Puregas P4200W2 User manual

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

PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
Page 3 of 113 P012308 - Rev. E
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.

PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
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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 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
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
8.12 Depressurizing the Dryer........................ 49
8.13 Connecting to Common Alarm Socket... 49
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
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

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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. 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
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
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

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

PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
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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.
IMPORTANT!
Performing routine maintenance as outlined in the Maintaining Your
Dryer section will ensure optimal performance over the lifecycle of
your air dryer.
CAUTION!
Incoming power to dryer must be:
•15 amp service recommended
•10 amp slow blow fuse
•110 - 125 VAC, 50/60 Hz for P4200W2 & P4200W2LP
models
•220 - 230 VAC, 50/60 Hz, 1 Phase for P4202W2,
P4202W2LP & P4202W2H models
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 P4200W2 Series Air Dryer User’s Guide
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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.
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.

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

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5.4 Technical Specifications
P4200W2 P4200W2LP P4202W2 P4202W2
LP P4202W2H
Output
Capacity Normal: 74 SCMD Maximum: 119 SCMD Normal: 90 SCMD
Max: 119 SCMD
Power
Requirements 110 - 125 VAC, 1 Phase,
50 / 60 Hz 220 - 230 VAC, 1 Phase, 50 / 60 Hz 220-230 VAC, 1 Phase, 50Hz
Running Amps 8.6 Amps
(15 Amp service
recommended)
3.9 Amps
(15 Amp service
recommended)
4.2 Amps
(15 Amp service
recommended)
Outlet Pressure
Range 35 - 138
KPa 2 – 69
KPa 35 - 138
KPa 2 – 69
KPa
35 – 138
KPa
Outlet Air
Humidity Less than 2% RH
Compressor 2-cylinder, 3/4 HP, oil-less type compressor
Drying Method Heatless Desiccant
Operating
Temperature
Range 5°to 30°C (optimal)
Noise Level: 63 dBA @ 1m
Heat
Dissipation 3,521 BTU / hr 2,924 BTU / hr
Alarms Standard alarms – complete readings of all critical measurement points, individual
alarm indication display
Monitoring Web Browser and SNMP compatible communications via Network IP
Outlet
Connections 1/2” NPT Female
Dimensions 53cm D x 64cm W x 124cm H
Net / Shipping
Weight 100 kgs / 126 kgs

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

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

PUREGAS, LLC P4200W2 Series Air Dryer User’s Guide
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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 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).
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!
Installation of PUREGAS air dryers are intended for network
telecommunication facilities (non-customer premises) only.

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

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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 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.

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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.

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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.

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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.

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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.

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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).