Altec AIR PUREGAS P4200W Series User Manual Download Page 113

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Altec AIR

P4200W Series Air Dryer User’s Guide

Page 113 of 113

P012306 - Rev. F

17. Notes

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Summary of Contents for PUREGAS P4200W Series

Page 1: ...P012306 Rev F P4200W Series Air Dryer User s Guide Models covered P4200W P4200WLP P4202W P4202WLP...

Page 2: ......

Page 3: ...ecAIR 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 sp...

Page 4: ...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 the Ou...

Page 5: ...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 High Humid...

Page 6: ...ention 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 pro...

Page 7: ...in the Maintaining 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 110 125 VAC 50 60 Hz for P...

Page 8: ...e supplied by the user CAUTION Observe precautions for handling Electrostatic Sensitive Devices IMPORTANT Installation of ALTEC AIR air dryers are intended for network telecommunication facilities non...

Page 9: ...access panels allowing 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 operat...

Page 10: ...ange 5 20 PSIG 0 3 10 PSIG 5 20 PSIG 0 3 10 PSIG Outlet Air Humidity Less than 2 RH Compressor 2 cylinder 3 4 HP oil less type compressor Drying Method Heatless Desiccant Operating Temperature Range 4...

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

Page 12: ...ewelry 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 h...

Page 13: ...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 fol...

Page 14: ...shown Package located inside the dryer 2 Alarm Connector 1 User s Guide not shown 1 Allen Wrench 1 Compressor Connector Tool 1 Purge Muffler 1 Power Cord 6 4 Required Tools and Materials Large adjusta...

Page 15: ...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...

Page 16: ...ch 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 instal...

Page 17: ...d to an outlet 110 125 VAC power outlet for P4200W and P4200WLP model 220 230 VAC 1 phase power outlet for P4202W P4202WLP models 6 5 12 Power the dryer ON NOTE The Compressor and Heatless Dryer will...

Page 18: ...ev F 6 5 13 2 Turn the knob until the reading on the Pressure Gauge is 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 NOTE...

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

Page 20: ...essure Gauge is 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 until...

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 hose...

Page 22: ...ration 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 re...

Page 23: ...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 AltecAIR...

Page 24: ...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 pot...

Page 25: ...Connect the air supply line to the Outlet Pressure Port ALTEC AIR recommends using Installation Kit P011752 to connect your air dryer to the air supply line See section 11 6 for detail 8 3 Powering th...

Page 26: ...ION 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 the...

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 Tem...

Page 28: ...e Screen LAST How many minutes the Compressor ran during the last Air Tank pressurization cycle TOTAL How many hours the Compressor has run since the last Compressor Total Time Reset 8 4 5 4 Unit in S...

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 Occ...

Page 30: ...me 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 Pressur...

Page 31: ...m 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 Compressor Last Run Time Alarm Occurs when the Compressor Last Run Time L...

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: ...ds 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 Ma...

Page 34: ...ay 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 su...

Page 35: ...ttons 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 Ri...

Page 36: ...rm 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...

Page 37: ...e 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 Butto...

Page 38: ...ss 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 digit...

Page 39: ...uttons 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 L...

Page 40: ...uttons 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 L...

Page 41: ...ttons 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 Le...

Page 42: ...w Buttons 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...

Page 43: ...row 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 t...

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 Rig...

Page 45: ...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 Ri...

Page 46: ...ns 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...

Page 47: ...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 8...

Page 48: ...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 Locking Latches 8 11 2 Depress the two 2 Locking Latches 8 11 3 Lift...

Page 49: ...sure 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 i...

Page 50: ...ng 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 i...

Page 51: ...v F 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 8...

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 set...

Page 53: ...x 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 ma...

Page 54: ...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 P4200W Series Air Dryer This screen is inf...

Page 55: ...arms monitored in the P4200W 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 St...

Page 56: ...de Page 56 of 113 P012306 Rev F 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 12345...

Page 57: ...6 Rev F 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 Enter...

Page 58: ...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 con...

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: ...F 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: ...Event Screen Displays all events such as alarms changes made and alarm resets registered by the P4200W Series Air Dryer This screen is informational only Click on the column headings to sort data acc...

Page 62: ...Rev F 8 21 Using the Alarm Screen Displays all the Alarms registered by the P4200W Series Air Dryer This screen is informational only Click on the column headings to sort data according to that colum...

Page 63: ...date of the P4200W Series Air Dryer Current Version Displays the current firmware version of the P4200W Series Air Dryer New Version File Displays the new location and new firmware version chosen The...

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 defaul...

Page 65: ...are 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 P4200W Series Air Dryers can be down...

Page 66: ...move 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 t...

Page 67: ...ire With the Compressor running the running amps should measure 8 6 amps or below for the P4200W P4200WLP models 3 9 or below for the P4202W P4202WLP models If the Compressor measures over the recomme...

Page 68: ...ure 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 P4200W P4200WLP models 220 23...

Page 69: ...o that they touch the metal contacts The voltage should measure 110 125 VAC for the P4200W P4200WLP models 220 230 VAC for the P4202W P4202WLP models If any of the voltage measurements are different t...

Page 70: ...on so that they touch the metal contacts The voltage should measure 110 125 VAC for the P4200W P4200WLP models 220 230 VAC for the P4202W P4202WLP models If the incoming voltage measures less than ind...

Page 71: ...11 9 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...

Page 72: ...for the P4200W P4200WLP models 220 230 VAC for the P4202W P4202WLP 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 Cover secti...

Page 73: ...he 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 Second...

Page 74: ...nd 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 connec...

Page 75: ...er VALVE 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 shou...

Page 76: ...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 Safety...

Page 77: ...e TANK reaches 50 0 PSI 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 V...

Page 78: ...on the Safety Relief Valve when necessary to keep the Tank Pressure TANK from reaching 50 PSI This prevents the Compressor from shutting down When the Compressor runs for 4 00 minutes unless adjusted...

Page 79: ...P012306 Rev F 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...

Page 80: ...4 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 Boar...

Page 81: ...eading 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 over...

Page 82: ...anel 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 th...

Page 83: ...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 t...

Page 84: ...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 t...

Page 85: ...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 more...

Page 86: ...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 the...

Page 87: ...igh Low Outlet Pressure Alarms 9 15 9 16 Set System Pressure 50 PSI 8 14 Set Static Pressure 20 PSI 8 15 Set Outlet Pressure 8 16 Test Consistent Heatless Dryer Cycling 9 7 Test Precooler Fan 9 10 Tes...

Page 88: ...000 16 000 24 000 32 000 40 000 Install 8 000 Hour Maintenance Kit P011471 11 6 Read Record Flow Rate FLOW 8 4 5 2 Measure Record Compressor Amp Draw 9 2 Set System Pressure 50 PSI 8 14 Set Static Pre...

Page 89: ...Top Section Parts Description Part Number Quantity Recommend Spare P4200W P4200WLP 120 VAC P4202W P4202WLP 220 VAC Power IEC Connector P012279 1 Power Line Filter P011628 1 Circuit Breaker P06136 1 1...

Page 90: ...are P4200W P4200WLP 120 VAC P4202W P4202WLP 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...

Page 91: ...iddle Lower Section Parts 2 Description Part Number Quantity Recommend Spare P4200W P4200WLP 120 VAC P4202W P4202WLP 220 VAC Fan P012366 P012368 1 Static Pressure Regulator P013203 1 1 Flow Block 1 Co...

Page 92: ...ty Recommend Spare P4200W P4200WLP 120 VAC P4202W P4202WLP 220 VAC Heatless Dryer Assembly PHF2C112041 PHF2C212041 1 Capacity Control Valve P4634 1 1 Pressure Gauge 0 100 PSI P010695 1 Cycle Timer P01...

Page 93: ...Rev F 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 Gu...

Page 94: ...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...

Page 95: ...tact 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...

Page 96: ...place desiccant o rings check valves springs and complete solenoid assembly o Test proper component operation Desiccant Tower Repack o Clean out tower and replace desiccant filter and o ring Circuit B...

Page 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: ...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...

Page 99: ...ect 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 C...

Page 100: ...gher 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...

Page 101: ...reshold 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: ...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...

Page 103: ...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 Tempe...

Page 104: ...mpressor 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 Defec...

Page 105: ...Last Run Time Alarm Possible Cause Check Corrective Action Low System Pressure Verify System Pressure section 8 14 Adjust System Pressure to 50 PSI section 8 14 High Flow condition Verify Flow Rate FL...

Page 106: ...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 thresh...

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 ALTEC AIR Technical Supp...

Page 108: ...Altec AIR P4200W Series Air Dryer User s Guide Page 108 of 113 P012306 Rev F 14 Appendix 14 1 Wiring Diagram...

Page 109: ...30 19 90 0 30 PSI High Flow Rate Alarm 0 4200 2600 SCFD Compressor Last Run Time Alarm 0 00 10 00 4 00 Minutes Compressor Total Run Time Alarm 8000 Hours High Cabinet Temperature Alarm 115 Deg F Shut...

Page 110: ...meric DEG F 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 Fl...

Page 111: ...the user and the user in turn should file any damage claim against the carrier All warranty items are F O B Broomfield Colorado Freight charges are the responsibility of the user This warranty shall n...

Page 112: ...orado 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 5...

Page 113: ..._________________________________ ________________________________________________________________________ ________________________________________________________________________ ____________________...

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