwise until Outlet Pressure OUTLET reading lowers to the reading recorded in step 9 15 1 9 15 8 Push knob in to lock 9 15 9 Reinstall the Front Panel section 8 10 If you are unable to create a High Outlet Pressure Alarm as described see section 13 6 for troubleshooting information ...

Page 82: ...TLET reading 9 16 2 Remove the Front Panel section 8 10 With Compressor running 9 16 3 Pull the Outlet Pressure Regulator knob out 9 16 4 Turn knob counter clockwise until Outlet Pressure OUTLET reading drops below the alarm threshold section 8 8 7 9 16 5 After one 1 minute verify that a Low Outlet Pressure Alarm appears on the display 9 16 6 Press the RESET Button to clear the alarm ...

Page 83: ...tlet Pressure Alarm as described see section 13 8 for troubleshooting information 9 17 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 DO NOT SOAP TEST THE HUMIDITY SENSOR FITTING DAMAGE TO THE SENSOR MAY OCCUR With Compressor NOT running 9 17 1 Listen for any hissing sounds which may indicate a fitting or...

Page 84: ... 84 of 114 100518835 Rev B 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 85: ...sheets and 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 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 perfor...

Page 86: ...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 hot when in operation or standby CAUTION SHUT DOWN IMMEDIATELY FOR REPAIRS if the air compressor shows any evidence of overheating or presents excessive noise CAUTION Depressurizing the air dryer may be necessary be...

Page 87: ...Guide Page 87 of 114 100518835 Rev B IMPORTANT After performing any maintenance always soap test pressure fittings to check for air leaks Also check for any loose or disconnected wiring CAUTION Observe precautions for handling Electrostatic Sensitive Devices ...

Page 88: ... Low Outlet Pressure Alarms 9 15 9 16 Set System Pressure 50 PSI 345 KPa 8 14 Set Static Pressure 20 PSI 138 KPa 8 15 Set Outlet Pressure 8 16 Test Consistent Heatless Dryer Cycling 9 7 Test Precooler Fan 9 10 Test Safety Relief Valve 9 11 Test Compressor ON OFF Cycling 9 12 Test Compressor Last Run Time Alarm 9 13 Test Humidity Alarm System Shutdown 9 14 Test Air Fittings and Hoses for Leaks 9 17...

Page 89: ...on 8 000 16 000 24 000 32 000 40 000 Install 8 000 Hour Maintenance Kit 11 6 Read Record Flow Rate FLOW 8 4 6 2 Measure Record Compressor Amp Draw 9 2 Set System Pressure 50 PSI 345 KPa 8 14 Set Static Pressure 20 PSI 138 KPa 8 15 Set Outlet Pressure 8 16 Test Consistent Heatless Dryer Cycling 9 7 Test Compressor ON OFF Cycling 9 12 Test Air Fittings and Hoses for Leaks 9 17 Reset COMPRESOR TOTAL ...

Page 90: ...11 1 Top Section Parts Description Part Number Quantity Recommend Spare BD4200W BD4200WL P 120 VAC BD4202W BD4202WLP 220 VAC Power IEC Connector P012279 1 Power Line Filter P011628 1 Circuit Breaker P06136 1 1 Control Board P017795 RFS 1 1 Varistor P012033 P012034 1 1 Solid State Relay P05992 1 1 Front Panel Display P012261 1 ...

Page 91: ...Recommend Spare BD4200W BD4200WL P 120 VAC BD4202W BD4202WL P 220 VAC Precooler P4642 1 Heatless Dryer Assembly See section 11 4 for detail Static Pressure Gauge 0 30 PSI P013339 1 Humitter P013401 1 Temperature Sensor P011823 1 Compressor Air Intake Filter In Kit P012314 See section 11 6 for detail Outlet Pressure Regulator Low Pressure P013203 P012316 1 1 1 ...

Page 92: ...ank 1 11 3 Middle Lower Section Parts 2 Description Part Number Quantit y Recommend Spare BD4200W BD4200WL P 120 VAC BD4202W BD4202WLP 220 VAC Fan P012366 P012368 1 Static Pressure Regulator P013203 1 1 Flow Block 1 Compressor P013261 P013262 1 Vibration Mounts P4582S 4 Safety Relief Valve P03646 1 ...

Page 93: ... Quantity Recommend Spare BD4200W BD4200WLP 120 VAC BD4202W BD4202WLP 220 VAC Heatless Dryer Assembly PHF2C112041 PHF2C212041 1 Capacity Control Valve P4634 1 1 Pressure Gauge 0 100 PSI P010695 1 Cycle Timer P010530F1 P010530F2 1 Desiccant Chamber P20040312 2 Unloader Valve P011022 P010453 1 1 Solenoid Valve In Kit P011471 See section 11 6 for detail ...

Page 94: ...100518835 Rev B 11 5 Frame Section Parts Description Part Number Quantity Recommend Spare Front Panel 1 Locking Trigger Latches 6 Air Intake Filter In Kit P012314 See section 11 6 for detail Top Cover 1 Fan Guard P03703 1 Purge Muffler In Kit P012314 See section 11 6 for detail ...

Page 95: ...e hose or 1 2 tubing P011752 Six Month Maintenance Kit Includes air intake filter compressor air intake filter and purge muffler P012314 2 8 000 Hour Maintenance Kit Includes heatless dryer maintenance kit and compressor maintenance kit P011471 1 Cycle Kit Allows multiple dryers to be cycled P08033W Cycle Kit Interface Kit PVDW34 1 2 Bleed Orifice Kit Allows the Compressor and Heatless Dryer to cy...

Page 96: ... contact 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 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 ...

Page 97: ...ld 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 Circuit Board Repair Limited to current model boards only Complete Dryer Repair 12 2 Initiating a Service Transaction Contact our Parts Service Department at 1 800 521 5351 option 3 to obtain a Return A...

Page 98: ... 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 13 2 Sa...

Page 99: ...mended that 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 Control Board without depressurizing the air dryer first or damage to the Control Board will occur CAUTION Do not test the Humidity Sensor with an ohm meter or apply any DC voltage This will rende...

Page 100: ...s not correct 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 Check Corrective Action Dryer experienced a power spike Power the air dryer OFF for 15 seconds Power the air dryer ON 13 5 High Outlet Pressure Alarm Possible Cause Check Corrective Action Ou...

Page 101: ...ing is higher 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 fails to create an alarm 13 7 Low Outlet Pressure Alarm Possible Cause Check Corrective Action Outlet Pressure set too low Verify Outlet Pressure OUTLET reading section 8 4 6 1 Adjust Outlet Press...

Page 102: ...rified threshold 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 OUTLET reading is under verified Low Outlet Pressure threshold for more than 1 minute and fails to create an alarm 13 9 High Flow Rate Alarm Possible Cause Check Corrective Action Air leak in...

Page 103: ...ity threshold section 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 13 Plugged or obstructed Outlet Purge Test fittings and hoses to Outlet Purge Remove obstruction Defective Humitter Perform the Testing Humidity Alarm and System Shutdown test section...

Page 104: ...ction 11 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 Temperature Alarm Possible Cause Check Corrective Action Fan Failure Verify fan is running section 9 10 Check for loose fan wiring section 14 1 Replace defective fan section 11 3 Defective Contro...

Page 105: ...ace 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 Cause Defective Solid State Relay Measure voltages at Solid State Relay section 9 6 If measurements are bad replace Solid State Relay section 11 1 System is in SHUTDOWN state On the Display Panel verify th...

Page 106: ...ompressor section 11 3 or send it in for repair section 12 13 17 Compressor Last Run Time Alarm Possible Cause Check Corrective Action Low System Pressure Verify System Pressure section 8 14 Adjust System Pressure to 50 PSI 345 KPa section 8 14 High Flow condition Verify Flow Rate FLOW reading is not higher than expected section 8 4 6 2 Troubleshoot High Flow Alarm condition section 13 9 Defective...

Page 107: ...than the verified threshold section 9 13 Defective Control Board Verify that the Compressor has run longer than the verified Compressor Last Run Time threshold above Replace Control Board section 11 1 if the Compressor runs longer than the verified Compressor Last Run Time threshold by 1 minute or more and fails to create an alarm 13 19 Compressor Rapid ON OFF Cycling Possible Cause Check Correcti...

Page 108: ...e 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 Altec AIR Technical Support 800 521 5351 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 109: ...Radio Frequency Systems BD4200W Series Air Dryer User s Guide Page 109 of 114 100518835 Rev B 14 Appendix 14 1 Wiring Diagram ...

Page 110: ... Rate Alarm 0 4200 119 2600 74 SCFD SCMD Compressor Last Run Time Alarm 0 00 10 00 4 00 Minutes High Duty Cycle Alarm 0 99 70 Compressor Total Run Time Alarm 8000 Hours High Cabinet Temperature Alarm 115 46 Deg F Deg C Shutdown at 120 F 50 C 14 2 3 System Operations Description ON Value OFF Value Default Value Unit of Measurement Compressor 25 172 50 345 PSI KPa Fan ON Description Minimum Value Ma...

Page 111: ...ing Numeric DEG F DEG C Compressor Total Run Time Reading Numeric Hours Compressor Last Run Time Reading Numeric Seconds System Status ON SHUTDOWN STANDBY Compressor Status ON OFF Alarm Readings Read Only High Flow Alarm OK Alarm High Outlet Pressure Alarm OK Alarm Low Outlet Pressure Alarm OK Alarm High Humidity Alarm OK Alarm High Cabinet Temperature Alarm OK Alarm Compressor Last Run Time Alarm...

Page 112: ...sit 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 RFS product which shall have been repaired or altered in any way by anyone other than RFS or authorized personnel so as to affect in our judgment its proper functi...

Page 113: ... LLC 226A Commerce Street Broomfield Colorado 80020 parts AltecAIR com 800 521 5351 Fax 303 657 2205 16 3 Technical Support Radio Frequency Systems ApplicationsEngineering rfsworld com 800 659 1880 Fax 203 634 2057 Altec AIR LLC 226A Commerce Street Broomfield Colorado 80020 support AltecAIR com 800 521 5351 Fax 303 657 2205 DON T FORGET TO REGISTER YOUR DRYER See Section 7 for details on Register...

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