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Puregas P4200PM, User Manual

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Puregas P4200PM User Manual Download Page 32

PUREGAS, LLC 

 

P4200PM / P5000PM Remote Air Dryer User’s Guide 

 

 

Page 32 of 79  

P012649 – Rev B 

9. Testing Your Dryer 

9.1 Safety & Warning Information 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

WARNING! 

Extreme care should be exercised to avoid contact with live 

electrical circuits. 

 Many procedures performed during 

installation, operation, testing, and maintenance of this air dryer 

require the equipment to be running, creating a situation for 

potential electrical shock.  It is highly recommended that you 

remove all jewelry before 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 board without depressurizing the air dryer first, or 

damage to the control board will occur.

 

CAUTION! 

This Air 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.

Summary of Contents for P4200PM

Page 1: ...P012649 Rev B P4200PM P5000PM Remote Air Dryer User s Guide ...

Page 2: ......

Page 3: ...se visit us on the web at www puregas 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 PUREGAS P4200PM P5000PM Air Dryer It will cover topics including safety specifications installation registration operation testing maintenance replacement...

Page 4: ... Pressure Alarm Set Point 29 8 11 Setting the Compressor Run Time Alarm30 8 12 Connecting to Common Alarm Terminal Block 31 8 13 Reconfiguring the Common Alarm 31 9 Testing Your Dryer 32 9 1 Safety Warning Information 32 9 2 Measuring Compressor Amp Draw 33 9 3 Measuring Voltage to Compressor 34 9 4 Measuring Incoming Voltage 35 9 5 Measuring Voltages at Solid State Relay 36 9 6 Testing Consistent...

Page 5: ... Alarm 67 13 6 High Humidity 68 13 7 Can t Create a High Humidity Alarm Shutdown 69 13 8 Inconsistent Heatless Dryer Cycling 69 13 9 Compressor Doesn t Operate 70 13 10 Compressor Won t Build Pressure 70 13 11 Compressor Excessive AMP Draw 71 13 12 Compressor Excessive Run Time Alarm 71 13 13 Can t Create a Compressor Excessive Run Time Alarm 72 13 14 Compressor Rapid ON OFF Cycling 72 13 15 Conta...

Page 6: ...se 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 live electrical circuits Many procedures performed during installation operation testing and mainte...

Page 7: ...formance over the lifecycle of your air dryer CAUTION Incoming power to dryer must be 110 125 VAC 1 Phase 50 60 Hz with minimum 30 amp service with a 25 amp slow blow fuse If hard wiring directly minimum of 14 AWG wire must be used CAUTION Proper Installation Maintenance as outlined in this User s Guide is extremely important to ensure the reliability and longevity of the equipment as well as prev...

Page 8: ...oys the principles of compression and pressure swing adsorption The operation is fully automatic and relatively maintenance free The unit offers the necessary gauges and controls to ensure the delivery of dry air at proper pressure and humidity along with removable component assemblies allowing easier access for adjustment and maintenance 5 2 Key Features Solid state based circuitry eliminates cos...

Page 9: ...let Pressure Range 0 20 PSI adjustable Outlet Air Humidity Less than 2 RH Compressor Type 2 cylinder 3 4 HP Rocker oil less 2 cylinder 1 HP Piston oil less Drying Method Heatless Desiccant Operating Temperature Range 40 to 120 F 40 to 48 C Optimal 40 to 85 F 5 to 30 C Noise Level 48 dBA at 3 68 dBA at 10 Alarms Standard alarms Complete measurement of all critical points Outlet Connections 1 2 NPT ...

Page 10: ...system pressure and prevents air from bleeding back through the heatless dryer 6 Safety Relief Valve Prevents system from over pressurizing by releasing at high pressure 7 Air Tank Stores dry compressed air 8 Humidity Sensor Measures the humidity of the compressed air 9 F Type Valve Provides a point to test system Humidity with an external tester 10 Outlet Pressure Regulator Regulates the outlet p...

Page 11: ... 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 Proper Installation Maintenance as outlined in this User s Guide is extremely important to ensure the reliability and longevity of the equ...

Page 12: ...ponents and procedures before performing the air dryer installation 6 2 3 Verify the installation location of the air dryer 6 2 3 1 Well secured location 6 2 3 2 PUREGAS recommends the air dryer be mounted a minimum of one 1 foot from the ground 6 2 3 3 Ambient temperature lower than 120 F 85 F optimal NOTE Higher temperatures will decrease component lifespan IMPORTANT Performing procedures not de...

Page 13: ...tify the alarm center of the installation and potential for alarms during the process as necessary 6 3 Included Contents 1 P4200PM P5000PM Air Dryer 1 Installation Guide not shown Package located inside the dryer 1 Compressor Connector Tool 1 User s Guide 6 4 Required Tools and Materials Large adjustable wrench 7 16 wrench Band cutters or snips 5 16 nut driver Medium Phillips head screwdriver Pipe...

Page 14: ...ials and hardware NOTE If ANY SHIPPING DAMAGE is detected file a claim with the shipping company prior to continuing the installation procedures 6 5 2 Open the front door 6 5 3 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 15: ... package 6 5 5 Pull out and rotate the quick pins turn to lock in the Open position 6 5 6 Pull the Compressor Tray out 6 5 7 With a 7 16 wrench remove the shipping blocks from under the compressor plate Discard blocks and bolts 6 5 8 Slide the Compressor Tray into place 6 5 9 Rotate the quick pins turn to the Lock position ...

Page 16: ... the operating location NOTE Close the front door if necessary 6 5 11 Verify that the dryer is powered OFF 6 5 12 Depress the latches and lower the front panel 6 5 13 Route incoming power through strain relief fitting on the back where shown 6 5 14 With a 5 16 nut driver remove the cover from the terminal block ...

Page 17: ...to the terminal block of the dryer 6 5 16 Reinstall the terminal block cover 6 5 17 Tighten the strain relief 6 5 18 Remove dust plug and connect the air supply line to the dryer Outlet Pressure port 6 5 19 Close the front panel 6 5 20 Power the dryer ON IMPORTANT Press RESET if the dryer goes into SHUTDOWN due to Humidity ...

Page 18: ...18 of 79 P012649 Rev B 6 5 21 Set the System Pressure 6 5 21 1 Lower the front panel With Compressor running 6 5 21 2 Pull the Capacity Control Valve knob out 6 5 21 3 Turn the knob until the reading on the pressure gauge is 50 PSI 6 5 21 4 Push the knob in to lock ...

Page 19: ... Turn knob until Outlet Pressure OUTP reading is at the desired setting 6 5 22 4 Tighten nut to lock 6 5 23 Check for air 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 DAMAGE TO THE SENSOR MAY OCCUR With Compressor NOT running 6 5 23 1 Listen for any hissing sounds which may indicate a fitting or h...

Page 20: ...ion 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 fitting Re connect the hose end Replace the fitting hose compon ent 6 5 24 Close the front panel and depress latches 6 5 25 Close the front door and latch 6 5 26 REGISTER YOUR DRYER See section 7 for details ...

Page 21: ...set to 50 PSI No air leaks are present in the system No alarms are present 7 Registering Your Dryer Please take a moment to register your PUREGAS P4200PM P5000PM Air Dryer Registering is necessary 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 co...

Page 22: ...creating a situation for potential electrical shock It is highly recommended that you remove all jewelry before performing any procedures WARNING Internal surfaces may be hot Use care when coming into 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 ...

Page 23: ...k of the Dryer and connect the air supply line to the dryer Outlet Pressure port 8 3 Powering the Dryer ON OFF 8 3 1 POWER Circuit Breaker Controls the main power to the Dryer CAUTION Incoming power to dryer must be 110 125 VAC 1 Phase 50 60 Hz with minimum 30 amp service with a 25 amp slow blow fuse If hard wiring directly minimum of 14 AWG wire must be used ...

Page 24: ... P5000PM Remote Air Dryer User s Guide Page 24 of 79 P012649 Rev B 8 4 Opening Doors and Panels 8 4 1 Open the Front Door 8 4 2 Depress the latches and lower the Front Panel 8 4 3 Remove wing nut and washer Open Top Cover ...

Page 25: ...on 8 5 2 Pull the Compressor Tray out 8 6 Depressurizing the Dryer 8 6 1 Open the Front Door section 8 4 1 8 6 2 Lower the Front Panel section 8 4 2 8 6 3 Pull the ring on the Safety Relief Valve OUT until all of the air pressure is released from the system 8 6 4 Raise the Front Panel NOTE To prevent air pressure from building back up power the Dryer OFF section 8 3 8 6 5 Close the Front Door ...

Page 26: ...re 8 7 1 Open the Front Door section 8 4 1 8 7 2 Lower the Front Panel section 8 4 2 With Compressor running 8 7 2 1 Pull the Capacity Control Valve knob out 8 7 2 2 Turn the knob until the reading on the Pressure Gauge is 50 PSI 8 7 2 3 Push the knob in to lock 8 7 3 Raise the Front Panel 8 7 4 Close the Front Door ...

Page 27: ...of 79 P012649 Rev B 8 8 Setting the Outlet Pressure 8 8 1 Open the Front Door section 8 4 1 8 8 2 Loosen the Outlet Pressure Regulator Locknut 8 8 3 Turn knob until Outlet Pressure reading is at the desired setting 8 8 4 Tighten nut to lock 8 8 5 Close the Front Door ...

Page 28: ...on 6 Bypass Valve TB Humidity Bypass Valve Connection 7 Control Board Power TB Incoming Power to the Control Board 115VAC 8 Reset Button Resets current alarms 9 Comp Run Time Adjustment Sets the Compressor Run Time Alarm 10 Low Pressure Adjustment Sets the Low Pressure Alarm 11 Open Circuit LED Indicates an Open alarm in the Humidity Circuit 12 Humidity LED Indicates a Humidity Alarm 13 Run Time L...

Page 29: ...Set Point 8 10 1 Open Front Door section 8 4 1 8 10 2 Loosen the Outlet Pressure Regulator Locknut 8 10 3 Turn knob until Outlet Pressure reading is at the desired alarm setting 8 10 4 Lower the Front Panel section 8 4 2 8 10 5 Locate Low Pressure Adjustment section 8 9 8 10 6 Turn Adjustment Arrow fully counter clockwise ...

Page 30: ...alarm 8 10 8 Raise the Front Panel 8 10 9 Set Outlet Pressure to desired normal setting Section 8 8 8 10 10 Close the Front Door 8 11 Setting the Compressor Run Time Alarm 8 11 1 Open Front Door section 8 4 1 8 11 2 Lower the Front Panel section 8 4 2 8 11 3 Locate Compressor Run Time Adjustment section 8 9 8 11 4 Turn Adjustment Arrow to desired alarm minute NOTE Each number represents the alarm ...

Page 31: ...lock 8 12 3 Wire the Common Alarm wire pair on the Terminal Bock as required 8 12 4 Close Front Door 8 13 Reconfiguring the Common Alarm NOTE The Common Alarm is wired as a CLOSE ON ALARM 8 13 1 Open Front Door section 8 4 1 8 13 2 Open the Front Panel section 8 4 2 8 13 3 Locate the Common Alarm Terminal Block on the Control Board section 8 9 8 13 4 Re wire 11 on the Common Terminal Block as requ...

Page 32: ...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 board without depressurizing th...

Page 33: ...e an Amp Meter to measure the running amps With the compressor running the running amps should measure 11 0 amps or below P4200PM or 15 0 amps or below P5000PM 9 2 5 Slide in Compressor Tray 9 2 6 Close Front Door If the compressor measures over stated running amps see section 13 11 for troubleshooting information WARNING Internal surfaces may be hot Use care when coming into contact with internal...

Page 34: ...n 8 4 1 9 3 2 Power the air dryer OFF section 8 3 9 3 3 Slide out Compressor Tray section 8 5 9 3 4 Locate the Compressor power connector 9 3 5 Power the air dryer ON section 8 3 WARNING Extreme care should be exercised to avoid contact with live electrical circuits It is highly recommended that you remove all jewelry before performing any procedures ...

Page 35: ... measure 110 125 VAC 9 3 7 Slide in Compressor Tray 9 3 8 Close Front Door 9 4 Measuring Incoming Voltage 9 4 1 Open Front Door section 8 4 1 9 4 2 Lower Front Panel section 8 4 2 9 4 3 Locate the POWER Circuit Breaker inside the front panel of the air dryer WARNING Extreme care should be exercised to avoid contact with live electrical circuits It is highly recommended that you remove all jewelry ...

Page 36: ... The voltage should measure 110 125 VAC 9 4 5 Close Front Panel 9 4 6 Close Front Door If the incoming voltage measures less than 110 VAC it is recommended that steps be taken at your facility to increase the power to the recommended level of 110 125 VAC 9 5 Measuring Voltages at Solid State Relay 9 5 1 Open Front Door section 8 4 1 9 5 2 Open Front Panel section 8 4 2 9 5 3 Locate the Solid State...

Page 37: ...d measure 5 24 VDC With the Compressor NOT running 9 5 6 Use a Voltmeter to measure across the AC terminals Should measure 110 125 VAC 9 5 7 Use a Voltmeter to measure across the DC terminals Should measure 0 VDC 9 5 8 Close Front Panel 9 5 9 Close Front Door If any of the voltage measurements are different than indicated above the Solid State Relay is defective and should be replaced See sections...

Page 38: ...r running 9 6 1 Open Front Door section 8 4 1 9 6 2 Open Front Panel section 8 4 2 9 6 3 Locate the Heatless Dryer and remove Mufflers 9 6 4 Place your hand beneath the purge fittings to feel for purging air Air should Purge from Tower 1 side 30 Seconds later Purge from Tower 2 side 30 Seconds later Purge from Tower 1 side 30 Seconds later and so on ...

Page 39: ...se Front Panel 9 6 7 Close Front Door If the Heatless Dryer is not cycling consistently as described see section 13 8 for troubleshooting information 9 7 Testing Unloader Valve With the Compressor running 9 7 1 Open Front Door section 8 4 1 9 7 2 Open Front Panel section 8 4 2 9 7 3 Locate the Unloader Valve and remove the muffler ...

Page 40: ...OT flow from this fitting continuously Air should only be released in a short burst when the compressor shuts off 9 7 5 Re install the muffler to the Unloader Valve 9 7 6 Close Front Panel 9 7 7 Close Front Door If air flows from this valve continuously the Unloader Valve is defective and should be replaced See sections 11 3 for part detail and 11 8 for ordering information ...

Page 41: ...s from left to right 53VDC Left solenoid IN Incoming power 53VDC Right solenoid 9 8 4 Use a Voltmeter to measure the DC voltage across each set of 53VDC terminals Continue to measure for up to 45 seconds if no voltage is initially measured The voltage should measure 53 Volts DC 9 8 5 Close Front Panel 9 8 6 Close Front Door If the voltage does not measure 53 Volts DC this is an indication that the...

Page 42: ...ction 8 4 1 9 9 2 Open Front Panel section 8 4 2 9 9 3 Place your hand below the Fan to feel for air being blown downwards into the cabinet 9 9 4 Close Front Panel 9 9 5 Close Front Door If the fan is not blowing air downwards as described Check for loose wiring Refer to the Wiring Diagram section 14 1 Replace defective fan see sections 11 1 for part detail and 11 8 for ordering information ...

Page 43: ...pressurize the air dryer section 8 4 9 10 4 Slide out Compressor Tray section 8 5 9 10 5 Locate the power lead wires to the Heater Wire s 9 21 9 10 6 Power the air dryer ON section 8 3 9 10 7 Use a Voltmeter to measure the voltage 9 10 7 1 Probe the terminal connections on the heater sensor The voltage should measure 110 125 VAC 9 10 8 Power the air dryer OFF section 8 3 9 10 9 Slide in Compressor...

Page 44: ...ressor ON OFF Cycling 9 11 1 Open Front Door section 8 4 1 9 11 2 Locate the Tank Pressure Gauge With Compressor running 9 11 3 Verify the compressor shuts down when the Tank Pressure Gauge reaches 50 0 PSI If the tank pressure gauge fails to reach 50 PSI see section 13 10 for troubleshooting information ...

Page 45: ...ontrol Board which may need to be replaced See sections 11 2 for part detail and 11 8 for ordering information 9 12 Testing Compressor Excessive Run Time Alarm 9 12 1 Open Front Door section 8 4 1 9 12 2 Open Front Panel section 8 4 2 9 12 3 Start timing when the compressor turns on 9 12 4 Push the outlet tube in and hold the ferrule While holding the ferrule pull the tube out until air pressure i...

Page 46: ...connect Outlet Tube 9 12 8 Close Front Panel 9 12 9 Close Front Door If you are unable to create a Compressor Excessive Run Time Alarm as described see section 13 12 for troubleshooting information 9 13 Testing Humidity Alarm and System Shutdown 9 13 1 Open Front Door section 8 4 1 9 13 2 Open Front Panel section 8 4 2 9 13 3 Push the outlet tube in and hold the ferrule While holding the ferrule p...

Page 47: ...umidity Block 9 13 5 Reinstall outlet tube 9 13 6 Green Humidity and Bypass Indicators will darken once the Humidity reading reaches 10 0 or higher 9 13 7 Verify that the Humidity LED flashes 9 13 8 After 5 minutes the Humidity LED illuminates solid and the dryer goes into SHUTDOWN mode 9 13 9 Replace the Humidity Sensor in the Humidity Block ...

Page 48: ...Close Front Panel 9 13 12 Close Front Door If you are unable to create a Humidity Shutdown Alarm as described see section 13 7 for troubleshooting information 9 14 Testing Humidity Open Circuit Bypass Valve and Shutdown 9 14 1 Open Front Door section 8 4 1 9 14 2 Open Front Panel section 8 4 2 9 14 3 Disconnect the Humidity Sensor from the Control Board ...

Page 49: ... the Bypass Valve opens 9 14 6 After 5 minutes the Open Humi LED illuminates solid and the dryer goes into SHUTDOWN mode 9 14 7 Reconnect the Humidity Sensor 9 14 8 Press the RESET Button to clear the Humidity alarm 9 14 9 Close Front Panel 9 14 10 Close Front Door If you are unable to create an Open Circuit Shutdown Alarm as described see section 13 7 for troubleshooting information ...

Page 50: ...esting Low Outlet Pressure Alarm 9 15 1 Open Front Door section 8 4 1 9 15 2 Make note of the current Outlet Pressure reading 9 15 3 Loosen the Outlet Pressure Regulator Locknut 9 15 4 Turn knob until Outlet Pressure reading is below 6 5 PSI unless adjusted to a different Set Point by the user ...

Page 51: ...r 5 minutes the LED will illuminate solid indicating a latched alarm 9 15 7 Press the RESET Button to clear the Humidity alarm 9 15 8 Close and latch the Front Panel 9 15 9 Set Outlet Pressure to desired normal setting Section 8 8 9 15 10 Close the Front Door If you are unable to create a Low Outlet Pressure Alarm as described see section 13 5 for troubleshooting information ...

Page 52: ...R MAY OCCUR With Compressor NOT running 9 16 1 Listen for any hissing sounds which may indicate a fitting or hose air leak With Compressor running 9 16 2 Use a 1 inch paint brush to dab soapy water on 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...

Page 53: ...cedure Please refer to these sections for detailed procedural information NOTE When operating at higher ambient temperatures it is recommended that maintenance be performed more frequently NOTE After 16 000 hours of run time PUREGAS recommends sending in your compressors and heatless dryers for a complete and comprehensive rebuild by our Service Department technicians See sections 12 1 and 12 2 fo...

Page 54: ...orming routine maintenance as outlined in the Maintaining Your Dryer section will ensure optimal performance over the lifecycle of your air dryer IMPORTANT After performing any maintenance always soap test pressure fittings to check for air leaks Also check for any loose or disconnected wiring CAUTION SHUT DOWN IMMEDIATELY FOR REPAIRS if the air compressor shows any evidence of overheating or pres...

Page 55: ...low Rate FLOW 11 1 Measure Record Compressor Amp Draw 9 2 Measure Record Incoming Voltage must be 110 125 VAC 9 4 Test Low Outlet Pressure Alarm 9 15 Set System Pressure 50 PSI 8 7 Set Outlet Pressure 8 8 Test Consistent Heatless Dryer Cycling 9 6 Test Fan 9 9 Test Cabinet Heater 9 10 Test Compressor ON OFF Cycling 9 11 Test Compressor Excessive Run Time Alarm 9 12 Test Humidity Alarm System Shutd...

Page 56: ...e section 11 2 for detail Trigger Latch See section 11 2 for detail Outlet Pressure Regulator See section 11 2 for detail Flow Meter Assembly See section 11 2 for detail Fan P012666 1 1 Air Intake Filter P15186 In Maintenance Kits P012907 P012879 See Section 11 7 for detail Tank Pressure Gauge See section 11 2 for detail Hour Meter See section 11 2 for detail Front Panel Assembly P012589 See secti...

Page 57: ...nd Spare Front Panel Assembly P012589 1 Humidity Bypass Valve P012663 1 1 Humidity Sensor P011380 1 1 Flow Meter Assembly P012778 1 Outlet Pressure Regulator P012779 1 1 Outlet Pressure Gauge P012781 1 Circuit Breaker P06138 1 1 Solid State Relay P013159 1 1 Control Board P012591 1 1 Hour Meter P012590 1 Tank Pressure Gauge P012780 1 Trigger Latch P08947F1 2 ...

Page 58: ...8 of 79 P012649 Rev B 11 3 Internal Cabinet Parts Description Part Number Quantity Recommend Spare Resistors 270K B142 2 Tank 1 Heatless Dryer Assembly P4200PM P5000PM P012831 P012608 See Section 11 4 for detail Lightning Arrestor P011788 1 Surge Protector P011835 1 ...

Page 59: ...tless Dryer Assembly P4200PM P5000PM P012831 P012608 1 Desiccant Tower P20040312 2 2 Cycle Timer P010530F1 1 Solenoid Valve In Kit P200499S See Section 11 7 for detail Purge Muffler 10040 In Maintenance Kits P012907 P012879 See Section 11 7 for detail Safety Relief Valve P03646 1 Capacity Control Valve P4634 1 1 Pressure Gauge 0 100 PSI P010695 1 Unloader Valve P011022 1 1 ...

Page 60: ...ction Parts Description Part Number Quantity Recommend Spare Compressor Assembly P4200PM P5000PM P012829 P012617 See Section 11 6 for detail Discharge Hose P05069 1 Temperature Sensor 8298 1 Common Alarm Terminal Block 1 Wire Harness Male Female P011283 P011284 1 1 Precooler Heater Assembly P012609 1 ...

Page 61: ...or Assembly P4200PM P5000PM P012829 P012617 1 1 Compressor Only P4200PM P5000PM P013256 P012878 1 Wire Harness Male End P011283 1 Intake Muffler P010192 In Maintenance Kits P012907 P012879 See Section 11 7 for detail Compressor Base P4200PM P5000PM P012830 P012606 1 Safety Relief Valve P3996 1 Vibration Mount P4200PM P5000PM P02626S P02626S 16 4 Compressor Bracket P012616 1 ...

Page 62: ...mufflers and purge mufflers P012907 2 P5000PM Six Month Maintenance Kit Includes air intake filter compressor mufflers and purge mufflers P012879 2 P4200PM Compressor Maintenance Kit Includes all necessary parts to repair compressor P010491 1 P5000PM Compressor Maintenance Kit Includes all necessary parts to repair compressor P3865 1 Heatless Dryer Maintenance Kit Includes all necessary parts to r...

Page 63: ...ies 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 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 64: ...uild 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...

Page 65: ...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 Safety W...

Page 66: ...efore 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 IMPORTANT Performing procedures not described in this User s Guide or installing components not supplied by PUREGAS is NOT RECOMMENDE...

Page 67: ...Outlet Pressure Alarm set point too high Verify Low Outlet Pressure Alarm set point section 8 10 Lower the Low Outlet Pressure Alarm set point section 8 10 13 5 Can t Create a Low Pressure Alarm Possible Cause Check Corrective Action Defective Outlet Pressure Regulator Verify that the Outlet Pressure Regulator can be adjusted section 8 8 Replace Outlet Pressure Regulator if unable to adjust pressu...

Page 68: ...ity Alarm and System Shutdown test section 9 13 Troubleshoot Can t Create a High Humidity Alarm Shutdown condition section13 7 Heatless Dryer not cycling between towers Verify consistent Heatless Dryer cycling section 9 6 Troubleshoot Inconsistent Heatless Dryer Cycling condition section 13 8 Defective Control Board Unplug Humidity Sensor from Control Board see section 9 14 Humidity Indicators sho...

Page 69: ...adic readings Replace Humidity Sensor section 11 2 Defective Control Board Verify that Humidity reading is over 15 for more than 5 minutes Replace Control Board if no alarm is created and system does not shut down section 11 2 13 8 Inconsistent Heatless Dryer Cycling Possible Cause Check Corrective Action Defective Solenoid Valve Measure voltage going to the Heatless Dryer Solenoid Valves section ...

Page 70: ...lay section 9 5 If measurements are bad replace Solid State Relay section 11 2 System is in Shutdown state Verify unit is not in a Humidity alarm section 8 9 Press the RESET Button section 8 9 13 10 Compressor Won t Build Pressure Possible Cause Check Corrective Action Low System Pressure Verify System Pressure section 8 7 Adjust System Pressure to 50 PSI section 8 7 Defective Unloader Valve Test ...

Page 71: ...3 12 Compressor Excessive Run Time Alarm Possible Cause Check Corrective Action Low System Pressure Verify System Pressure section 8 7 Adjust System Pressure to 50 PSI section 8 7 High Flow condition Verify Flow Rate reading is not higher than expected Troubleshoot High Flow condition Defective Unloader Valve Test Unloader Valve operation section 9 7 If this is continuously flowing high amounts of...

Page 72: ...ify that the compressor has run longer than the verified Excessive Compressor Run Time Alarm set point above Replace Control Board section 11 2 if the compressor runs longer than the verified Excessive Compressor Run Time Alarm set point by 1 minute or more and fails to create an alarm 13 14 Compressor Rapid ON OFF Cycling Possible Cause Check Corrective Action Defective Solid State Relay Measure ...

Page 73: ...hausted 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 Support 800 521 5351 option 1 Have the following information available Trouble Ticket if following up on a previous call Technician Name Phone Model P4200PM P5000PM Serial Company Name Location Name City State ...

Page 74: ...PUREGAS LLC P4200PM P5000PM Remote Air Dryer User s Guide Page 74 of 79 P012649 Rev B 14 Appendix 14 1 Wiring Diagram ...

Page 75: ...PUREGAS LLC P4200PM P5000PM Remote Air Dryer User s Guide Page 75 of 79 P012649 Rev B ...

Page 76: ...ment Shutdown Low Outlet Pressure Alarm 1 0 9 5 6 5 PSI High Humidity Alarm 10 0 YES Excessive Compressor Run Time Alarm 1 0 10 0 3 0 Minutes 14 2 3 System Operations Description ON Value OFF Value Default Value Unit of Measurement Compressor 20 0 50 0 PSI Fan 85 0 67 0 Deg F Heater 40 0 60 0 Deg F Description Minimum Value Maximum Value Default Value Unit of Measurement System Pressure 48 0 52 0 ...

Page 77: ...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 PUREGAS product which shall have been repaired or altered in any way by anyone other than PUREGAS or authorized personnel so as to affect in our judgment its proper functionin...

Page 78: ...ld Colorado 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 5351 option 3 Fax 303 657 2205 16 4 Technical Support 800 521 5351 option 1 DON T FORGET TO REGISTER YOUR DRYER See Section 7 for details on Registering Your Dryer ...

Page 79: ...______________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ _____________________________________________________________________...

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