RFS BD4200W Series User manual

100518835 - Rev. B
BD4200W Series Air Dryer
User’s Guide
Models covered:
BD4200W BD4200WLP BD4202W BD4202WLP

Radio Frequency Systems BD4200W Series Air Dryer User’s Guide
Page 3 of 114 100518835 - Rev. B
1. Welcome & Congratulations
Congratulations on your purchase of a new RFS BD4200W Series Air Dryer! We here at
RFS 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 RFS 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 RFS products, please visit us on the web at:
www.rfsworld.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 RFS BD4200W Series Air Dryer. Models covered include
BD4200W, BD4200WLP, BD4202W, and BD4202WLP. 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.

Radio Frequency Systems BD4200W 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 BD4200W 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 ................39
8.9 Using the Network Setup Menu.............45
8.10 Removing the Front Panel...................51
8.11 Removing the Top Cover.....................51
8.12 Depressurizing the Dryer.....................52
8.13 Connecting to Common Alarm Socket 52
8.14 Setting the System Pressure.................53
8.15 Setting the Static Pressure....................54
8.16 Setting the Outlet Pressure...................55
8.17 Connecting via Web Browser..............56
8.18 Using the Status Screen .......................57
8.19 Using the Setup Screen........................60
8.20 Using the Event Screen........................62
8.21 Using the Firmware Screen..................63
8.22 Connecting via SNMP.........................64
9. Testing Your Dryer ....................................65
9.1 Safety & Warning Information..............65
9.2 Measuring Compressor Amp Draw .......66
9.3 Measuring Voltage to Compressor ........67
9.4 Measuring Voltage at the Power Line
Filter ............................................................68
9.5 Measuring Incoming Voltage ................69
9.6 Measuring Voltages at Solid State Relay
.....................................................................70
9.7 Testing Consistent Heatless Dryer
Cycling.........................................................71
9.8 Testing Unloader Valve.........................72
9.9 Measuring Heatless Dryer Solenoid
Voltage.........................................................73
9.10 Testing Precooler Fan..........................75
9.11 Testing Safety Relief Valve.................75
9.12 Testing Compressor ON/OFF Cycling 76
9.13 Testing Compressor Last Run Time
Alarm...........................................................77
9.14 Testing Humidity Alarm and System
Shutdown.....................................................78
9.15 Testing High Outlet Pressure Alarm....80
9.16 Testing Low Outlet Pressure Alarm.....82

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9.17 Testing Air Fittings & Hoses for Leaks
.....................................................................83
10. Maintaining Your Dryer..........................85
10.1 Safety & Warning Information............86
10.2 Six Month Maintenance.......................88
10.3 8,000 Hour Maintenance .....................89
11. Replacement Parts & Accessories...........90
11.1 Top Section Parts.................................90
11.2 Middle & Lower Section Parts 1 .........91
11.3 Middle & Lower Section Parts 2 .........92
11.4 Heatless Dryer Assembly Parts............93
11.5 Frame Section Parts.............................94
11.6 Accessories for Your Dryer.................95
Ordering Parts from RFS.............................96
12. Service & Repair.......................................97
12.1 Services Offered ..................................97
12.2 Initiating a Service Transaction...........97
13. Troubleshooting Your Dryer...................98
13.1 Before You Call Altec AIR .................98
13.2 Safety & Warning Information............98
13.3 Air Dryer Won’t Power ON...............100
13.4 Display Screen Not Functioning........100
13.5 High Outlet Pressure Alarm...............100
13.6 Can’t Create a High Pressure Alarm..101
13.7 Low Outlet Pressure Alarm ...............101
13.8 Can’t Create a Low Pressure Alarm ..102
13.9 High Flow Rate Alarm.......................102
13.10 High Humidity.................................103
13.11 Can’t Create a High Humidity Alarm /
Shutdown...................................................104
13.12 High Cabinet Temperature Alarm....104
13.13 Inconsistent Heatless Dryer Cycling105
13.14 Compressor Doesn’t Operate...........105
13.15 Compressor Won’t Build Pressure...105
13.16 Compressor Excessive AMP Draw..106
13.17 Compressor Last Run Time Alarm..106
13.18 Can’t Create a Compressor Last Run
Time Alarm................................................107
13.19 Compressor Rapid ON/OFF Cycling
...................................................................107
13.20 Contacting Altec AIR Technical
Support.......................................................108
14. Appendix .................................................109
14.1 Wiring Diagram.................................109
14.2 Operational Limits and Defaults........110
14.3 SNMP Parameters..............................111
15. Limited Warranty Agreement...............112
Registration Reminder...............................112
16. Contacting RFS.......................................113
16.1 General / Sales...................................113
16.2 Service ...............................................113
16.3 Technical Support..............................113
17. Notes.........................................................114

Radio Frequency Systems BD4200W 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.

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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!
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
110 - 125 VAC, 50/60 Hz for BD4200W & BD4200WLP
models
220 - 230 VAC, 50/60 Hz, 1 Phase for BD4202W &
BD4202WLP 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. RFS air dryers are meant to be installed in an unattended
area.

Radio Frequency Systems BD4200W Series Air Dryer User’s Guide
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IMPORTANT!
Performing routine maintenance as outlined in the Maintaining Your
Dryer section will ensure optimal performance over the lifecycle of
your air dryer.
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 RFS 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 RFS is NOT RECOMMENDED AND
MAY VOID THE WARRANTY.

Radio Frequency Systems BD4200W Series Air Dryer User’s Guide
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5. Overview & Specifications
5.1 Product Description
The BD4200W Series Air Dryer from RFS 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 BD4200W 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 5 – 20 PSIG (35-138 KPa) or 0.3 – 10 PSIG (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 BD4200W Series Air Dryer Models
Model Description
BD4200W 110 - 125 VAC, Standard Pressure 5 - 20 PSIG (35-138 KPa)
BD4200WLP 110 - 125 VAC , Low Pressure 0.3 - 10 PSIG (2-69 KPa)
BD4202W 220 - 230 VAC , Standard Pressure 5 - 20 PSIG (35-138 KPa)
BD4202WLP 220 - 230 VAC , Low Pressure 0.3 - 10 PSIG (2-69 KPa)

Radio Frequency Systems BD4200W Series Air Dryer User’s Guide
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5.4 Technical Specifications
BD4200W BD4200WLP BD4202W BD4202WLP
Output
Capacity Normal: 2,600 SCFD Maximum: 4,200 SCFD (74 SCMD Maximum 119 SCMD)
Power
Requirements 110 - 125 VAC, 1 Phase, 50 / 60 Hz 220 - 230 VAC, 1 Phase, 50 / 60 Hz
Running Amps 8.6 Amps
(15 Amp service recommended) 3.9 Amps (15 Amp service recommended)
Outlet Pressure
Range 5 – 20 PSIG (35-138 KPa) 0.3 – 10 PSIG
(2-69 KPa)
5 – 20 PSIG
(35-138 KPa)
0.3 – 10 PSIG
(2-69 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
40to 85F (optimal)
5to 30C (optimal)
Noise Level: 63 dBA @ 3’
Heat
Dissipation 3,500 BTU / hr 2,900 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 21” D x 25.25” W x 49” H
Net / Shipping
Weight 222 lbs / 278 lbs 100 kgs/126 kgs

Radio Frequency Systems BD4200W 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
C
ompressor head
pressure
.
4
Heatless Dryer
Removes moisture from
compressed air.
5 Capacity Control Valve Regulates System Pressure (50 PSI/345 KPa) and
prevents air from bleeding back through the
H
eatless
D
ryer.
6
Air Tank
Stores dry compressed air.
7 Static Pressure Regulator Regulates the Static Pressure (20 PSI/138 KPa)
and maintains constant pressure on the Combo
B
lock for accurate F
low measuring.
8 Combo Block Measures the Flow of compressed air and houses
the
H
umitter
.
9
Outlet Pressure Regulator
Regulates the
O
utlet
P
ressure.
10 Pressure Outlet Outputs the pressure set by the Outlet Pressure
Regulator.

Radio Frequency Systems BD4200W 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. RFS 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.

Radio Frequency Systems BD4200W 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 40° and 85° F (optimal).
NOTE: Higher temperatures will decrease component lifespan.
6.2.3.3 Meets the following power requirements:
110 - 125 VAC for BD4200W and BD4200WLP models
220 - 230 VAC, 1 Phase for BD4202W and BD4202WLP models
All models require 50/60 Hz and minimum 15 amp service.
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 RFS is NOT
RECOMMENDED AND MAY VOID THE WARRANTY.
IMPORTANT!
Installation of RFS air dryers are intended for network
telecommunication facilities (non-customer premises) only.

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6.3 Included Contents
(1) BD4200W Series Air Dryer
(1) Installation Guide (not shown)
Package located inside the dryer:
(2) Alarm Connector
(1) User’s Guide (not shown)
(1) Compressor Connector Tool
(1) Purge Muffler (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)

Radio Frequency Systems BD4200W Series Air Dryer User’s Guide
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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.

Radio Frequency Systems BD4200W Series Air Dryer User’s Guide
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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 BD4200W and
BD4200WLP model
220 – 230 VAC, 1 phase, power outlet for BD4202W & BD4202WLP
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 50
PSI (345 KPa).
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.
RFS 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 20 PSI (138
KPa).
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).
6.5.21 Check for air leaks: