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Puregas P4200W2 User Manual

P4200w2 series
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P4200W2 Series Air Dryer
User's Guide
Models covered:
P4200W2
P4200W2LP
P4202W2
P4202W2LP
P4202W2H
P012308 - Rev. E

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Summary of Contents for Puregas P4200W2

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

  • Page 3: Welcome & Congratulations

    1. Welcome & Congratulations Congratulations on your purchase of a new PUREGAS P4200W2 Series Air Dryer! We here at PUREGAS are very proud of our products and we are committed to providing you with the best value and service possible.

  • Page 4: Table Of Contents

    8.21 Using the Alarm Screen ......62 5.2 Key Features ..........9 8.22 Using the Firmware Screen ..... 63 5.3 P4200W2 Series Air Dryer Models .... 9 8.23 Connecting via SNMP ......65 5.4 Technical Specifications ......10 5.5 Dryer Function Overview ......11 9.
  • Page 5 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 13.11 Can’t Create a High Humidity Alarm / 10. Maintaining Your Dryer ......85 10.1 Safety & Warning Information ....85 Shutdown ............103 10.2 Six Month Maintenance ......87 13.12 High Cabinet Temperature Alarm..103 10.3 8,000 Hour Maintenance ......

  • Page 6: Safety & Warning Information

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 4. Safety & Warning Information This section contains general information about safety and warning points to consider and adhere to during installation, operation, and maintenance of your air dryer. PLEASE READ THIS SECTION BEFORE PERFORMING ANY OPERATION OR PROCEDURE ON YOUR AIR DRYER.
  • Page 7 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide WARNING! High Noise. PUREGAS air dryers are meant to be installed in an unattended area. 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 prevent damage or personal injury.
  • Page 8 (SPD). If an SPD is required it must be supplied by the user. CAUTION! Observe precautions for handling Electrostatic Sensitive Devices. IMPORTANT! Installation of PUREGAS air dryers are intended for network telecommunication facilities (non-customer premises) only. Page 8 of 113 P012308 - Rev. E...

  • Page 9: Overview & Specifications

    5. Overview & Specifications 5.1 Product Description The P4200W2 Series Air Dryer from PUREGAS is designed to intake wet ambient air and remove the moisture for delivery to applications requiring a constant, on- demand source of dry, pressurized air. This process is fully automatic and will remain consistent with minimal required periodic maintenance.

  • Page 10: Technical Specifications

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 5.4 Technical Specifications P4202W2 P4200W2 P4200W2LP P4202W2 P4202W2H Normal: 90 SCMD Output Normal: 74 SCMD Maximum: 119 SCMD Capacity Max: 119 SCMD Power 110 - 125 VAC, 1 Phase, 220 - 230 VAC, 1 Phase,...

  • Page 11: Dryer Function Overview

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 5.5 Dryer Function Overview Component Description Compressor Compresses drawn in ambient air. Precooler Cools compressed air prior to drying function. Unloader Valve Relieves excess Compressor head pressure. Heatless Dryer Removes moisture from compressed air.

  • Page 12: Installing Your Dryer

    It is highly recommended that you remove all jewelry before performing any procedures. WARNING! High Noise. Puregas air dryers are meant to be installed in an unattended area. 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 prevent damage or personal injury.

  • Page 13: Before You Begin

    PUREGAS is NOT RECOMMENDED AND MAY VOID THE WARRANTY. IMPORTANT! Installation of PUREGAS air dryers are intended for network telecommunication facilities (non-customer premises) only. 6.2 Before You Begin 6.2.1 Carefully inspect the unit, including the shipping box as well as the air dryer, for ANY DAMAGE CAUSED BY SHIPPING.

  • Page 14: Included Contents

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 6.3 Included Contents (1) P4200W2 Series Air Dryer Package located inside the dryer: (2) Alarm Connector (1) User’s Guide (not shown) (1) Mini CD (not shown) (1) Allen Wrench (1) Purge Muffler...

  • Page 15: Installation Steps

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 6.5 Installation Steps 6.5.1 Remove all shipping materials. NOTE: If ANY 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.
  • Page 16 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 6.5.5 Using a 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.
  • Page 17 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 6.5.10 Plug the AC Power Cord into the dryer. 6.5.11 Plug in or wire the Power Cord to an outlet: • 110 - 125 VAC power outlet for P4200W2 and P4200W2LP model •...
  • Page 18 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 6.5.13.2 Turn the knob until the reading on the Pressure Gauge is 345 KPa (50 PSI). 6.5.13.3 Push the knob in to lock. 6.5.14 Let the dryer run until the Humidity drops below 2% (may take up to 15 minutes).
  • Page 19 System may be pressurized. 6.5.17 Connect the air supply line to the Outlet Pressure Port. PUREGAS recommends using Installation Kit P011752 to connect your air dryer to the air supply line (See section 11.6 for detail). 6.5.18 Power the dryer ON.
  • Page 20 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 6.5.19.2 Turn knob until the reading on the Pressure Gauge is 138 KPa (20 PSI). 6.5.19.3 Push knob in to lock. 6.5.20 Set the Outlet Pressure: 6.5.20.1 Pull the Outlet Pressure Regulator knob...
  • Page 21 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 6.5.21 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 FITTING.

  • Page 22: Installation Checklist

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 6.5.23 Connect a Common Alarm (as required): 6.5.23.1 Insert the included Alarm Connector into either of the two (2) Alarm Ports. 6.5.23.2 Wire an external alarm wire pair to the Alarm Connector as required: •...

  • Page 23: Registering Your Dryer

    P4200W2 Series Air Dryer User’s Guide 7. Registering Your Dryer Please take a moment to register your PUREGAS P4200W2 Series 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.

  • Page 24: Operating Your Dryer

    WARNING! High Noise. Puregas air dryers are meant to be installed in an unattended area. CAUTION! Observe precautions for handling Electrostatic Sensitive Devices.

  • Page 25: Connecting An Air Line To The Dryer

    CAUTION! Incoming power to dryer must be: • 15 amp service recommended • 10 amp slow blow fuse • 110 - 125 VAC, 50/60 Hz for P4200W2 & P4200W2LP models • 220 - 230 VAC, 50/60 Hz, for P4202W2, 1 Phase P4202W2LP &...

  • Page 26: Using The Front Panel Display

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.4 Using the Front Panel Display CAUTION! The Display Screen is covered by a clear protective layer that guards against Electrostatic Discharge (ESD). DO NOT REMOVE THIS LAYER. 8.4.1 ALARM LED – Indicates an alarm is present.
  • Page 27 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.4.5 Display Screen - Shows the current dryer readings. Will cycle between the following three (3) information screens (unless the HOLD button has been pressed): 8.4.5.1 Sys Status Screen SYS STATUS - Running Status of the system: •...
  • Page 28 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.4.5.3 Compressor Run Time Screen DUTY CYCLE – The percentage of time the Compressor is ON versus time it is OFF during the last Air Tank pressurization cycle. TOTAL – How many hours the Compressor has run since the last Compressor Total Time Reset.

  • Page 29: Identifying Dryer Alarms

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.5 Identifying Dryer Alarms 8.5.1 High Cabinet Temperature Alarm - Occurs when the temperature in the dryer cabinet (CAB TEMP) rises above 46°C for more than one (1) minute. If the temperature rises above 50°C for more than one (1) minute, the air dryer will go into SHUTDOWN mode to protect against damage due to overheating.
  • Page 30 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.5.3 Low Outlet Pressure Alarm – Occurs when the Outlet Pressure (OUTLET) drops below the alarm threshold for more than one (1) minute. (Default setting is 2.0 KPa) This screen will be displayed, showing the Date and Time that the alarm occurred.
  • Page 31 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.5.5 High Flow Rate Alarm – Occurs when the Flow Rate (FLOW) rises above the alarm threshold for more than one (1) minute. (Default setting is 74.0 SCMD) This screen will be displayed, showing the Date and Time that the alarm occurred.
  • Page 32 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.5.7 Compressor Total Run 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.

  • Page 33: Accessing The Setup Menu

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.6 Accessing the Setup Menu The P4200W has three (3) Setup sections: • System Setup – Used to set specific values for the system. • Alarm Setup– Used to set the alarm thresholds for specific readings.

  • Page 34: Using The System Setup Menu

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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.
  • Page 35 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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 Left () & Right () Arrow Buttons to Select the digit to change.
  • Page 36 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.7.7 Reset Compressor Total Time – 8.7.7.1 Press 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).
  • Page 37 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.7.11 Set Date / Time – 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.

  • Page 38: Using The Alarm Setup Menu

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.8 Using the Alarm Setup Menu In the Setup Menu: 8.8.1 Press the Up () & Down () Arrow Buttons to Select the “A” in Alarm Setup. 8.8.2 Press the Enter () Button to access Alarm Setup.
  • Page 39 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.8.5 Set High Outlet Threshold (default setting is 138.0 KPa) – 8.8.5.1 Press the Enter () Button to access the edit screen. 8.8.5.2 Press the Left () & Right () Arrow Buttons to Select the digit to change.
  • Page 40 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.8.7 Set Low Pressure Threshold (default setting is 2.0 KPa) – 8.8.7.1 Press the Enter () Button to access the edit screen. 8.8.7.2 Press the Left () & Right () Arrow Buttons to Select the digit to change.
  • Page 41 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.8.9 Set High Flow Threshold (default setting is 74.0 SCMD) 8.8.9.1 Press the Enter () Button to access the edit screen. 8.8.9.2 Press the Left () & Right () Arrow Buttons to Select the digit to change.
  • Page 42 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.8.11 Set High 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 Buttons to Select the digit to change.

  • Page 43: Using The Network Setup Menu

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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.
  • Page 44 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.9.3 Set IP Address (default is 192.168.1.100) – 8.9.3.1 Press the Enter () Button to access the edit screen. 8.9.3.2 Press the Left () & Right () Arrow Buttons to Select the digit to change.
  • Page 45 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.9.5 Set Subnet Mask (default is 255.255.255.000) – 8.9.5.1 Press the Enter () Button to access the edit screen. 8.9.5.2 Press the Left () & Right () Arrow Buttons to Select the digit to change.
  • Page 46 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.9.7 Set Gateway Address (default is 000.000.000.000) – 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.
  • Page 47 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.9.9 Change Keyword (default is 123456) – 8.9.9.1 Press the Enter () Button to access the edit screen. 8.9.9.2 Press the Left () & Right () Arrow Buttons to Select the digit to change.

  • Page 48: Removing The Front Panel

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.10 Removing the Front Panel 8.10.1 Depress the four (4) Trigger Latches. 8.10.2 Pull the Front Panel away from the dryer. 8.11 Removing the Top Cover 8.11.1 Use he included Allen Wrench to unlock the two (2) Trigger Latches.

  • Page 49: Depressurizing The Dryer

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.12 Depressurizing the Dryer 8.12.1 Remove the Front Panel (section 8.10 ). 8.12.2 Pull the ring handle on the Safety Relief Valve until all air pressure is released. NOTE: To prevent pressure from building back up, power the dryer OFF (section 8.3 ).

  • Page 50: Setting The System Pressure

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.14 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 345 KPa (50 PSI).

  • Page 51: Setting The Static Pressure

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.15 Setting the Static Pressure 8.15.1 Remove the Front Panel (section 8.10 ). 8.15.2 Pull the Static Pressure Regulator knob out. 8.15.3 Turn knob until the reading on the Pressure Gauge is 138 KPa (20 PSI).

  • Page 52: Setting The Outlet Pressure

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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.

  • Page 53: Connecting Via Web Browser

    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 P4200W2 Series Air Dryer in the Address text box of the Web Browser.
  • Page 54 P4200W2 Series Air Dryer. This screen is informational only. • Alarm Screen - Displays all the Alarms registered by the P4200W2 Series Air Dryer. This screen is informational only. • Firmware Screen – Allows the user to upload any software updates or upgrades to the Air Dryer.

  • Page 55: Using The Status Screen

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.18 Using the Status Screen Displays the readings and alarms monitored in the P4200W2 Series Air Dryer. Provides remote ALARM RESET. • Readings are displayed in BLACK unless an alarm is present.
  • Page 56 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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 123456) 8.18.1.3 Click on SUBMIT Button when done.
  • Page 57 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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 Keyword (default is 123456) 8.18.2.3 Click on SUBMIT Button when done.

  • Page 58: Using The Setup Screen

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.19 Using the Setup Screen All configurations 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.
  • Page 59 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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) 8.19.1.5 Click on SUBMIT Button when done.
  • Page 60 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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 Click on SUBMIT Button to confirm. This will lock in the new setting value.

  • Page 61: Using The Event Screen

    8.20 Using the Event Screen Displays all events such as alarms, changes made, and alarm resets registered by the P4200W2 Series Air Dryer. This screen is informational only. • Click on the column headings to sort data according to that column.

  • Page 62: Using The Alarm Screen

    P4200W2 Series Air Dryer User’s Guide 8.21 Using the Alarm Screen Displays all the Alarms registered by the P4200W2 Series Air Dryer. This screen is informational only. • Click on the column headings to sort data according to that column.

  • Page 63: Using The Firmware Screen

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.22 Using the Firmware Screen Displays the current firmware version and date of the P4200W2 Series Air Dryer. • Current Version: Displays the current firmware version of the P4200W2 Series Air Dryer.
  • Page 64 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 8.22.1 Updating the 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 (default is 123456) 8.22.1.5 Click on SUBMIT Button when done.

  • Page 65: Connecting Via Snmp

    P4200W2 Series Air Dryer User’s Guide 8.23 Connecting via SNMP Using SNMP to connect and communicate with the P4200W2 Series Air Dryer is dependant 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.

  • Page 66: Testing Your Dryer

    WARNING! High Noise. Puregas air dryers are meant to be installed in an unattended area. CAUTION! Observe precautions for handling Electrostatic Sensitive Devices.

  • Page 67: Measuring Compressor Amp Draw

    With the Compressor running, the running amps should measure: • 8.6 amps or below for the P4200W2 & P4200W2LP models. • 3.9 or below for the P4202W2 & P4202W2LP models. • 4.2 or below for the P4202W2H model. If the Compressor measures over the recommended running amps, see section 13.16 for troubleshooting information.

  • Page 68: Measuring Voltage To Compressor

    The voltage should measure: • 110 - 125 VAC for the P4200W2 & P4200W2LP models. • 220 - 230 VAC for the P4202W2, P4202W2LP & P4202W2H models. 9.3.4 Reinstall the Front Panel (section 8.10 ).

  • Page 69: Measuring Voltage At The Power Line Filter

    The voltage should measure: • 110 - 125 VAC for the P4200W2 & P4200W2LP models. • 220 - 230 VAC for the P4202W2, P4202W2LP & P4202W2H models. If any of the voltage measurements are different than indicated above, the Power Line Filter is defective and should be replaced.

  • Page 70: Measuring Incoming Voltage

    The voltage should measure: • 110 - 125 VAC for the P4200W2 & P4200W2LP models. • 220 - 230 VAC for the P4202W2, P4202W2LP & P4202W2H models. If the incoming voltage measures less than indicated above, it is recommended that steps be taken at your facility to increase the incoming power to the recommended levels.

  • Page 71: Measuring Voltages At Solid State Relay

    9.6.4 Use a Voltmeter to measure across the DC terminals. The voltage should measure: • 5 VDC for the P4200W2 & P4200W2LP models. • 12 VDC for the P4202W2, P4202W2LP & P4202W2H models. Page 71 of 113 P012308 - Rev. E...
  • Page 72 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide With the Compressor NOT running: 9.6.5 Use a Voltmeter to measure across the AC terminals. The voltage should measure: • 110 - 125 VAC for the P4200W2 & P4200W2LP models. • 220 - 230 VAC for the P4202W2, P4202W2LP & P4202W2H models.

  • Page 73: Testing Consistent Heatless Dryer Cycling

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 9.7 Testing Consistent Heatless Dryer Cycling 9.7.1 Remove the Front Panel (section 8.10 ). With the Compressor running: 9.7.2 Disconnect the purge tubes from the Heatless Dryer. 9.7.3 Place your hand beneath the purge fittings to feel for purging air.

  • Page 74: Testing Unloader Valve

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 9.8 Testing Unloader Valve 9.8.1 Remove the Front Panel (section 8.10 ). With the Compressor running: 9.8.2 Disconnect the Unloader tube from the Unloader Valve. 9.8.3 Place your hand beneath the Unloader Valve fitting to feel for air flow.

  • Page 75: Measuring Heatless Dryer Solenoid Voltage

    The voltage should measure: • 53 VDC for the P4200W2 & P4200W2LP models. • 106 VDC for the P4202W2, P4202W2LP & P4202W2H 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 should be replaced.

  • Page 76: Testing Precooler Fan

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 9.10 Testing Precooler Fan 9.10.1 Place your hand in front of the Precooler Fan to feel for air being blown outward. If the fan is not blowing air outward as described: • Check for loose wiring. Refer to the Wiring Diagram (section 14.1 ) •...

  • Page 77: Testing Compressor On/Off Cycling

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 9.12 Testing Compressor ON/OFF Cycling 9.12.1 Remove the Front Panel (section 8.10 ). 9.12.2 When the Outlet Screen (section 8.4.5.2 ) appears on the display, press the HOLD Button on the Front Panel to freeze that screen.

  • Page 78: Testing High Duty Cycle Alarm

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 9.13 Testing High Duty Cycle Alarm NOTE: For this test, allow the Display Screen to cycle through the information screens. 9.13.1 Remove the Front Panel (section 8.10 ). 9.13.2 Allow the Compressor run and then turn off.

  • Page 79: Testing Humidity Alarm And System Shutdown

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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 80 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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.

  • Page 81: Testing High Outlet Pressure Alarm

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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.

  • Page 82: Testing Low Outlet Pressure Alarm

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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 ).
  • Page 83 PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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. 9.16.7 Turn Outlet Pressure Regulator knob clockwise...

  • Page 84: Testing Air Fittings & Hoses For Leaks

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 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.

  • Page 85: Maintaining Your Dryer

    P4200W2 Series Air Dryer User’s Guide 10. Maintaining Your Dryer In order to ensure that your P4200W2 Series Air Dryer continues to operate efficiently and reliably, PUREGAS recommends performing the following maintenance procedures at the specified Six Month and 8,000 Hour intervals.
  • Page 86 Control Board without depressurizing the air dryer first, or damage to the Control Board will occur. WARNING! High Noise. Puregas air dryers are meant to be installed in an unattended area. CAUTION! Observe precautions for handling Electrostatic Sensitive Devices.

  • Page 87: Six Month Maintenance

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 10.2 Six Month Maintenance MODEL: LOCATION NAME: SERIAL NUMBER: ADDRESS: DATE INSTALLED: Maintenance Interval (Months) Procedure Section Install Six Month Maintenance Kit P012314      11.6 Install P012514 for P4202W2H ONLY Read &...

  • Page 88: Hour Maintenance

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 10.3 8,000 Hour Maintenance Under typical operating conditions: 8,000 hours of run time will occur between one (1) and two (2) years of use. This will be identified by a COMPERSSOR RUN TIME: TOTAL Alarm on the display.

  • Page 89: Replacement Parts & Accessories

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 11. Replacement Parts & Accessories 11.1 Top Section Parts Recommend Description Part Number Quantity Spare P4200W2 P4202W2 P4200W2LP P4202W2LP (120 VAC) P4202W2H (220 VAC) Power IEC Connector P012279 Power Line Filter P011628 (1)

  • Page 90: Middle & Lower Section Parts 1

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 11.2 Middle & Lower Section Parts 1 Recommend Description Part Number Quantity Spare P4200W2 P4202W2 P4200W2LP P4202W2LP (120 VAC) P4202W2H (220 VAC) Precooler P4642 Heatless Dryer Assembly See section 11.4 for detail...

  • Page 91: Middle & Lower Section Parts 2

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 11.3 Middle & Lower Section Parts 2 Recommend Description Part Number Quantity Spare P4200W2 & P4202W2 & P4202W2H P4200W2LP P4202W2LP (220VAC) (120 VAC) (220 VAC) P012366 P012368 Static Pressure  (1) P013203...

  • Page 92: Heatless Dryer Assembly Parts

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 11.4 Heatless Dryer Assembly Parts Recommend Description Part Number Quantity Spare P4200W2 & P4202W2 & P4202W2H P4200W2LP P4202W2LP (220 VAC) (120 VAC) (220 VAC) Heatless Dryer PHF2C112041 PHF2C212041 PHF2C212045 Assembly Capacity Control ...

  • Page 93: Frame Section Parts

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 11.5 Frame Section Parts Recommend Description Part Number Quantity Spare Front Panel Trigger Latch Air Intake Filter In Kit P012314. See section 11.6 for detail. In Kit P012514 for P4202W2H ONLY Top Cover...

  • Page 94: Accessories For Your Dryer

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 11.6 Accessories for Your Dryer Recomme Description Part Number nd Spare Installation Kit P011752 Includes fittings required to connect to 3/4” flexible hose or 1/2” tubing. Six Month Maintenance Kit P012314  (2)

  • Page 95: Ordering Parts From Puregas

    User’s Guide and will not be covered. Please refer to the information included with the specific replacement part for this instruction. Once you have identified your required parts and accessories, contact the PUREGAS Inside Sales / Service department to order: (800) 521-5351 (option 2) Fax –...

  • Page 96: Service & Repair

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 12. Service & Repair Only PUREGAS can offer factory direct rebuilds backed by a 6 month factory warranty. • 2 week turnaround time • Estimates available upon request • Minimum service charge fee applies 12.1 Services Offered...

  • Page 97: Troubleshooting Your Dryer

    PLEASE READ THIS SECTION FIRST. It is important that you use the following sections in order to diagnose and attempt to fix the problem with your air dryer before placing a call to PUREGAS Technical Support. This troubleshooting guide is intended to simplify the isolation of problems, present possible causes, provide test procedures for verification, and suggest corrective actions to restore the air dryer back to normal operation.
  • Page 98 Do not test the Humidity Sensor with an ohm meter or apply any DC voltage. This will render the Humidity Sensor defective. WARNING! High Noise. Puregas air dryers are meant to be installed in an unattended area. CAUTION! Observe precautions for handling Electrostatic Sensitive Devices.

  • Page 99: Air Dryer Won't Power On

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 13.3 Air Dryer Won’t Power ON Possible Cause Check Corrective Action Power Circuit Breaker Verify Power Circuit Move Power Circuit in OFF position Breaker is in ON Breaker to ON position position (section 8.3 )

  • Page 100: Can't Create A High Pressure Alarm

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 13.6 Can’t Create a High Pressure Alarm Possible Cause Check Corrective Action Defective Outlet Verify that the Outlet Replace Outlet Pressure Pressure Regulator Pressure Regulator can Regulator if unable to be adjusted adjust pressure (section 8.16 )

  • Page 101: Can't Create A Low Pressure Alarm

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 13.8 Can’t Create a Low Pressure Alarm Possible Cause Check Corrective Action Defective Outlet Verify that the Outlet Replace Outlet Pressure Pressure Regulator Pressure Regulator can Regulator if unable to be adjusted adjust pressure (section 8.16 )

  • Page 102: High Humidity

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 13.10 High Humidity CAUTION! Do not test the Humidity Sensor with an ohm meter or apply any DC voltage. This will render the Humidity Sensor defective. Possible Cause Check Corrective Action Low System Pressure...

  • Page 103: Shutdown

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 13.11 Can’t Create a High Humidity Alarm / Shutdown These troubleshooting steps assume that the Humitter is removed from the Humidity Block during the Testing Humidity Alarm and System Shutdown (section 9.14 ) procedures.

  • Page 104: Inconsistent Heatless Dryer Cycling

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 13.13 Inconsistent Heatless Dryer Cycling Possible Cause Check Corrective Action Defective Solenoid Measure voltage going If correct VDC IS Valve to the Heatless Dryer present, replace Solenoid Valves Solenoid Valves (section 9.9 )

  • Page 105: Compressor Excessive Amp Draw

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 13.16 Compressor Excessive AMP Draw Possible Cause Check Corrective Action Restriction in air line Remove Discharge Hose If measurement is below from Compressor (see the recommended section 11.3 for location running amps, trace...

  • Page 106: Can't Create A High Duty Cycle Alarm106

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 13.18 Can’t Create a High Duty Cycle Alarm Possible Cause Check Corrective Action High Duty Cycle Alarm Verify High Duty Cycle Allow the Compressor threshold too high threshold to run longer than the (section 8.8.11 )

  • Page 107: Contacting Puregas Technical Support

    P4200W2 Series Air Dryer User’s Guide 13.20 Contacting PUREGAS Technical Support Please read the Before You Call PUREGAS section 13.1 Once 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...

  • Page 108: Appendix

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 14. Appendix 14.1 Wiring Diagram Page 108 of 113 P012308 - Rev. E...

  • Page 109: Operational Limits And Defaults

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 14.2 Operational Limits and Defaults 14.2.1 System Adjustments Minimum Maximum Default Unit of Description Value Value Value Measurement System Pressure (50) (PSI) Static Pressure (20) (PSI) Outlet Pressure 35.0 138.0 (LP UNITS) (2.0)

  • Page 110: Snmp Parameters

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 14.3 SNMP Parameters Device Configuration Information Device ID Alphanumeric (Defined by Customer) Device Model Alphanumeric (Factory Preset) Device Firmware Version Numeric (Factory Preset) Current Date/Time Numeric (mm/dd/yy hh:mm) IP Address Numeric (xxx.xxx.xxx.xxx) Subnet Mask Numeric (xxx.xxx.xxx.xxx)

  • Page 111: Limited Warranty Agreement

    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 functioning or reliability, neither will it apply to any product which has been subject to misuse, negligence, or accident.

  • Page 112: Contacting Puregas

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 16. Contacting PUREGAS 16.1 General PUREGAS, LLC 226A Commerce Street Broomfield, 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...

  • Page 113: Notes

    PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide 17. Notes ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ Page 113 of 113...

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