Puregas P20KW User manual

P011238 – Rev. L
P20KW / P30KW Air Dryer
User’s Guide

PUREGAS, LLC P20KW / P30KW Air Dryer User’s Guide
Page 3 of 109 P011238 – Rev L
1. Welcome & Congratulations
Congratulations on your purchase of a new PUREGAS P20KW / P30KW 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 P20KW / P30KW Air Dryer. 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.

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3. Table of Contents
1. Welcome & Congratulations .......................... 3
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 Dryer Function Overview......................... 10
5.4 Technical Specifications........................... 12
6. Installing Your Dryer.................................... 13
6.1 Safety & Warning Information................. 13
6.2 Before You Begin..................................... 15
6.3 Included Contents..................................... 16
6.4 Required Tools and Materials................... 16
6.5 Installation Steps....................................... 17
6.6 Installation Checklist ................................ 27
7. Registering Your Dryer................................. 28
8. Operating Your Dryer .................................. 29
8.1 Safety & Warning Information................. 29
8.2 Connecting Air Lines to the Dryer ........... 30
8.3 Powering the Dryer ON & OFF................ 30
8.4 Using the Front Panel Display.................. 31
8.5 Identifying Dryer Alarms ......................... 34
8.6 Adjusting & Resetting Dryer Set Points... 38
8.7 Opening Panels......................................... 42
8.8 Connecting to Common Alarm Terminals 43
8.9 Rewiring the Common Alarm Socket....... 44
8.10 Connecting to Discrete Alarm Terminals44
8.11 Depressurizing the Dryer........................ 45
8.12 Setting the System Pressure.................... 45
8.13 Setting the Static Pressure....................... 46
8.14 Setting the Outlet Pressure...................... 47
8.15 Setting the RRU Temperature................. 48
9. Testing Your Dryer ....................................... 50
9.1 Safety & Warning Information................. 50
9.2 Measuring Compressor Amp Draw .......... 52
9.3 Measuring Voltage to Compressor ........... 53
9.4 Measuring Incoming Voltage ................... 54
9.5 Testing High Outlet Pressure Alarm......... 55
9.6 Testing Low Outlet Pressure Alarm.......... 56
9.7 Testing Low System Pressure Alarm........ 57
9.8 Testing 4-Way Valve Cycling .................. 59
9.9 Measuring 4-Way Valve Solenoid
Voltage............................................................ 62
9.10 Measuring Tower Heater Voltage........... 65
9.11 Testing Precooler Fan............................. 68
9.12 Testing Low Water Sensor Function &
System Shutdown ........................................... 69
9.13 Testing Dump Sensor and Primary
Water Dump Functions................................... 70
9.14 Testing High Water and Secondary
Water Dump Functions................................... 72
9.15 Testing Humidity Alarm and System
Shutdown........................................................ 76
9.16 Testing Power Contactor ........................ 77
9.17 Testing Fittings & Hoses for Leaks ........ 79
10. Maintaining Your Dryer............................. 80
10.1 Safety & Warning Information ............... 80
10.2 Six Month Maintenance.......................... 82
11. Replacement Parts & Accessories .............. 83
11.1 Top Front Section Parts .......................... 83
11.2 Bottom Front Section Parts..................... 84
11.3 Top Front Panel Parts ............................. 85
11.4 Top Back Section Parts........................... 86

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11.5 Bottom Back Section Parts..................... 87
11.6 Frame Section Parts................................ 88
11.7 Accessories for Your Dryer.................... 89
11.8 Ordering Parts from PUREGAS............. 90
12. Service & Repair.......................................... 91
12.1 Services Offered ..................................... 91
12.2 Initiating a Service Transaction.............. 91
13. Troubleshooting Your Dryer...................... 92
13.1 Before You Call PUREGAS................... 92
13.2 Safety & Warning Information............... 92
13.3 Air Dryer Won’t Power ON.................... 94
13.4 Display Screen Not Functioning............. 94
13.5 Low System Pressure Alarm .................. 94
13.6 Can’t Create a Low System Pressure
Alarm.............................................................. 95
13.7 High Outlet Pressure Alarm.................... 95
13.8 Can’t Create a High Pressure Alarm....... 96
13.9 Low Outlet Pressure Alarm .................... 96
13.10 Can’t Create a Low Pressure Alarm ..... 97
13.11 High Flow Rate Alarm.......................... 97
13.12 High Humidity...................................... 98
13.13 Can’t Create a High Humidity Alarm /
Shutdown........................................................ 99
13.14 High Outlet Temperature Alarm........... 99
13.15 High RRU Temperature Alarm........... 100
13.16 Low Water Alarm............................... 100
13.17 Can’t Create a Low Water Alarm....... 101
13.18 High Water Alarm .............................. 101
13.19 Can’t Create a High Water Alarm ...... 102
13.20 High Water Temperature Alarm......... 102
13.21 Compressor Doesn’t Operate.............. 103
13.22 Unit Trips Breaker .............................. 103
13.23 Contacting PUREGAS Technical
Support.......................................................... 104
14. Appendix .................................................... 105
14.1 Wiring Diagram.................................... 105
14.2 Set Point Limits and Defaults ............... 106
15. Limited Warranty Agreement.................. 107
Registration Reminder.................................. 107
16. Contacting PUREGAS .............................. 108
16.1 General.................................................. 108
16.2 Sales...................................................... 108
16.3 Service .................................................. 108
16.4 Technical Support................................. 108
17. Notes............................................................ 109

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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.

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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!
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 user.
WARNING!
High Noise. PUREGAS air dryers are meant to be installed in an
unattended area.
CAUTION!
Incoming power to Air Dryer must be:
•30 amp service recommended
•20 amp slow blow fuse
•208 - 230 VAC, 1 Phase for P20KW model
•208 - 230 VAC, 3 Phase for P30KW model
•If hard-wiring directly, minimum of 10 AWG wire must be
used

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IMPORTANT!
Performing procedures not described in this User’s Guide or installing
components not supplied by PUREGAS is NOT RECOMMENDED
AND MAY VOID THE WARRANTY.
IMPORTANT!
Performing routine maintenance as outlined in the Maintaining Your
Dryer section will ensure optimal performance over the lifecycle of
your air dryer.
CAUTION!
DO NOT USE DISTILLED OR DE-IONIZED WATER IN THIS
UNIT. It will cause damage to the compressor and other major
components over time. This unit is designed for clean tap water only.
IMPORTANT!
If installing more than one air dryer in the same location, use individual
drain tubing. If plumbed together, damage to the air dryers may occur.
CAUTION!
Observe precautions for handling Electrostatic Sensitive Devices.
IMPORTANT!
Installation of PUREGAS air dryers are intended for network
telecommunication facilities (non-customer premises) only.

PUREGAS, LLC P20KW / P30KW Air Dryer User’s Guide
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5. Overview & Specifications
5.1 Product Description
The P20KW / P30KW Air Dryer from PUREGAS is designed to intake wet ambient
air and remove the moisture for delivery to applications requiring a constant, on-
demand source of dry, pressurized air. This process is fully automatic and will
remain consistent with minimal required periodic maintenance. This dryer is
designed specifically for indoor use.
The P20KW / P30KW Air Dryer employs a fully digital operating platform offering
the most accurate readings of dryer variables, removable access panels allowing easy
access for adjustment and maintenance, heat activated desiccant towers, a
refrigeration system, and a single water sealed air compressor.
5.2 Key Features
•Real-time monitoring of over 15 points
•Remote access and alarm reset capabilities
•LCD display of all operating parameters
•Solid state microprocessor-based circuitry
•Accurate humidity sensing within ±0.1% RH
•Lowest Energy Cost
•Single water sealed compressor
•Dual pressure outlets
•Unique heated drying system
•Maintenance-free sealed cooling system

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5.3 Dryer Function Overview

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# Component Description
1 Inlet Air Filter Draws in ambient air.
2 Accumulator Prevents the return of air or water from the
compressor.
3 Compressor Creates compressed air.
4 Primary Water Separator Separates water from compressed air.
5 Precooler Cools water from the compressor.
6 Water Filter Filters water.
7 Primary Dump Valve Dumps excessive water from the primary water
separator.
8 Primary Drain Outlet Outputs the water released by the primary dump
valve.
9 Refrigeration Unit Lowers the temperature of the moist compressed
air causing condensation.
10 Secondary Water
Separator Separates condensation from compressed air.
11 Secondary Dump Valve Dumps excessive water from the secondary water
separator.
12 Secondary Drain Outlet Outputs the water released by the secondary
dump valve.
13 System Pressure
Regulator Maintains operating pressure.
14 4-Way Valve Assembly Directs the cold, saturated air from the secondary
separator to the on-line desiccant tower.
15 Desiccant Towers Dries the saturated air.
16 Static Pressure Regulator Regulates the static pressure (17 PSI).
Maintains constant pressure on the combo block
for accurate flow measuring.
17 Combo Block Measures the flow of compressed air, houses the
adjustable pressure regulator, humitter and outlet
temperature probe.
18 Outlet Pressure Regulator Regulates the outlet pressure
19 Pressure Outlet Outputs the air at the pressure set by the
adjustable pressure regulator.
20 Static Pressure Outlet Outputs the air at the pressure set by the Static
Pressure Regulator (17 PSI).

PUREGAS, LLC P20KW / P30KW Air Dryer User’s Guide
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5.4 Technical Specifications
P20KW P30KW
Output Capacity 20,000 SCFD 30,000 SCFD
Power Requirements 208 - 230 VAC, 1 Phase 208 - 230 VAC, 3 Phase
Electrical Characteristics
(30 Amp service
recommended) Running Amps: 17.5 Running Amps: 16.5
Outlet Pressure Range Variable Pressure Outlet: 0 – 15 PSI (adjustable)
Static Pressure Outlet: 17 PSI
Outlet Air Humidity Less than 2% RH
Compressor Type Water sealed, 2 HP, 1 Phase Water sealed, 3 HP, 3 Phase
Drying Method Refrigeration (R134A) and Heat Desiccant
Operating Temperature
Range 40°to 85°F (5°to 30°C) optimal
Noise Level 86.6 dBA
Heat Dissipation 12,420 BTU/hr 11,710 BTU/hr
Alarms Standard alarms – complete readings of all critical
measurement points, individual alarm indication display
Outlet Connections Variable Pressure Outlet: 3/4” NPT Female
Static Pressure Outlet: 3/4” NPT Female
Dimensions 20.5” D x 40” W x 58.5” H
(52 cm x 101.6 cm x 148.6 cm)
Net / Shipping Weight 550 lbs (249.5 kg) / 621 lbs (282 kg)

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6. Installing Your Dryer
6.1 Safety & Warning Information
WARNING!
Extreme care should be exercised to avoid contact with live
electrical circuits. Many procedures performed during
installation, operation, testing, and maintenance of this air dryer
require the equipment to be running, creating a situation for
potential electrical shock. It is highly recommended that you
remove all jewelry before performing any procedures.
WARNING!
Internal surfaces may be hot. Use care when coming into contact
with internal components as there is a potential for some of these
components to become hot when in operation or standby.
CAUTION!
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.
WARNING!
High Noise. PUREGAS air dryers are meant to be installed in an
unattended area.

PUREGAS, LLC P20KW / P30KW Air Dryer User’s Guide
Page 14 of 109 P011238 – Rev L
IMPORTANT!
Performing procedures not described in this User’s Guide or
installing components not supplied by PUREGAS is NOT
RECOMMENDED AND MAY VOID THE WARRANTY.
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.
IMPORTANT!
Installation of PUREGAS air dryers are intended for network
telecommunication facilities (non-customer premises) only.
IMPORTANT!
If installing more than one air dryer in the same location, use
individual drain tubing. If plumbed together, damage to the air
dryers may occur.
CAUTION!
Incoming power to Air Dryer must be:
•30 amp service recommended
•20 amp slow blow fuse
•208 - 230 VAC, 1 Phase for P20KW model
•208 - 230 VAC, 3 Phase for P30KW model
•If hard-wiring directly, minimum of 10 AWG wire must
be used

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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 Unobstructed drain or bucket for water dump.
6.2.3.3 Ambient temperature is between 40° and 85° F (optimum).
NOTE: Higher temperatures will decrease component lifespan.
6.2.3.4 Meets the following power requirements:
•208 - 230 VAC, 1 Phase for P20KW
•208 - 230 VAC, 3 Phase for P30KW
•Minimum 30 amp service with a 20 amp slow blow fuse
•If hard-wiring directly, minimum of 10 AWG wire must be used
6.2.4 Notify the alarm center of the installation and potential for alarms during
the process (as necessary).

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6.3 Included Contents
(1) P20KW / P30KW Air Dryer
(2) 10’ - 3/8” Drain Tubing
(1) Installation Guide (not shown)
Package located inside the dryer:
(1) User’s Guide -
Paper copy or digital file on CD (not shown)
(1) Water Sensor (1) Alarm Plug
(1) Compressor Connector Tool
6.4 Required Tools and Materials
•Large adjustable wrench
•Medium adjustable wrench
•Band cutters or snips
•7/16” wrench
•1/2” wrench
•3/8” wrench
•Medium phillips head
screwdriver
•1+ gallon of clean tap water
(DO NOT USE DISTILLED
WATER)
•Medium flat head screwdriver
•Small flat head screwdriver
•Pipe dope or pipe thread tape
•Cup of soapy water
•1-inch paint brush
(recommended)
•Shop Towels

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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 Lower Front
and Side Panels.
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.

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6.5.5 Using a 1/2” wrench, loosen
the nuts on the RRU
Compressor.
6.5.6 Remove the shipping blocks
and discard.
6.5.7 Retighten the RRU Compressor nuts.
6.5.8 Using a 7/16” wrench, remove bolt and shipping block from under the
compressor plate. Discard block and bolt.
6.5.9 Remove the ship-loose
contents package.
On BACK of dryer:
6.5.10 Install 3/8” drain tubing
into the primary and
secondary fittings and route
to an unobstructed drain or
bucket.
.
CAUTION: Use individual drain tubing. If plumbed together, damage
to the air dryer may occur.

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6.5.11 Verify that the dryer is
powered OFF.
On TOP of dryer:
6.5.12 Verify that the orifice plug
is still installed where shown.
6.5.13 Wire directly or plug the
power cord into a power
outlet
•208 - 230 VAC, 1 phase
for the P20KW
•208 - 230 VAC, 3 phase
for the P30KW
NOTE: PUREGAS recommends using a 20 amp 250 VAC plug. (not provided)

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6.5.14 Prime the compressor:
CAUTION: The following steps must be performed to avoid damage to the
compressor.
6.5.14.1 Remove Inlet Air
Filter Assembly.
6.5.14.2 Push the
Accumulator’s
diaphragm down by
inserting a screwdriver
as shown.
6.5.14.3 Slowly pour water
into the Accumulator
until it is full.