P4200W2 Series Air Dryer
P4200W2 P4200W2LP P4202W2 P4202W2LP P4202W2H
User’s Guide
Models covered:
P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
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.
We are sure that you will be satisfied with your new air dryer and would like to thank you
for choosing PUREGAS for your air dryer requirements. We also hope that you will
continue to choose us for your future air pressure and related product purchases.
For information about this and other PUREGAS products, please 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 P4200W2 Series Air Dryer. Models covered
include P4200W2, P4200W2LP, P4202W2, P4202W2H and P4202W2LP. It will cover
topics including: safety, specifications, installation, registration, operation, testing,
maintenance, replacement parts, service, and troubleshooting issues. Observation and
compliance with this User’s Guide will ensure the maximum life and efficiency of your
air dryer.
This User’s Guide should be read thoroughly prior to installing, operating, or servicing
the air dryer in order to become familiar with the recommended procedures. This will
minimize the possibility of personal injury or damage to the unit due to improper
operation or handling.
Page 3 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
3. Table of Contents
8.12 Depressurizing the Dryer ........................ 49
1. Welcome & Congratulations .......................... 3
8.13 Connecting to Common Alarm Socket ... 49
2. Introduction ..................................................... 3
3. Table of Contents ............................................. 4
4. Safety & Warning Information ...................... 6
5. Overview & Specifications .............................. 9
5.1 Product Description .................................... 9
5.2 Key Features ............................................... 9
5.3 P4200W2 Series Air Dryer Models ............ 9
5.4 Technical Specifications ........................... 10
5.5 Dryer Function Overview ......................... 11
6. Installing Your Dryer .................................... 12
6.1 Safety & Warning Information ................. 12
6.2 Before You Begin ..................................... 13
6.3 Included Contents ..................................... 14
6.4 Required Tools and Materials ................... 14
6.5 Installation Steps ....................................... 15
6.6 Installation Checklist ................................ 22
8.14 Setting the System Pressure .................... 50
8.15 Setting the Static Pressure ....................... 51
8.16 Setting the Outlet Pressure ...................... 52
8.17 Connecting via Web Browser ................. 53
8.18 Using the Status Screen .......................... 55
8.19 Using the Setup Screen ........................... 58
8.20 Using the Event Screen ........................... 61
8.21 Using the Alarm Screen .......................... 62
8.22 Using the Firmware Screen ..................... 63
8.23 Connecting via SNMP ............................ 65
9. Testing Your Dryer ....................................... 66
9.1 Safety & Warning Information ................. 66
9.2 Measuring Compressor Amp Draw .......... 67
9.3 Measuring Voltage to Compressor ........... 68
9.4 Measuring Voltage at the Power Line
Filter ............................................................... 69
9.5 Measuring Incoming Voltage ................... 70
9.6 Measuring Voltages at Solid State Relay .. 71
9.7 Testing Consistent Heatless Dryer
7. Registering Your Dryer................................. 23
8. Operating Your Dryer .................................. 24
8.1 Safety & Warning Information ................. 24
8.2 Connecting an Air Line to the Dryer ........ 25
8.3 Powering the Dryer ON & OFF ................ 25
8.4 Using the Front Panel Display .................. 26
8.5 Identifying Dryer Alarms ......................... 29
8.6 Accessing the Setup Menu ........................ 33
8.7 Using the System Setup Menu .................. 34
8.8 Using the Alarm Setup Menu ................... 38
8.9 Using the Network Setup Menu................ 43
8.10 Removing the Front Panel ...................... 48
8.11 Removing the Top Cover ........................ 48
Page 4 of 113 P012308 - Rev. E
Cycling............................................................ 73
9.8 Testing Unloader Valve ............................ 74
9.9 Measuring Heatless Dryer Solenoid
Voltage............................................................ 75
9.10 Testing Precooler Fan ............................. 76
9.11 Testing Safety Relief Valve .................... 76
9.12 Testing Compressor ON/OFF Cycling ... 77
9.13 Testing High Duty Cycle Alarm ............. 78
9.14 Testing Humidity Alarm and System
Shutdown ........................................................ 79
9.15 Testing High Outlet Pressure Alarm ....... 81
9.16 Testing Low Outlet Pressure Alarm........ 82
9.17 Testing Air Fittings & Hoses for Leaks .. 84
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
10. Maintaining Your Dryer ............................. 85
10.1 Safety & Warning Information ............... 85
10.2 Six Month Maintenance .......................... 87
10.3 8,000 Hour Maintenance ........................ 88
11. Replacement Parts & Accessories .............. 89
11.1 Top Section Parts .................................... 89
11.2 Middle & Lower Section Parts 1 ............ 90
11.3 Middle & Lower Section Parts 2 ............ 91
11.4 Heatless Dryer Assembly Parts............... 92
11.5 Frame Section Parts ................................ 93
11.6 Accessories for Your Dryer .................... 94
11.7 Ordering Parts from PUREGAS ............. 95
12. Service & Repair.......................................... 96
12.1 Services Offered ..................................... 96
12.2 Initiating a Service Transaction .............. 96
13.11 Can’t Create a High Humidity Alarm /
Shutdown ...................................................... 103
13.12 High Cabinet Temperature Alarm....... 103
13.13 Inconsistent Heatless Dryer Cycling ... 104
13.14 Compressor Doesn’t Operate .............. 104
13.15 Compressor Won’t Build Pressure ...... 104
13.16 Compressor Excessive AMP Draw ..... 105
13.17 High Duty Cycle Alarm ...................... 105
13.18 Can’t Create a High Duty Cycle Alarm106
13.19 Compressor Rapid ON/OFF Cycling .. 106
13.20 Contacting PUREGAS Technical
Support.......................................................... 107
14. Appendix .................................................... 108
14.1 Wiring Diagram .................................... 108
14.2 Operational Limits and Defaults ........... 109
14.3 SNMP Parameters ................................. 110
13. Troubleshooting Your Dryer ...................... 97
13.1 Before You Call PUREGAS ................... 97
13.2 Safety & Warning Information ............... 97
13.3 Air Dryer Won’t Power ON.................... 99
13.4 Display Screen Not Functioning ............. 99
13.5 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 Humidity .................................... 102
15. Limited Warranty Agreement .................. 111
Registration Reminder .................................. 111
16. Contacting PUREGAS .............................. 112
16.1 General .................................................. 112
16.2 Sales ...................................................... 112
16.3 Service .................................................. 112
16.4 Technical Support ................................. 112
17. Notes............................................................ 113
Page 5 of 113 P012308 - Rev. E
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.
Additional warnings specific to an operation or procedure will also be presented
throughout the following sections. These will include the symbol as well as a label of
“WARNING!”, “CAUTION!”, or “IMPORTANT!”. Please be sure to pay close
attention for these warnings and read them as you encounter them.
WARNING!
For your safety, all the information in this User’s Guide must be
followed to minimize the risk of electrical shock, and prevent
property damage or personal injury.
WARNING!
Extreme care should be exercised to avoid contact with 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.
Page 6 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
your air dryer.
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.
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!
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, 1 Phase for P4202W2,
P4202W2LP & P4202W2H models
IMPORTANT!
Performing routine maintenance as outlined in the Maintaining Your
Dryer section will ensure optimal performance over the lifecycle of
Page 7 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
AND MAY VOID THE WARRANTY.
IMPORTANT!
Performing procedures not described in this User’s Guide or installing
components not supplied by PUREGAS is NOT RECOMMENDED
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.
IMPORTANT!
Installation of PUREGAS air dryers are intended for network
telecommunication facilities (non-customer premises) only.
Page 8 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
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, ondemand source of dry, pressurized air. This process is fully automatic and will
remain consistent with minimal required periodic maintenance. This dryer is
designed specifically for indoor use.
The P4200W2 Series Air Dryer employs a fully digital operating platform offering
the most accurate readings of dryer variables, removable 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 operating parameters
• Solid state microprocessor-based circuitry eliminates costly maintenance
• Accurate humidity sensing within ±0.1% RH
• Quietest dryer on the market
• Pressure Ranges from 35 – 138 KPa or 2 – 69 KPa (LP Models)
• Remote alarm reset capabilities
• SNMP communication compatible
• Remote access through HTML interface
• Oil-less compressor with 8,000 hour maintenance interval
5.3 P4200W2 Series Air Dryer Models
Model Description
P4200W2 110 - 125 VAC, Standard Pressure 35 – 138 KPa
P4200W2LP 110 - 125 VAC , Low Pressure 2 – 69 KPa
P4202W2 220 - 230 VAC , Standard Pressure 35 – 138 KPa
P4202W2LP 220 - 230 VAC , Low Pressure 2 – 69 KPa
P4202W2H 220 - 230 VAC , Standard Pressure 35 – 138 KPa
Page 9 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
5.4 Technical Specifications
Output
Capacity
Power
Requirements
Running Amps
Outlet Pressure
Range
Outlet Air
Humidity
Compressor
Drying Method
P4200W2 P4200W2LP P4202W2
Normal: 74 SCMD Maximum: 119 SCMD
110 - 125 VAC, 1 Phase,
50 / 60 Hz
8.6 Amps
(15 Amp service
recommended)
35 - 138
KPa
2 – 69
KPa
2-cylinder, 3/4 HP, oil-less type compressor
220 - 230 VAC, 1 Phase,
50 / 60 Hz
3.9 Amps
(15 Amp service
recommended)
35 - 138
KPa
Less than 2% RH
Heatless Desiccant
P4202W2
LP
2 – 69
KPa
P4202W2H
Normal: 90 SCMD
Max: 119 SCMD
220-230 VAC, 1 Phase,
50Hz
4.2 Amps
(15 Amp service
recommended)
35 – 138
KPa
Operating
Temperature
Range
Noise Level:
Heat
Dissipation
Alarms
Monitoring
Outlet
Connections
Dimensions
Net / Shipping
Weight
5° to 30° C (optimal)
63 dBA @ 1m
3,521 BTU / hr 2,924 BTU / hr
Standard alarms – complete readings of all critical measurement points, individual
alarm indication display
Web Browser and SNMP compatible communications via Network IP
1/2” NPT Female
53cm D x 64cm W x 124cm H
100 kgs / 126 kgs
Page 10 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
5.5 Dryer Function Overview
# Component Description
1 Compressor Compresses drawn in ambient air.
2 Precooler Cools compressed air prior to drying function.
3 Unloader Valve Relieves excess Compressor head pressure.
4 Heatless Dryer Removes moisture from compressed air.
5 Capacity Control Valve Regulates System Pressure at 345 KPa (50 PSI)
and prevents air from bleeding back through the
Heatless Dryer.
6 Air Tank Stores dry compressed air.
7 Static Pressure Regulator Regulates the Static Pressure at 138 KPa (20 PSI)
and maintains constant pressure on the Combo
Block for accurate Flow measuring.
8 Combo Block Measures the Flow of compressed air and houses
the Humitter.
9 Outlet Pressure Regulator Regulates the Outlet Pressure.
10 Pressure Outlet Outputs the pressure set by the Outlet Pressure
Regulator.
Page 11 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
user.
6. Installing Your Dryer
6.1 Safety & Warning Information
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.
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!
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.
CAUTION!
This Air Dryer does not contain an internal Surge Protection
Device (SPD). If an SPD is required it must be supplied by the
Page 12 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
RECOMMENDED AND MAY VOID THE WARRANTY.
IMPORTANT!
Performing procedures not described in this User’s Guide or
installing components not supplied by PUREGAS is NOT
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. If any shipping
damage is detected, it is important to file a claim with the shipping
company prior to continuing the installation procedures.
6.2.2 Read the entire Installing Your Dryer section to familiarize yourself with
the components and procedures before performing the air dryer installation.
6.2.3 Verify the installation location of the air dryer:
6.2.3.1 Well ventilated and free from abrasive dust or chemicals.
6.2.3.2 Ambient temperature is between 5° and 30° C (optimal).
NOTE: Higher temperatures will decrease component lifespan.
6.2.3.3 Meets the following power requirements:
• 110 - 125 VAC for P4200W2 and P4200W2LP models
• 220 - 230 VAC, 1 Phase for P4202W2, P4202W2LP & P4202W2H models
• All models require 50/60 Hz and minimum 15 amp service with a 10 amp
slow blow fuse
6.2.4 Notify the alarm center of the installation and potential for alarms during
the process (as necessary).
Page 13 of 113 P012308 - Rev. E
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 (1) Compressor Connector Tool
(1) Power Cord
6.4 Required Tools and Materials
• Large adjustable wrench
• Medium adjustable wrench
• 7/16” wrench
• Band cutters or snips
• Pipe dope or pipe thread tape
• Cup of soapy water
• 1-inch paint brush
(recommended)
Page 14 of 113 P012308 - Rev. E
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.
6.5.3 Remove the Front Panel.
6.5.4 Check for loose parts,
hoses, or wiring.
NOTE: If ANY SHIPPING
DAMAGE is detected, file a
claim with the shipping
company prior to continuing
the installation procedures.
Page 15 of 113 P012308 - Rev. E
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.
6.5.8 Install the Purge Muffler
(optional).
6.5.9 Verify that the dryer is
powered OFF.
Page 16 of 113 P012308 - Rev. E
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
• 220 – 230 VAC, 1 phase, power outlet for P4202W2, P4202W2LP, and
P4202W2H models.
6.5.12 Power the dryer ON.
NOTE: The Compressor and
Heatless Dryer will start,
creating air flow through the
Red Orifice Plug.
6.5.13 Set the System Pressure:
With Compressor running:
6.5.13.1 Pull the Capacity
Control Valve knob out.
Page 17 of 113 P012308 - Rev. E
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).
NOTE: Press RESET if the
dryer goes into
SHUTDOWN.
6.5.15 Power the dryer OFF.
Page 18 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
6.5.16 Remove the Red Orifice
Plug from the Outlet Pressure
Port.
CAUTION: Be careful when
removing plug. 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.
6.5.19 Set the Static Pressure:
6.5.19.1 Pull Static Pressure
Regulator knob out.
Page 19 of 113 P012308 - Rev. E
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
out or loosen the
retaining nut (LP
models).
6.5.20.2 Turn knob until
Outlet Pressure
(OUTLET) reading is
at the desired setting.
6.5.20.3 Push knob in to lock
or tighten retaining nut
(LP models).
Page 20 of 113 P012308 - Rev. E
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. DAMAGE TO THE SENSOR MAY OCCUR.
With Compressor 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
connection to be tested.
If air bubbles appear at the
connection, this indicates that
air is leaking from the
connection.
If any leaks are detected, take steps to seal them off (as necessary):
• Tighten the fitting
• Re-connect the hose end
• Replace the fitting / hose / component
6.5.22 Re-install the Front Panel.
Page 21 of 113 P012308 - Rev. E
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:
• Common and N.C. for
OPEN ON ALARM
operation.
• Common and N.O. for CLOSE ON ALARM operation.
6.5.24 REGISTER YOUR DRYER. See section 7 for details.
6.6 Installation Checklist
No shipping damage was detected.
Dryer location meets the following requirements:
o Well ventilated
o Free from abrasive dust or chemicals
o Ambient temperature is between 5° and 30° C (optimal)
Shipping block removed from Compressor Tray.
System Pressure is set to 345 KPa (50 PSI).
Static Pressure is set to 138 KPa (20 PSI).
No air leaks are present in the system.
No alarms are present on the Display Panel.
Page 22 of 113 P012308 - Rev. E
PUREGAS, LLC 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.
Register Online at www.puregas.com/registration
Or by Phone 1-800-521-5351 (option 2)
Have the following information available:
Model #: Serial #:
Company Name: Location Name:
Shipping Address:
City: State: Zip Code:
Contact Name: Phone #: ( ) - ext.
Email:
Page 23 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
RECOMMENDED AND MAY VOID THE WARRANTY.
8. Operating Your Dryer
8.1 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.
WARNING!
High Noise. Puregas air dryers are meant to be installed in an
unattended area.
CAUTION!
Observe precautions for handling Electrostatic Sensitive Devices.
IMPORTANT!
Performing procedures not described in this User’s Guide or
installing components not supplied by PUREGAS is NOT
Page 24 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
8.2 Connecting an Air Line to the Dryer
8.2.1 Remove the Red Orifice
Plug from the Outlet Pressure
Port.
CAUTION: Be careful when
removing plug. System may be
pressurized.
8.2.2 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).
8.3 Powering the Dryer ON & OFF
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, 1 Phase for P4202W2,
P4202W2LP & P4202W2H models
8.3.1 Power Circuit Breaker -
Controls the main power to
the dryer.
Page 25 of 113 P012308 - Rev. E
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.
8.4.2 RESET Button – Clears an alarm and allows the system to continue
operating.
8.4.3 FUNCTION 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 Setup Menu screens.
8.4.4 Arrow Buttons – Used to access, navigate, and change values in the Setup
Menu screens.
Page 26 of 113 P012308 - Rev. E
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:
• ONLINE – System is Online.
• SHUTDOWN – System has been shutdown as a result of either a
High Humidity or High Cabinet Temperature alarm.
CAB TEMP – Temperature of the dryer cabinet compartment.
HUMIDITY – Humidity level of the system.
8.4.5.2 Outlet Screen
OUTLET – Outlet Pressure regulated by the Outlet Pressure Regulator.
FLOW – Air Flow Rate.
TANK – Air Tank Pressure - fluctuates between 172 – 345 KPa.
Page 27 of 113 P012308 - Rev. E
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.
8.4.5.4 Unit in Standby Screen
Occurs when the dryer is connected to a Cycle Kit and has been switched
to Standby Mode.
Page 28 of 113 P012308 - Rev. E
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.
This screen will be 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 –
Occurs when the Humidity level (HUMIDITY) rises above the alarm
threshold for more than one (1) minute. The air dryer will go into
SHUTDOWN mode to prevent saturated air from being delivered to the
supply line. (Default setting is 10%)
This screen will be displayed,
showing the Date and Time that
the alarm occurred.
8.5.2.1 Press the Info () Button
to see the detail of the
alarm.
See section 13.10 for troubleshooting information.
Page 29 of 113 P012308 - Rev. E
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.
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 Pressure (OUTLET) rises above the alarm threshold
for more than one (1) minute. (Default setting is 138.0 KPa)
This screen will be displayed,
showing the Date and Time that
the alarm occurred.
8.5.4.1 Press the Info () Button
to see the detail of the
alarm.
See section 13.5 for troubleshooting information.
Page 30 of 113 P012308 - Rev. E
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.
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 High Duty Cycle Alarm –
Occurs when the Duty Cycle (DUTY CYCLE) exceeds the alarm threshold
during the Air Tank pressurization cycle. (Default setting is 70%)
This screen will be displayed,
showing the Date and Time that
the alarm occurred.
8.5.6.1 Press the Info () Button
to see the detail of the
alarm.
See section 13.17 for troubleshooting information.
Page 31 of 113 P012308 - Rev. E
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.
8.5.7.1 Press the Info () Button
to see the detail of the
alarm.
See section 10.3 for maintenance information.
Page 32 of 113 P012308 - Rev. E
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.
Once the threshold is reached (or exceeded) this results in an alarm. Each
of these thresholds is factory programmed with a default value. Many of
can be modified to levels based upon your specific application.
• Network Setup – Used to configure network settings including the IP
Address, Subnet Mask, Gateway Address, and Keyword.
NOTE: Reference Appendix Section 14.2 for Limits, Defaults, and Formats.
8.6.1 Press the Up () Arrow Button
to access the Setup Menu.
8.6.2 Press the Up () & Down ()
Arrow Buttons to Select the
required menu option.
8.6.3 Press the Enter () Button to access the menu selected or press the Left
() Arrow Button to Escape to the information screens.
Page 33 of 113 P012308 - Rev. E
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.
8.7.3 Set Alarm Delay (default setting is ON) –
8.7.3.1 Press the Enter ()
Button to access the edit
screen.
8.7.3.2 Press the Left () &
Right () Arrow Buttons
to Select the correct choice
(On or Off).
8.7.3.3 Press the Enter () Button to submit the selection.
8.7.3.4 Press the Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.7.3.5 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.7.4 Press the Up () Arrow Button to access the next screen.
Page 34 of 113 P012308 - Rev. E
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.
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 () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.7.5.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.7.6 Press the Up () Arrow Button to access the next screen.
Page 35 of 113 P012308 - Rev. E
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).
8.7.7.3 Press the Enter () Button to confirm the selected choice. This will
reset the Total Time to zero (0).
8.7.8 Press the Up () Arrow Button to access the next screen.
8.7.9 Reset To Factory Default Values –
8.7.9.1 Press the Enter ()
Button to access the reset
screen.
8.7.9.2 Press the Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.7.9.3 Press the Enter () Button to confirm the selected choice. This will
reset all settings to Factory Default Values (section 14.2 ).
8.7.10 Press the Up () Arrow Button to access the next screen.
Page 36 of 113 P012308 - Rev. E
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.
8.7.11.3 Press the Up () & Down () Arrow Buttons to Change the value of
the selected digit.
8.7.11.4 Press the Enter () Button to submit the new setting.
8.7.11.5 Press the Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.7.11.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.7.12 Press the Up () Arrow Button to access the next screen.
Page 37 of 113 P012308 - Rev. E
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.
8.8.3 Set High Humidity Threshold (default setting is 10%) –
8.8.3.1 Press 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.
8.8.3.4 Press the Enter () Button when to submit the new setting.
8.8.3.5 Press the Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.8.3.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.8.4 Press the Up () Arrow Button to access the next screen.
Page 38 of 113 P012308 - Rev. E
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.
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 Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.8.5.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.8.6 Press the Up () Arrow Button to access the next screen.
Page 39 of 113 P012308 - Rev. E
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.
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 Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.8.7.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.8.8 Press the Up () Arrow Button to access the next screen.
Page 40 of 113 P012308 - Rev. E
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.
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 Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.8.9.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.8.10 Press the Up () Arrow Button to access the next screen.
Page 41 of 113 P012308 - Rev. E
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.
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 the Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.8.11.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.8.12 Press the Up () Arrow Button to access the next screen.
Page 42 of 113 P012308 - Rev. E
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.
8.9.2 Enter Keyword (default Keyword is 123456) –
8.9.2.1 Press the Left () &
Right () Arrow Buttons
to Select the digit to
change.
8.9.2.2 Press the Up () & Down
() Arrow Buttons to
Change the value of the
selected digit.
8.9.2.3 Press the Enter () Button to submit the Keyword.
Page 43 of 113 P012308 - Rev. E
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.
8.9.3.3 Press the Up () & Down () Arrow Buttons to Change the value of
the selected digit.
8.9.3.4 Press the Enter () Button when to submit the new setting.
8.9.3.5 Press the Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.9.3.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.9.4 Press the Up () Arrow Button to access the next screen.
Page 44 of 113 P012308 - Rev. E
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.
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 () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.9.5.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.9.6 Press the Up () Arrow Button to access the next screen.
Page 45 of 113 P012308 - Rev. E
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.
8.9.7.3 Press the Up () & Down () Arrow Buttons to Change the value of
the selected digit.
8.9.7.4 Press the Enter () Button when to submit the new setting.
8.9.7.5 Press the Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.9.7.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
8.9.8 Press the Up () Arrow Button to access the next screen.
Page 46 of 113 P012308 - Rev. E
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.
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.
8.9.9.5 Press the Left () &
Right () Arrow Buttons
to Select the correct
confirmation choice (Yes
or No).
8.9.9.6 Press the Enter () Button to confirm the selected choice. This will
lock in the new setting.
Page 47 of 113 P012308 - Rev. E
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.
8.11.2 Depress the two (2)
Trigger Latches.
8.11.3 Lift the Top Cover off of
the dryer.
NOTE: There is a wire connected between the Top Cover and the dryer’s
main frame. This is used for grounding purposes.
Page 48 of 113 P012308 - Rev. E
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 ).
8.12.3 Reinstall the Front Panel (section 8.10 ).
8.13 Connecting to Common Alarm Socket
8.13.1 Insert the included Alarm
Connector into either of the
two (2) Alarm Ports.
8.13.2 Wire an external alarm
wire pair to the Alarm
Connector as required:
• Common and N.C. for
OPEN ON ALARM
operation.
• Common and N.O. for
CLOSE ON ALARM operation.
Page 49 of 113 P012308 - Rev. E
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).
8.14.4 Push the knob in to lock.
8.14.5 Reinstall the Front Panel (section 8.10 ).
Page 50 of 113 P012308 - Rev. E
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).
8.15.4 Push knob in to lock.
8.15.5 Reinstall the Front Panel (section 8.10 ).
Page 51 of 113 P012308 - Rev. E
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.
8.16.4 Push knob in to lock.
8.16.5 Reinstall the Front Panel (section 8.10 ).
Page 52 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
8.17 Connecting via Web Browser
If the Air Dryer IS connected to an IP network:
• The Air Dryer must be configured with a valid IP Address, Subnet Mask, and
Gateway Address for the network.
• An IP cable must be connecting the air dryer to the network.
• Use a computer that is on the same network as the air dryer.
• Use Internet Explorer (6.0 or newer) or Mozilla Firefox 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 (may require Cross-over cable) plugged directly into a
Laptop/PC and the other end plugged into the Network Port of the air dryer.
• Configure the network card on the Laptop/PC to use the IP Address
192.168.1.101. This will make the Laptop/PC compatible with the air dryer.
• Use Internet Explorer (6.0 or newer) or Mozilla Firefox Web Browser.
8.17.1 Type the IP Address of the P4200W2 Series Air Dryer in the Address text
box of the Web Browser.
Page 53 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
The Web Browser connection offers five (5) screens to the user:
• Status Screen - Displays the readings and alarms monitored in the
P4200W2 Series Air Dryer. Provides remote ALARM RESET.
• Setup Screen - All configurations for 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 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.
8.17.2 Click on the Menu Bar selection to access a specific screen.
Page 54 of 113 P012308 - Rev. E
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.
• Alarms are displayed in RED next to the parameter in alarm.
• Alarm Status will display ALARM if any alarms are present.
• Keyword validation is required for ALARM RESET and RESET
COMPRESSOR TOTAL RUN TIME.
Page 55 of 113 P012308 - Rev. E
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 56 of 113 P012308 - Rev. E
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 57 of 113 P012308 - Rev. E
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.
• The CHANGE KEYWORD Button allows you to configure a new Keyword.
• Keyword validation is required for the following:
o Changing a Threshold value
o Changing the Keyword
Page 58 of 113 P012308 - Rev. E
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. This will lock in the new
setting value.
Page 59 of 113 P012308 - Rev. E
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 60 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
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.
• Click the Arrow Buttons to navigate through all the event log pages.
Page 61 of 113 P012308 - Rev. E
PUREGAS, LLC 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.
• Click the Arrow Buttons to navigate through all the event log pages.
Page 62 of 113 P012308 - Rev. E
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.
• New Version File: Displays the new location and new firmware version
chosen.
• The BROWSE Button allows you to locate the new firmware file.
• The ACCEPT Button is used to change values.
• Keyword validation is required to update firmware.
Page 63 of 113 P012308 - Rev. E
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. This will lock in the new
firmware version.
Page 64 of 113 P012308 - Rev. E
PUREGAS, LLC 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. This file is named “PuregasP4200W2.mib”
and is located on the Mini CD included with your Air Dryer. It is necessary to import
this file into your SNMP operating software.
NOTE: Reference Appendix section 14.3 for a list of SNMP Parameters.
Page 65 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
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.
WARNING!
High Noise. Puregas air dryers are meant to be installed in an
unattended area.
CAUTION!
Observe precautions for handling Electrostatic Sensitive Devices.
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.
Page 66 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
9.2 Measuring Compressor Amp Draw
WARNING!
Internal surfaces may be hot. Use care when coming into contact
with internal components as there is a potential for some these
components to become hot when in operation or standby.
9.2.1 Remove the Front Panel (section 8.10 ).
With the Compressor running:
9.2.2 Locate the BLACK wire
coming directly from the
Compressor.
9.2.3 Use an Amp Meter to
measure the Amps of the
BLACK wire.
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.
9.2.4 Reinstall the Front Panel (section 8.10 ).
Page 67 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
9.3 Measuring Voltage to Compressor
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.
9.3.1 Remove the Front Panel (section 8.10 ).
With the Compressor running:
9.3.2 Locate the Compressor
power connector.
9.3.3 Use a Voltmeter to measure
the voltage between the
BLACK and WHITE wires:
9.3.3.1 Place the Voltmeter
probes in the openings
in the power connector.
The voltage should measure:
• 110 - 125 VAC for the P4200W2 & P4200W2LP models.
• 220 - 230 VAC for the P4202W2, P4202W2LP & P4202W2H models.
9.3.4 Reinstall the Front Panel (section 8.10 ).
Page 68 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
9.4 Measuring Voltage at the Power Line Filter
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.
9.4.1 Remove the Top Cover (section 8.11 ).
9.4.2 Locate the Power Line
Filter inside the Top Section
of the air dryer.
9.4.3 Use a Voltmeter to measure
the voltage:
9.4.3.1 Place the probes
between the Power Line
Filter and terminal
insulation so that they
touch the metal
contacts.
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. See sections 11.1 for part detail
and 11.7 for ordering information.
9.4.4 Reinstall the Top Cover (section 8.11 ).
Page 69 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
9.5 Measuring Incoming Voltage
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.
9.5.1 Remove the Top Cover (section 8.11 ).
9.5.2 Locate the Power IEC
Connector inside the Top
Section of the air dryer.
9.5.3 Use a Voltmeter to measure
the voltage:
9.5.3.1 Place the probes
between the IEC
Connector and terminal
insulation so that they
touch the metal
contacts.
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.
9.5.4 Reinstall the Top Cover (section 8.11 ).
Page 70 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
9.6 Measuring Voltages at Solid State Relay
9.6.1 Remove the Top Cover (section 8.11 ).
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.
9.6.4 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
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.
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 (section 8.11 ).
If any of the voltage measurements are different than indicated above, the Solid
State Relay is defective and should be replaced. See sections 11.1 for part detail
and 11.7 for ordering information.
Page 72 of 113 P012308 - Rev. E
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. Air should:
• Purge from Tower 1 side
• Purge from Tower 2 side
30 Seconds later
• Purge from Tower 1 side
30 Seconds later
• …and so on.
9.7.4 Re-connect the purge tubes
to the Heatless Dryer.
9.7.5 Reinstall the Front Panel
(section 8.10 ).
If the Heatless Dryer is not cycling consistently as described, see section 13.13
for troubleshooting information.
Page 73 of 113 P012308 - Rev. E
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.
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-connect the Unloader
tube to the Unloader Valve.
9.8.5 Reinstall the Front Panel
(section 8.10 ).
If air flows from this valve continuously the Unloader Valve is defective and
should be replaced. See sections 11.4 for part detail and 11.7 for ordering
information.
Page 74 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
9.9 Measuring Heatless Dryer Solenoid Voltage
9.9.1 Remove the Front Panel (section 8.10 ).
With the Compressor running:
9.9.2 Locate the Heatless Dryer
Cycle Timer.
The timer has three (3) sets of
terminals (from left-to-right):
“VALVE” – Left solenoid
“IN” – Incoming power
“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 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. See sections 11.4 for part detail
and 11.7 for ordering information
Page 75 of 113 P012308 - Rev. E
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 )
• Replace 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 Relief Valve to verify
air pressure is released.
9.11.3 Release ring handle and
verify that no air is leaking
from the valve.
9.11.4 Reinstall the Front Panel (section 8.10 ).
If the Safety Relief Valve fails either test described, it must be replaced. See
sections 11.3 for part detail and 11.7 for ordering information.
Page 76 of 113 P012308 - Rev. E
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.
With Compressor running:
9.12.3 Verify the Compressor
shuts down when the Tank
Pressure (TANK) reaches
345 KPa.
If the Tank Pressure (TANK) fails
to reach 345 KPa, see section
13.15 for troubleshooting
information.
With Compressor NOT running:
9.12.4 Pull the ring handle on the
Safety Relief Valve to release
air pressure from the Air
Tank.
9.12.5 Verify the Compressor
turns on when the Tank
Pressure (TANK) falls to 172
KPa.
9.12.6 Reinstall the Front Panel (section 8.10 ).
If the Compressor Cycling fails either test described, it indicates a problem with
the Control Board which may need to be replaced. See sections 11.1 for part
detail and 11.7 for ordering information.
Page 77 of 113 P012308 - Rev. E
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.
9.13.3 Immediately after the
Compressor turns off, pull
the ring handle on the Safety
Relief Valve until the
Compressor turns on again.
A High Duty Cycle Alarm
should appear on the Display
Screen.
9.13.4 Allow the Compressor to
turn off.
9.13.5 Press the RESET Button
to clear the alarm.
9.13.6 Reinstall the Front Panel (section 8.10 ).
If you are unable to create a High Duty Cycle Alarm as described, see section
13.18 for troubleshooting information.
Page 78 of 113 P012308 - Rev. E
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.
9.14.5 Power the air dryer ON.
Page 79 of 113 P012308 - Rev. E
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.
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 Board, **% will appear
on the Humidity reading and after 5 minutes the unit will Shutdown. This is to
allow for troubleshooting.
If you are unable to create a Humidity / Shutdown alarm as described, see section
13.11 for troubleshooting information.
Page 80 of 113 P012308 - Rev. E
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.
9.15.4 Turn knob clockwise until
Outlet Pressure (OUTLET)
reading climbs over the alarm
threshold. (section 8.8.5 )
9.15.5 After one (1) minute,
verify that a High Outlet
Pressure Alarm appears on
the display.
9.15.6 Press the RESET Button
to clear the alarm.
Page 81 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
9.15.7 Turn Outlet Pressure
Regulator knob counterclockwise until Outlet
Pressure (OUTLET) reading
lowers to the reading
recorded in step 9.15.1
9.15.8 Push knob in to lock.
9.15.9 Reinstall the Front Panel (section 8.10 ).
If you are unable to create a High Outlet Pressure Alarm as described, see
section 13.6 for troubleshooting information.
9.16 Testing Low Outlet Pressure Alarm
9.16.1 Make a note of the current
Outlet Pressure (OUTLET)
reading.
9.16.2 Remove the Front Panel
(section 8.10 ).
With Compressor running:
9.16.3 Pull the Outlet Pressure
Regulator knob out.
9.16.4 Turn knob counterclockwise until Outlet
Pressure (OUTLET) reading
drops below the alarm
threshold. (section 8.8.7 )
Page 82 of 113 P012308 - Rev. E
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
until Outlet Pressure
(OUTLET) reading raises to
the reading recorded in step
9.16.1
9.16.8 Push knob in to lock.
9.16.9 Reinstall the Front Panel (section 8.10 ).
If you are unable to create a Low Outlet Pressure Alarm as described, see section
13.8 for troubleshooting information.
Page 83 of 113 P012308 - Rev. E
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. DAMAGE TO THE SENSOR 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 the air fitting or hose
connection to be tested.
If air bubbles appear at the
connection, this indicates that
air is leaking from the
connection.
If any leaks are detected, take steps to seal them off (as necessary):
• Tighten the fitting
• Re-connect the hose end
• Replace the fitting / hose / component
Page 84 of 113 P012308 - Rev. E
PUREGAS, LLC 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.
It is also recommended that you print out the included Six Month Maintenance (section
10.2 ) and 8,000 Hour Maintenance (section 10.3 ) log sheets and record all completed
maintenance for historical tracking and reference purposes.
The log sheets include a Section reference column which indicates the User’s Guide
section containing the information about the specific procedure. Please refer to these
sections for detailed procedural information.
NOTE: When operating at higher ambient temperatures, it is recommended that
maintenance be performed more frequently.
NOTE: After 16,000 hours of run time, PUREGAS recommends sending in your
Compressor and Heatless Dryer for a complete and comprehensive rebuild by our
Service Department technicians. See sections 12.1 and 12.2 for information on
services and contacting PUREGAS.
10.1 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.
Page 85 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
excessive noise.
WARNING!
Internal surfaces may be hot. Use care when coming into contact
with internal components as there is a potential for some of these
components to become hot when in operation or standby.
CAUTION!
SHUT DOWN IMMEDIATELY FOR REPAIRS if the air
compressor shows any evidence of overheating or presents
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.
WARNING!
High Noise. Puregas air dryers are meant to be installed in an
unattended area.
CAUTION!
Observe precautions for handling Electrostatic Sensitive Devices.
IMPORTANT!
After performing any maintenance, always soap test pressure
fittings to check for air leaks. Also, check for any loose or
disconnected wiring.
Page 86 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
P01
2314
FLOW
10.2 Six Month Maintenance
MODEL: LOCATION NAME:
SERIAL NUMBER: ADDRESS:
DATE INSTALLED:
Maintenance Interval (Months)
Procedure Section 6 12 18 24 30
Install Six Month Maintenance Kit
Install P012514 for P4202W2H ONLY
Read & Record Flow Rate (
Measure & Record Compressor Amp Draw 9.2
Measure & Record Incoming Voltage 9.5
Test High & Low Outlet Pressure Alarms 9.15 &
Set System Pressure (345 KPa / 50 PSI) 8.14
Set Static Pressure (138 KPa / 20 PSI) 8.15
Set Outlet Pressure 8.16
Test Consistent Heatless Dryer Cycling 9.7
Test Precooler Fan 9.10
Test Safety Relief Valve 9.11
Test Compressor ON/OFF Cycling 9.12
Test Duty Cycle Alarm 9.13
Test Humidity Alarm & System Shutdown 9.14
Test Air Fittings and Hoses for Leaks 9.17
Clean Precooler Coils
Visually Inspect Inside & Outside of Unit for Loose
Wiring or Hardware
) 8.4.5.2
Maintenance Performed by:
Date of Maintenance:
11.6
9.16
NOTE: COPY OR PRINT THIS PAGE AND KEEP IT WITH THE AIR DRYER
Page 87 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
P011471
FLOW
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.
MODEL: LOCATION NAME:
SERIAL NUMBER: ADDRESS:
DATE INSTALLED:
Maintenance Interval (Hours)
Procedure Section 8,000 16,000 24,000 32,000 40,000
Install 8,000 Hour Maintenance Kit
Install P012519 for P4202W2H ONLY
Read & Record Flow Rate (
Measure & Record Compressor Amp Draw 9.2
Set System Pressure (345 KPa / 50 PSI) 8.14
Set Static Pressure (138 KPa / 20 PSI) 8.15
Set Outlet Pressure 8.16
Test Consistent Heatless Dryer Cycling 9.7
Test Compressor ON/OFF Cycling 9.12
Test Air Fittings and Hoses for Leaks 9.17
Reset COMPRESOR TOTAL RUN TIME Reading
to Zero
Visually Inspect Inside & Outside of Unit for Loose
Wiring or Hardware
) 8.4.5.2
Maintenance Performed by:
Date of Maintenance:
11.6
8.7.7
NOTE: COPY OR PRINT THIS PAGE AND KEEP IT WITH THE AIR DRYER
Page 88 of 113 P012308 - Rev. E
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
P4200W2LP
(120 VAC)
P4202W2
P4202W2LP
P4202W2H
(220 VAC)
Power IEC Connector P012279 1
Power Line Filter P011628 1
Circuit Breaker P06136 1 (1)
Control Board P012304 1
Varistor P012033 P012034 1
Solid State Relay P05992 1
(1)
(1)
(1)
Front Panel Display P012276 1
Page 89 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
11.2 Middle & Lower Section Parts 1
Description Part Number Quantity
Precooler
Heatless Dryer Assembly
Static Pressure Gauge
P4200W2
P4200W2LP
(120 VAC)
P4642 1
P4202W2
P4202W2LP
P4202W2H
(220 VAC)
See section 11.4 for detail
P013339 1
(0-30 PSI)
Humitter
Temperature Sensor
Compressor Air Intake
Filter
Outlet Pressure Regulator
(Low Pressure)
P011380 1
P011823 1
In Kit P012314. See section 11.6 for detail
In Kit P012514 for P4202W2H ONLY
P013203
(P012316)
1
(1)
Recommend
Spare
(1)
Page 90 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
11.3 Middle & Lower Section Parts 2
Recommend
Description Part Number Quantity
Spare
P4200W2 &
P4200W2LP
(120 VAC)
Fan P012366 P012368 1
Static Pressure
Regulator
Flow Block 1
Compressor P013261 P013262 P012518 (1)
Vibration Mounts P4582S 4
Safety Relief Valve P03646 1
P4202W2 &
P4202W2LP
(220 VAC)
P013203 1 (1)
P4202W2H
(220VAC)
Page 91 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
11.4 Heatless Dryer Assembly Parts
Description Part Number Quantity
P4200W2 &
P4200W2LP
(120 VAC)
Heatless Dryer
PHF2C112041 PHF2C212041 PHF2C212045 1
Assembly
Capacity Control
Valve
Pressure Gauge
(0–100 PSI)
Cycle Timer P010530F1 P010530F2 1
Desiccant
Chamber
Unloader Valve P011022 P010453 1
Solenoid Valve In Kit P011471. See section 11.6 for detail.
P4202W2 &
P4202W2LP
(220 VAC)
P4634 1 (1)
P010695 1
P20040312 2
P4202W2H
(220 VAC)
Recommend
Spare
(1)
Page 92 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
11.5 Frame Section Parts
Recommend
Description Part Number Quantity
Spare
Front Panel 1
Trigger Latch 6
Air Intake Filter In Kit P012314. See section 11.6 for detail.
In Kit P012514 for P4202W2H ONLY
Top Cover 1
Fan Guard P03703 1
Purge Muffler In Kit P012314. See section 11.6 for detail
In Kit P012514 for P4202W2H ONLY
Page 93 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
11.6 Accessories for Your Dryer
Recomme
Description Part Number
nd Spare
Installation Kit
Includes fittings required to connect to
3/4” flexible hose or 1/2” tubing.
Six Month Maintenance Kit
Includes air intake filter, compressor air
P4202W2H = P012514
intake filter, and purge muffler.
8,000 Hour Maintenance Kit
Includes heatless dryer maintenance kit
P4202W2H = P012519
and compressor maintenance kit.
Cycle Kit
Allows multiple dryers to be cycled.
Cycle Kit Interface Kit P012341
1/2” Bleed Orifice Kit
Allows the Compressor and Heatless
P011752
P012314
(2)
P011471
(1)
P08033W
P013292
Dryer to cycle in low flow applications.
Page 94 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
11.7 Ordering Parts from PUREGAS
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
Once you have identified your required parts and accessories, contact the PUREGAS
Inside Sales / Service department to order:
(800) 521-5351 (option 2)
Fax – (303) 657-2205
sales@puregas.com
parts@puregas.com
Page 95 of 113 P012308 - Rev. E
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
• Compressor Rebuild
o Replace motor bearings, piston rod assemblies, and install a
complete compressor maintenance kit.
o Test air flow, air pressure, and electrical performance
• Heatless Dryer Rebuild
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 Authorization (RA) number.
• Carefully package the item(s) to be returned.
• Mark the Return Authorization (RA) number on the outside of the
shipping container.
• Include the main address and phone number of the individual to contact
for related inquiry and follow-up information.
• Include the purchase order number.
Page 96 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
13. Troubleshooting Your Dryer
13.1 Before You Call PUREGAS
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. Each section begins with the
most likely cause(s) of the issue. Otherwise, they start from the simplest possibilities
and progress to more complicated ones.
This troubleshooting guide is designed to be easy to follow and very effective when
used properly. It is suggested to always start at the beginning of the specific problem
section and continue in sequence, following the procedures indicated.
13.2 Safety & Warning Information
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!
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.
Page 97 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
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.
CAUTION!
Depressurizing the air dryer may be necessary before performing
certain procedures. NEVER remove pressure sensing tubes from
the Control Board without depressurizing the air dryer first, or
damage to the Control Board will occur.
CAUTION!
Do not test the Humidity Sensor with an ohm meter or apply
any DC voltage. This will 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 98 of 113 P012308 - Rev. E
PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
OFF
13.3 Air Dryer Won’t Power ON
Possible Cause Check Corrective Action
Power Circuit Breaker
in OFF position
No voltage to the Circuit
Breaker
No incoming voltage to
air dryer
Verify Power Circuit
Breaker is in ON
position
(section 8.3 )
Measure voltage to the
Power Line Filter
(section 9.4 )
Measure incoming
voltage (section 9.5 )
Move Power Circuit
Breaker to ON position
(section 8.3 )
If voltage is correct
replace Circuit Breaker
(section 11.1 ). If
voltage is not correct go
to next possible cause
Troubleshoot facility
power supply to air
dryer
13.4 Display Screen Not Functioning
Possible Cause Check Corrective Action
Dryer experienced a
power spike
13.5 High Outlet Pressure Alarm
Possible Cause Check Corrective Action
Outlet Pressure set too
high
High Outlet Pressure
Alarm threshold too low
Verify Outlet Pressure
(OUTLET) reading
(section 8.4.5.2 )
Verify High Outlet
Pressure threshold
(section 8.8.5 )
Power the air dryer
for 15+ seconds.
Power the air dryer ON.
Adjust Outlet Pressure
Regulator (section 8.16 )
Raise High Outlet
Pressure threshold
(section 8.8.5 )
Page 99 of 113 P012308 - Rev. E
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
Pressure Regulator
High Outlet Pressure
Alarm threshold higher
than default
Defective Control Board Verify that the Outlet
Verify that the Outlet
Pressure Regulator can
be adjusted
(section 8.16 )
Verify High Outlet
Pressure threshold
(section 8.8.5 )
Pressure (OUTLET)
reading is higher than
the High Outlet Pressure
threshold (above)
Replace Outlet Pressure
Regulator if unable to
adjust pressure
(section 11.2 )
Adjust Outlet Pressure
Regulator so that Outlet
Pressure (OUTLET)
reading climbs over
verified threshold
(section 8.16 )
Replace Control Board
(section 11.1 ) if Outlet
Pressure (OUTLET)
reading is over verified
High Outlet Pressure
threshold for more than
1 minute and fails to
create an alarm.
13.7 Low Outlet Pressure Alarm
Possible Cause Check Corrective Action
Outlet Pressure set too
low
High Flow condition Verify Flow Rate
Compressor will not
build up pressure
Low Outlet Pressure
Alarm threshold too
high
Verify Outlet Pressure
(OUTLET) reading
(section 8.4.5.1 )
(FLOW) reading is not
higher than expected
(section 8.4.5.2 )
Verify System Pressure
(section 8.14 )
Verify Low Outlet
Pressure threshold
(section 8.8.7 )
Adjust Outlet Pressure
Regulator (section 8.16 )
Troubleshoot High Flow
condition
(section 13.9 )
Troubleshoot Compressor
Won’t Build Pressure
(section 13.15 )
Lower the Low Outlet
Pressure threshold (section
8.8.7 )
Page 100 of 113 P012308 - Rev. E
Loading...