Instruction Manual for PUREGAS Compressed Air Dryers and Adsorbers Models: PHF PCR PCDA PHCA PCME PMD TOC PUREGAS LLC 226A Commerce Street Broomfield, CO 80020 Tel: 800-521-5351 Fax: 303-657-2205 Info@puregas.com www.puregas.com Made in USA P010535 Rev.
Instruction Manual for PUREGAS Compressed Air Dryers and Adsorbers IMPORTANT NOTE! This instruction manual is designed for the benefit of our customers and is intended to assist them with the installation, operation, and maintenance of their PUREGAS compressed air dryer or adsorber. The entire manual should be read thoroughly prior to the installation of the unit and should be retained for future reference. Failure to do so could result in safety issues and poor performance, and could void the warranty.
Instruction Manual for PUREGAS Compressed Air Dryers and Adsorbers Table of Contents SECTION 1 – GENERAL...........................................................................................................................................1 SCOPE OF MANUAL ....................................................................................................................................................1 INITIAL INSPECTION .................................................................................
SECTION 1 – GENERAL Scope of Manual This instruction manual is intended to assist our customers with the installation, operation, and maintenance of their PUREGAS compressed air dryer or adsorber. The information contained in this manual is designed to ensure a productive, trouble-free ownership experience and should be retained for future reference. Initial Inspection PUREGAS products are produced in a lean manufacturing environment, where quality assurance practices are built into all processes.
Please consult the factory PRIOR to installing a unit for any application other than air or inert gases. Use with certain liquids or gases could be harmful to the unit, result in a combustible condition, or cause hazardous leakage. In the event of a misapplication, the product warranty is voided and PUREGAS will assume no responsibility or liability for any resulting loss.
Operation of PCR Model As previously described, the PCR model employs PSA technology to effectively remove moisture (or other unwanted components) from a compressed air stream. It is, however, configured differently than other PUREGAS models based on a common air manifold. Instead of a manifold and 3-way valves to direct the airflow through the unit, the PCR model uses shuttle valves and 2-way solenoid valves.
Operation of PMD and TOC Models The PMD and TOC models also employ Pressure Swing Adsorption (PSA) technology to remove water vapor and/or CO2 from ordinary compressed air. These models are configured differently than the PHF or PCR models, in that they employ a shuttle valve and 4-way valve to direct the airflow through the unit. The 4-way valve directs the incoming air into one of the two desiccant chambers, where the water vapor and/or CO2 are removed.
SECTION 3 – INSTALLATION AND OPERATION Inspection Remove the compressed air dryer or adsorber from the shipping carton. Inspect the unit for any visible shipping damage. If shipping damage is noted, immediately contact the responsible carrier to file a freight claim to be reimbursed for the repair. Location Desiccant-type compressed air dryers and adsorbers should be installed in the coolest practical location that is not subject to freezing temperatures.
MODEL A B C D E F PCR 15 18.625 6 25.5 3.25 5.5 8.25 PCR 25 22.935 6 30 4.25 6.4 9.25 PCR 50 28.125 6 35.25 4.25 6.4 9.25 Note: All dimensions are in inches.
TOC MODEL PMD-S PMD-M TOC Height (A) 10 12 10 12 Width (B) 4 5 4 15 Depth (C) 4 5 4 5 with cabinet & filters Note: All dimensions are in inches FIGURE 6: DIMENSIONS OF PMD AND TOC MODELS Page 7 of 24
Recommended Installation Diagram A diagram of the recommended installation is below. It depicts all of the essential elements of a properly installed compressed air dryer or adsorber, as well as certain options described in the following sections. FIGURE 7: RECOMMENDED INSTALLATION DIAGRAM Piping and Air Connections IMPORTANT! Do not apply air pressure to the PCR, PMD, or TOC models unless the unit is also being supplied with electrical power.
outlet can be changed if necessary. This is accomplished by detaching the shuttle valve from the tower and reassembling it with the desired orientation. The inlet for the PMD model (and the TOC model without a cabinet) is the brass fitting fastened to the bottom of the 4-way valve, and the outlet is the brass fitting in shuttle valve at the top of the unit. The word “OUT” is inscribed in the shuttle valve body.
or flow variation, PUREGAS manufactures various tanks, which will completely eliminate downstream pressure surges. IMPORTANT! For optimum performance, the maximum available operating pressure should be maintained across the unit -- up to 150 psig for most models (the maximum operating pressure for the PMD and TOC models is 125 psig). Any pressure reduction or flow control should be done downstream of the unit.
minimize the outlet pressure and flow variation, as well as desiccant shock as the flow switches from one chamber to the other. The PCR model also utilizes a re-pressurizing timer. It maintains a 2-minute cycle, with a 7-second re-pressurizing period prior to switching towers. The PMD and TOC models follow a standard 1-minute cycle like the PHF300A model. The timer wiring diagrams for all models are shown in Figure 8.
The sizing of the purge orifice is also important to the performance of a PSA system. The orifice must be large enough to admit sufficient air to purge the off-line tower, but not too large to be wasteful of the dry or purified air. Please note that the operating pressure is closely associated with the orifice sizing, since both the orifice aperture dimension and pressure determine the quantity of purge air.
SECTION 4 - MAINTENANCE General Information When properly installed and operated, PUREGAS compressed air dryers and adsorbers are designed to deliver years of reliable service without minimal attention. Most recommended maintenance procedures can be easily and quickly performed in the field without the need for specialized tools or skills. Annual Inspection Although optional, an annual inspection of the dryer or adsorber is recommended for critical processes to anticipate potential failures.
Purge Mufflers: Remove the mufflers from the solenoid valves and check for excessive pressure drop by blowing through the muffler. The muffler should be replaced if significant back-pressure is sensed. Filtration: Inlet and outlet filters must be kept clean for efficient filtering. A visible coating of dirt on the element’s surface or an excessive pressure drop (greater than 5-6 psig), indicate that replacement is needed.
SECTION 5 – REPLACEMENT PARTS General Information The following exploded view drawings and tables show the available replacement parts, accessories, and repair kits for all of the compressed air dryers and adsorbers covered by this instruction manual. Please note that parts for non-current models are not listed, but may be available. Simply identify the required parts for your model from the exploded view drawings and contact PUREGAS (or an authorized distributor) to order.
REPLACEMENT PARTS MODEL Desiccant Tower PHF PHF PHF PHF PHF PHF PHF PHF PCDA PCDA PCDA PCDA PHCA PHCA PCME PCME Solid State Timer PHF & PHCA PHF & PHCA PHFR, PCDA & PCME PHFR, PCDA & PCME Solenoid Valve All models All models Solenoid Repair Kit Dryer Maintenance Kit Purge Orifice Mounting Bracket Manifold Cover Manifold All All All All All All models models models models models models SIZE PART NUMBER 6", Black 6", White 9", Black 9", White 12", Black 12", White 20", Black 20", White 12", Black
FIGURE 11: EXPLODED VIEW OF PCR MODEL Page 17 of 24
REPLACEMENT PARTS MODEL SIZE PART NUMBER Desiccant Tower PCR-15B PCR-15W PCR-SBX PCR-SWX PCR-25B PCR-25W PCR-MBX PCR-MWX PCR-50B PCR-50W 15", Black 15", White 15", Black, CO2 15", White, CO2 19", Black 19", White 19", Black, CO2 19", White, CO2 25", Black 25", White P010764-F1B P010764-F1W P010764-F2B P010764-F2W P010764-F3B P010764-F3W P010764-F4B P010764-F4W P010764-F5B P010764-F5W Solid State Timer PCR-xxx-xA PCR-xxx-xB PCR-xxx-xC PCR-xxx-xD 110 VAC 220 VAC 24 VAC 12-24 VDC P09740 P09783 P0107
FIGURE 13: EXPLODED VIEW OF PMD AND TOC MODELS Page 19 of 24
REPLACEMENT PARTS MODEL Dryer Maintenance Kit** PMD-S PMD-SX (TOC) PMD-M PMD-MX PMD-L PMD-LX **Includes desiccant chambers (2), tubing & fittings.
SECTION 6 – TROUBLESHOOTING INFORMATION General Information The following troubleshooting guide is intended to assist in the analysis of problems related to PUREGAS compressed air dryers and adsorbers. Based on a given symptom, the troubleshooting guide suggests possible causes, items to check, and corrective actions. Please note that the most likely potential causes are listed first. Thus, each potential cause should be checked in the sequence given.
Problem A: Expected outlet dewpoint or purity is not met. Model A1 A2 A3 A4 All Potential Cause Verification Corrective Action Current operating Verify that the actual operating Reduce the outlet flow conditions do not match pressure and inlet/outlet flow rates requirements, increase the the unit's specifications. match the specified performance of operating pressure, or resize the the unit. Contact the factory if you dryer by increasing the orifice require sizing data for your model.
Problem B: Excessive purge flow or blowdown. Model Potential Cause Verification Corrective Action B1 All The purge orifice size is larger than what is required for the current operating conditions. Verify that the orifice size corresponds to the actual operating pressure and flow rate. Contact the factory if you require sizing data for your model. Resize the dryer by replacing the orifice(s) with a smaller size. B2 PCR PMD TOC Inlet or outlet shuttle disc not shifting.
Problem C: Excessive pressure drop across unit. Model Potential Cause Verification Corrective Action C1 All Current operating conditions do not match the unit's specifications. Verify that the maximum flow rate for the unit is not being exceeded. Contact the factory if you require sizing data for your model. Reduce the outlet flow rate. C2 All Dirty or obstructed filter element.
