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Summary of Contents for Puregas P4200DCO3A
- Page 1 OPERATING INSTRUCTIONS AND PARTS LIST FOR PUREGAS MODEL P4200DCO3A CENTRAL OFFICE AIR DRYER Made in USA P010290 REV B...
- Page 2 This instruction manual is for the benefit of our customers. It is intended to provide the basic information that will enable our customers to install, maintain and service PUREGAS air dryers economically, capably, and with minimum delay. Careful observation of the instructions and maintenance procedures will ensure maximum life and efficiency from the unit.
- Page 3 This warranty shall not apply to any air dryer which shall have been repaired or altered in any way by anyone other than Puregas so as to affect, in our judgment, its proper functioning or reliability, neither will it apply to a dryer which has been subject to misuse, negligence, or accident.
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Page 4: Table Of Contents
PUREGAS INSTRUCTION MANUAL MODEL P4200DCO3A AIR DRYER TABLE OF CONTENTS SECTION 1 – GENERAL ................... 1 1.1 Scope of Manual ..................... 1 1.2 Initial Inspection..................... 1 1.3 Warranty......................... 1 SECTION 2 – DESCRIPTION ................2 SECTION 3 – PRINCIPLES OF OPERATION..........3 3.1 Air System....................... - Page 5 6.5 Air Compressor Pressure Switch................15 6.6 High/Low Pressure Alarm Adjustment ..............15 6.7 Capacity Control Valve Adjustment..............15 6.8 Air Compressor Maintenance Kit................. 16 6.9 Air Compressor Troubleshooting Chart .............. 17 6.10 Air Compressor Disassembly ................18 6.11 Air Compressor Assembly................... 18 6.12 Heatless Dryer (dehydrator) ................
- Page 6 CONTROL BOARD P05847F ................10 COMPRESSOR PERFORMANCE TIME DELAY SWITCH......11 AIR COMPRESSOR PRESSURE SWITCH............15 HIGH/LOW PRESSURE ALARM SWITCH ..........15 EXPLODED VIEW OF PUREGAS HEATLESS DRYER ......23 EXPLODED VIEW OF COMPRESSOR AND MOTOR ASSEMBLY ..24 TOP PANEL FRONT VIEW ................26 TOP PANEL REAR VIEW................26 WIRING DIAGRAM..................28...
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Page 7: Section 1 - General
This instruction Manual covers the description, operating principles, installation and start up, test procedures, maintenance, and troubleshooting techniques for the Model P4200DCO3A Air Dryer. The Model P4200DCO3A is designed for indoor use. 1.2 Initial Inspection Carefully inspect both the exterior and interior of the air dryer for any shipping damage. -
Page 8: Section 2 - Description
SECTION 2 – DESCRIPTION The model P4200DCO3A Air Dryer employs the principles of compression and physical adsorption. The operation is fully automatic and relatively maintenance free. The unit essentially consists of an oilless air compressor and heatless desiccant dryer. It also incorporates the necessary gauges, controls, and automatic alarms to ensure the delivery of dry air at the proper pressure and relative humidity. -
Page 9: Section 3 - Principles Of Operation
SECTION 3 – PRINCIPLES OF OPERATION This unit has successfully completed a three day operational test at the factory. Each component was individually calibrated and tested over its full range of operation. The operation and existing settings are explained in the sections following. 3.1 Air System The air flow is shown schematically in the Figure 1 below. -
Page 10: Heatless Dryer
3.3 Heatless Dryer The Puregas heatless dryer, which is located downstream from the air compressor, consists of two desiccant-filled towers, a manifold, a solid state timer and two solenoid valves. It is arranged and cycled so one tower delivers dry air while the desiccant in the other tower is purged and dried by a small quantity of dry air supplied by the first tower, refer to Figure 2. -
Page 11: Humidity Sensing Tube
3.4 Humidity Sensing Tube Air is then channeled to the humidity sensing tube and flows over the humidity sensor. The humidity sensor (not shown) will signal the alarm systems if the relative humidity rises above 10%. A relative humidity rise would indicate a malfunction. 3.5 Capacity Control Valve This valve has two functions. -
Page 12: Humidity Condition - Humidity, -Cond
3.9.4 Humidity Condition – HUMIDITY, -COND.- During the time when the HUMIDITY, -COND.- is being displayed the following sequence occurs: A. The solid state humidity time delay switch starts counting down from its preset value, which is factory set at 2 minutes. B. -
Page 13: Section 4 - Installation And Start-Up
SECTION 4 – INSTALLATION AND START-UP CAUTION !!! It is extremely important to perform the installation, start-up, and test procedures in Sections 4 and 5 in the sequence outlined or damage to components may result and the warranty voided. 4.1 Inspection Remove the lower front door and open the upper instrument panel. -
Page 14: Start-Up
4.5 Start-Up A plastic plug with a small hole is located in the low pressure outlet port at the rear of the dryer. This orifice plug will permit the unit to operate in a simulated “on-line” condition. A. Place the main power switch to the ON position. B. -
Page 15: Section 5 - Test Procedures
SECTION 5 – TEST PROCEDURES WARNING !!! Avoid contact with energized circuits when access doors are open. REMOVE ALL JEWELRY before performing any test or maintenance on the air dryer. 5.1 Low Pressure Alarm Test A. Open the front instrument panel. B. -
Page 16: Humidity Alarm Test
5.4 Humidity Alarm Test A humidity alarm will result after the system has remained in a humidity condition for longer than the time set on the humidity time delay switch. To perform the test, simply keep the dryer in a humidity condition for longer than two minutes. This may be done by depressing the humidity test switch on the humidity board. -
Page 17: Compressor Performance Test
5.5 Compressor Performance Test A compressor performance alarm (COMP. RUN TIME ALARM) will result when the air compressor remains running for a period longer than normal for a particular application. Example: If the time between the air compressor starting and stopping is one minute, then the normal run time is one minute. -
Page 18: Section 6 - Maintenance
When working around energized circuits, extreme caution should be taken to prevent injury to personnel and damage to equipment. 6.1 Routine Maintenance The following maintenance procedure is recommended by Puregas. If maintenance problems persist after thoroughly consulting this manual, contact Puregas Service Department, 1-800-521-5351 extension 2156. -
Page 19: Maintenance Matrix
1 year Humidity sensing element Replace 1 year Chart 2 Puregas P4200DCO3A Maintenance The air compressor kit, and the humidity sensing element are supplied in the annual maintenance kit. The part number for the heatless dryer maintenance kit is P200499S. -
Page 20: Recommended Spare Parts List
6.3 Recommended Spare Parts List Part Number Description P02626S vibration mounts P010369 pressure switch P05285 precooler fan P07580F2 humidity board P5000647D humidity sensor P05847F1 logic board P07599F1 display board P05992 solid state relay (25 amp) P06136 circuit breaker (15 amp) P400589DC1 solenoid valve assembly P200499S... -
Page 21: Air Compressor Safety Valves
6.4 Air Compressor Safety Valves The air compressor safety valve is factory preset to prevent the air compressor from delivering over 60 PSIG. Check for proper operation 6.5 Air Compressor Pressure Switch The ON/OFF pressure switch is factory set to stop and start the air compressor and ,maintain the pressure in the air storage tank. -
Page 22: Air Compressor Maintenance Kit
6.8 Air Compressor Maintenance Kit The maintenance kit contains the parts necessary for scheduled maintenance on the P4200DCO3A air dryer when operating under normal conditions. The contents of the maintenance kit are as follows: Part Number Description QTY/Kit P3861 piston seal... -
Page 23: Air Compressor Troubleshooting Chart
6.9 Air Compressor Troubleshooting Chart The wear of the air compressor rings are affected by ambient conditions. At 80 to 85 maximum ambient temperature and 40% (maximum average) relative humidity, it is suggested the compressor life between maintenance checks be set at approximately 4,000 hours of run time. -
Page 24: Air Compressor Disassembly
6.10 Air Compressor Disassembly A. Remove or loosen the four screws, which secure the fan shroud to the motor and slide the shroud off. Remove the four cylinder head bolts and separate them from the cylinder bolts. Remove the air manifold tube and the cylinder head with the valve components. -
Page 25: Heatless Dryer (Dehydrator)
NOTE: The ends of two fins on the cylinder have been omitted. They are always on the exhaust port. D. Install the head assembly using the four head bolts and finger tighten. E. Install the new manifold seals on the manifold, and assemble to the elbow fitting on the head assembly. - Page 26 30 seconds, and then DC2 to L2 for 30 seconds. If this is not happening, replace the solid state timer (P06521F). I. If the air dryer is still in humidity alarm after the above steps have been taken, contact the Puregas Service Department for technical help.
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Page 27: Maintenance Kit
6.15 Maintenance Kit This maintenance kit is designed to provide the parts necessary for one year’s normal maintenance on the Puregas P4200DCO3A air dryers. The maintenance indicated should be performed at the noted intervals. See Section 6 for more information. -
Page 28: Dehydrator Parts List
6.16 Dehydrator Parts List Numbers refer to parts shown in Figure 9. Reference Part Number Description Number P20040312 desiccant chamber assembly, 12 in P400312924 o-ring (included in above) P400313110 o-ring P20040441 purge orifice P400312908 o-ring P400375 check valve ball P4003074 hex plug P400312904 o-ring... -
Page 29: Exploded View Of Puregas Heatless Dryer
Heatless dryer maintenance kit P200499S includes items 2,3,5,6, and 17. Solenoid maintenance kit P200498S includes item 17 which consists of items 36 to 41. Figure 9 EXPLODED VIEW OF PUREGAS HEATLESS DRYER... -
Page 30: Compressor Parts List
6.17 Compressor Parts List Figure 10 EXPLODED VIEW OF COMPRESSOR AND MOTOR ASSEMBLY Ref. Ref. Part No. Description Part No. Description P3998 pipe plug P3862 piston ring P3996 safety valve P3861 piston seal (included in #2) P3872 piston rod assy. (included in #2) P3981 rider ring... - Page 31 Figure 11 FRONT VIEW OF PUREGAS P4200DCO3A...
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Page 32: Top Panel Front View
power on light flowmeter circuit breaker run-time meter alarm reset switch tank pressure gauge (0-100) outlet pressure gauge (0-30) Figure 12 AIR DRYER FRONT VIEW display board (beneath logic board) logic board solid state relay humidity board Figure 13 TOP PANEL REAR VIEW... - Page 33 Air Dryer Parts List Refer to drawings on previous pages. Part Number Description P5000647D humidity sensor P03348 outlet pressure regulator P07677 high/low pressure alarm switch P4634 capacity control valve P3197 pressure gauge 0-100 PSIG P05893 cabinet filter P39664L compressor P010369 compressor pressure switch PHF2C112041 heatless dryer...
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Page 35: Section 7 - Troubleshooting Information Guide
The troubleshooting information guide can by no means cover every possible cause of malfunction, but will help solve most problems. If the problem persists after thoroughly consulting the troubleshooting section, contact Puregas Technical Service at 1-800-521- 5351 extension 2156, or (303) 657-2156. -
Page 36: Alarm Display Summary
7.1 Alarm Display Summary Problem 1. Low Pressure Alarm Possible Cause: Check: Corrective Action: Refer to Section 3 and Section 5. Problem 2. Comp. Run Time Alarm Possible Cause: Check: Corrective Action: Refer to Section 3 and Section 5. Problem 3. Humidity –Cond.- Alarm Possible Cause: Check: Corrective Action:... -
Page 37: Humidity Alarm System
Problem 3. Rapid ON/OFF Cycling Possible Cause: Check: Corrective Action: with no outlet flow, check all fittings tighten any loose connections as leak in air system with soapy water required incorrect capacity control valve adjust capacity control vale to 50 properly adjust capacity control adjustment PSIG +/- 2 PSIG... -
Page 38: Electrical System
7.4 Electrical System Problem 1. No Power To The Air Dryer Possible Cause: Check: Corrective Action: power has been interrupted to the toggle the humidity switch on the reset the main power supply, or dryer humidity board replace bad fuse check circuit break to see if it has circuit breaker tripped out main reset circuit breaker, and check for... -
Page 39: Dehydrator
7.5 Dehydrator Problem 1. Heatless Dryer Delivers Wet Air Possible Cause: Check: Corrective Action: check core assembly for broken defective solenoid valve defective parts should be replaced spring and proper seating clean orifice from debris, do not purge orifice plugged check orifice for obstruction clean with abrasive material check coil for magnetic pull with...
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