Models 5000 / 7200

Moderate Capacity
Compressor Dehydrators
Instruction manual

IB-131 REV. I PART NUMBER 52649

 Notes, Cautions, and Warnings herein this manual
are used to prevent personal injury.
Warning: To reduce the risk of fire or electric shock, do not expose this equipment to rain
or moisture. For Indoor use only.

Warning: If the equipment is used in a manner not specified herein, the protection
provided by the equipment may be impaired.

Warning: Turn off Power, Isolate power by unplugging or by locking separate disconnect
before servicing.

Warning!: High Voltage Disconnect Power before working within

Caution: This Unit may start automatically at any time

NOTE: All machinery must be fitted with means to isolate it from electrical energy sources.
The isolator must be capable of being locked where the operator is unable from any of the
points to which he/she has access to check that the energy is off!

Caution: Use care when lifting compressor as compressor weight exceeds 60 lbs. (27.3
kg)

ATTENTION: Observe Precautions for Handling Electrostatic Sensitive Devices

Important Safety Instructions

1. Read and follow all instructions
2. Keep these instruction with the equipment
3. Heed all warnings, cautions and notes
4. Do not block any ventilation openings
5. Install in accordance with instructions
6. Do not defeat the safety purpose of the grounding type plug
7. Protect the power cord from being walked on or pinched
8. Use Wrist Strap when handling ESD Sensitive Circuit Boards

WARNING! Risk of Electrocution

Isolate power by unplugging or by locking seporate disconnect.

CAUTION - REFER TO ACCOMPANYING

WARNING - RISK OF ELECTROCUTION
DOCUMENTS

ATTENTION - ELECTROSTATIC SENSI-

WARNING - HOT SURFACE TIVE DEVICE.
OBSERVE PRECAUTIONS FOR HANDLING

CAUTION - LIFTING HAZARD PROTECTIVE CONDUCTOR TERMINAL

 TABLE I
TABLE OF CONTENTS

SECTION TITLE PAGE

1 INTRODUCTION 2
1.3 Before Installing 2
2 PRINCIPLE of OPERATION 2
3 DRY-PAK OPERATING CYCLE 3
4 RECEIVING AND INSPECTION 4
5 SITE REQUIREMENTS 4
6 INSTALLATION AND START-UP 4
7 GENERAL MAINTENANCE 5
8 ADJUSTMENTS AND TESTS 5
8.1 Tank Pressure Switch 5
8.2 Back Pressure Regulator Adjustment 6
8.3 Alarm Pressure Switch Adjustment and Test 6
8.4 Adjustment of Duplex Run Timer 6
8.5 Alarm Wiring Options 7
8.6 Replace Compressor Filters 7
8.7 Humidity Alarm Moisture Test 7
8.8 Compressor Rebuild 7
8.9 DRY-PAK Cycling Test 9
9 TROUBLE SHOOTING 9

LIST OF TABLES

TABLE DESCRIPTION PAGE

I TABLE OF CONTENTS i
II TABLE OF LEADING PARTICULARS ii
III MAINTENANCE CHART 5
IV LIST OF SPARE PARTS 12
V LIST OF ELECTRIAL PARTS - LOCATIONS AND FUCTIONS 20-21
VI LIST OF COMPRESSOR PARTS 22

LIST OF ILLUSTRATIONS

FIGURE DESCRIPTION PAGE

1 MODELS 5000 / 7200 COMPRESSOR DEHYDRATOR Cover
2 AIR FLOW DIAGRAM 1
3 DRY-PAK CYCLE 3
4 MODELS 5000 / 7200 ( front view ) 13
5 MODELS 5000 / 7200 ( rear view ) 14
6 MODELS 5000 / 7200 (top view - cover open) 15
7 HUMIDITY MANIFOLD ASSEMBLY 15
8 ELECTRICAL COMPARMENT (inside left) 16
9 ELECTRICAL COMPARMENT (inside right) 16
10 DRY-PAK DRYER ASSEMBLY 17
11 ELECTRICAL DIAGRAM 18-19
12 COMPRESSOR - EXPLODED VIEW 22

i
 TABLE II
TABLE OF LEADING PARTICULARS
CHARACTERISTIC MODEL 5000 MODEL 7200
5000 SCFD / 141.6 SCMD 7200 SCFD - 203 SCMD
CAPACITY
(2500 SCFD/70 SCMD X 2 @ 60 H Z * )(3600 SCFD / 101 SCMD X 2 @ 60 H Z * )

DRY AIR DEW POINT LESS THEN 2% RH LESS THEN 2% RH

WEIGHT 300 LBS / 136 KG 335 LBS / 151 KG

ELECTRICAL OPTIONS 230V - 60H Z - 1 PH 230V - 60H Z - 1 PH

220V - 50H Z - 1 PH 220V - 50H Z - 1 PH

AIR COMPRESSOR SIZE (2 )- 3/4 HP (2 )- 1.0 HP

OPERATING CURRENT 11 AMPS 13 AMPS

COMPRESSOR CIRCUIT (2 ) 7.5 AMP C.B. (2 ) 10 AMP C.B.

CONTROL CIRCUIT (3 ) 0.5 AMP C.B. (3 ) 0.5 AMP C.B.

72 DBA 72 DBA
MAX SOUND PRESSURE @ 1 M, 1.6 M ELEV. ** @ 1 M, 1.6 M ELEV. **

* CAPACITY LESS FOR 50H Z OPERATION

** SOUND PRESSURE AT INSTALLATION WILL BE HIGHER, AND WORKER EXPOSURE TO
SOUND MUST BE ADDRESSED ON A SITE-BY-SITE BASIS

TABLE OF LEADING PARTICULARS

DRY AIR DEWPOINT . . . . . . . . . . . . Below -40°F (below -40°C.)
DESICCANT DRYER TYPE . . . . . . . DRY-PAK® Heatless twin-tower dryer. Efficient, internal check-ball valving, purge con-
trolled by two-way solenoid valves.
OPERATING PRESSURE . . . . . . . . . DRY-PAK® and compressor 60 PSIG(414 kPa), (50 PSIG (345 kPa) ON MODEL 7200/
60Hz ONLY) independent of tank pressure.
TANK PRESSURE RANGE . . . . . . . 25 PSIG (172 kPa), (compressor start) to 60 PSIG (414 kPa), (compressor stop) : 20 PSIG
(138 kPa) (compressor start) to 50 PSIG (345 kPa) (compressor stop) on Model 7200/
60Hz ONLY.
AIR COMPRESSOR TYPE . . . . . . . . Oilless, direct drive, motors are thermally protected.
REGULATED LOW
OUTLET PRESSURE . . . . . . . . . . . . Adjustable 2 TO 20 PSIG (14-138 kPa) (Equipped with high and low line pressure alarm
REGULATED HIGH switches)

OUTLET PRESSURE . . . . . . . . . . . . . Adjustable 2 TO 20 PSIG (14-138 kPa)

ALARMS - GENERAL . . . . . . . . . . . Eight independent alarm circuits can be monitored individually or as a single C.O. alarm.
Excepting Power alarm, each signaled by red alarm light on front panel. Common, NO and
NC terminals are provided.
HUMIDITY ALARM . . . . . . . . . . . . . Factory preset, protects storage tank via Wet Air Bypass solenoid valve. Clears automati-
cally when below preset limit.

LOW LINE PRESSURE ALARM . . . Adjustable pressure switch, factory set @ 7 PSIG (48 kPa), range 2 to 20 PSIG (14-138 kPa).
HIGH LINE PRESSURE ALARM . . . Adjustable pressure switch, factory set @ 13 PSIG (90 kPa), range 2 to 20 PSIG(14-138 kPa).
EXCESS RUN ALARM A and B . . . .solid
. state timer, fixed 10 minute.

POWER ALARM . . . . . . . . . . . . . . . . Active in event of service interruption, compressor or control-circuit breaker overload or
unit turned off manually.
DUPLEX RUN ALARM . . . . . . . . . . Adjustable, solid state timer, Range to 15 minutes active only in alternate mode.
CABINET DIMENSIONS . . . . . . . . . H 50 in. x W 29 in. x D 22.5 in. (H127 cm x W73.7 cm x D57.2 cm)
AIR TANK . . . . . . . . . . . . . . . . . . . . . 1.6 Cubic Foot (45.3 L) - Agency certified per national codes
AIR TANK RELIEF VALVE . . . . . . . Pop-off 80 ± 5 PSIG (552 ±34 kPa)- Agency certified per national codes

ii
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

PANEL INDICATORS AND SWITCHES

HUMIDITY CIRCUIT TEST Test toggle switch on each humidistat (subsystem "A" and "B") provides complete
electronic operational verification.

DUPLEX MODE LIGHT Indicates flow capacity problems requiring both systems to operate together (duplex).

"A" MODE Dryer operation in which only the "A" dryer system is in operation. The "B" dryer
system is off.

"B" MODE Dryer operation in which only the "B" dryer system is in operation. The "A" dryer
system is off.

ALTERNATING MODE Dryer operation that allows dryer system "A" and dryer system "B" to alternate on
every other start-up. Duplexing occurs (BOTH SYSTEMS RUNNING TOGETHER) automatically
if a flow capacity problem exist in one system.

)(23 )(23

1. Motor Compressor 13. Pressure Relief Valve

2. Heat Exchangers 14. Tank Pressure Gauge
3. DRY-PAK® Dryer Tower 15. High Outlet Pressure Regulator
4. 5 Micron Filter 16. Low Outlet Pressure Regulator
5. Manifold Block 17. Low Pressure Switch
6. Humidity Sensing Element 18. High Pressure Switch
7. Back Pressure Gauge 19. Low Outlet Pressure Gauge
8. Back Pressure Regulator 20. Flow Meter
9. Humidity Bypass Solenoid Valve 21. Outlet
10. System Check Valve 22. High Outlet Pressure Gauge
11. Reservoir Tank 23. Orifice
12. Pressure Switch Start/Stop

Figure 2
Air Flow Diagram
1
1.0 INTRODUCTION 2.3 In the DRY-PAK®, the moisture is adsorbed in
one of the desiccant towers (see figure 3 and section
1.1 This manual covers installation, operation, and
3.0 for an explanation of dryer operation). When the
maintenance with spare parts list for the Model 5000
air leaves the dryer, it is at a dewpoint of -40°F (-
and 7200 Central Office air dryers.
40°C)or lower.
1.2 The Model 5000 and 7200 features two indepen-
2.4 The moisture content of the air is monitored by a
dent compressor/dryer systems, either of which can
humidity sensor in the manifold block and will activate
be operated independently or is capable of operating
if the relative humidity of the air rises above the set
both systems together (Duplexing) in the event of in-
point.
creased flow requirements. Cabinet flow-through
forced air ventilation and vibration isolation optimize
2.5 The dry air flows from the manifold to the ad-
service life. Special consideration has been given to
justable back pressure regulator. The back pressure
accessibility and ease of service.
regulator maintains the pressure in the DRY-PAK® at
60 PSIG, (414 kPa) (50 PSIG (345 kPa) ON MODEL
1.3 BEFORE INSTALLING - - -
7200/60Hz ONLY) to insure efficient drying of the air.
The pressure setting of the back pressure regulator is
READ THE MANUAL THOROUGHLY, then, with
shown on the back pressure gauge only when the com-
the manual as a reference, examine the air dryer. Learn
pressor is operating.
to recognize the various components and the function
performed by each. Section 5 of this manual provides
2.6 After leaving the back pressure regulator, the air
guidelines for selection of a suitable installation site.
passes through the automatic humidity bypass solenoid
valve, through a tank mounted check valve and into
1.4 SELECTED MODES OF OPERATION
the dry air storage tank. Pressure in the tank is con-
trolled by the tank pressure switch, which interrupts
"A" MODE - Dryer operation in which only the "A"
both the "A" and "B" system heatless dryer cycles and
dryer system is in operation. The "B" dryer system is
which stops both compressors when the tank pressure
off.
reaches 60 PSIG, (414 kPa) (50 PSIG (345 kPa) ON
MODEL 7200/60Hz ONLY). The switch starts the
"B" MODE - Dryer operation in which only the
heatless dryers and the compressors again when the
"B"dryer system is in operation. The "A" dryer system
tank pressure drops to 25 PSIG,(172 kPa) (20 PSIG
is off.
(138 kPa) on Model 7200/60Hz ONLY). The tank pres-
sure is indicated on the tank pressure gauge located on
ALTERNATING MODE - Dryer operation that allows dryer
the front panel of the dryer.
system "A" and dryer system "B" to alternate on every
other start-up. If either of the operating systems oper-
2.7 The dry air storage tank is equipped with an
ates continuously for more that the preset excess op-
safety valve set at 80 ± 5 PSIG(552± 34 kPa) .
erating time, the standby system will automatically start
and whereby both systems will operate together
2.8 The dry air from the tank, supplies air to a high
(Duplexing).
output pressure regulator that is monitored by the high
2.0 PRINCIPAL OF OPERATION output pressure gauge located on the front panel. High
output dry air is supplied to the high output outlet.
2.1 The Model 5000 and 7200 Air Dryers are heat-
less, automatic regeneration, self contained dual sys- 2.9 The dry air from the tank, supplies air to a low
tem dryers. output pressure regulator. The low output regulator
maintains the required cable pressure, as shown on the
2.2 Ambient air is taken in by the compressor and low output pressure gauge located on the front panel.
compressed to approximately 60 PSIG (414 kPa), (50 The dry air flow rate (measured in STANDARD CUBIC FEET
PSIG (345 kPa) ON MODEL 7200/60Hz ONLY). The PER DAY, or SCFD) is shown on the output air flow meter.
compressed air flows through the heat exchanger,
where it is cooled, to the inlet fitting of the twin tower 2.10 The low line pressure alarm and high line pres-
DRY-PAK ®.
2
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

sure alarm switches (both located in the electric com- Cycle phase 2..Right dehydration and left
partment) monitor the low outlet air pressure. dwell..duration 5 seconds. (3 sec. for model 7200 60Hz
only)
2.11 Both the system "A" and system "B" solid state Both purge solenoid valves are closed and dry air con-
dryer timers maintain their memory whenever the de- tinues to flow through the calibrated purge orifice until
hydrator power switch is ON. The timers control the the air pressure in the left tower is equal to the air
drying cycles of the DRY-PAK® and progress only when pressure in the right tower. At completion of cycle phase
the compressors operate. 2, the elapsed cycle time is 30 seconds.

2.12 Two fans operate concurrently with the com- Cycle phase 3.. Left dehydration and right tower
pressors. This provides sufficient ventilation to allow purge..duration 25 seconds. (27 sec. for model 7200
continuous operation without overheating. 60Hz only)

3.0 DRY-PAK® OPERATING CYCLE

3.1 The two-way purge solenoid valves of the DRY-

PAK® handle only the purge air. Both the wet main air
flow from the compressor and the dried air are con-
trolled by the ball checks without appreciable pressure
loss. This very low pressure drop is the key to the high
efficiency of the Heatless dryer.

There are four distinct phases of the one minute DRY-

PAK® cycle. Since the DRY-PAK® operates only when
the compressor is running, the cycle may be interrupted
during any cycle phase if the tank pressure reaches 60
PSIG(414 kPa), (50 PSIG (345 kPa) ON MODEL 7200/
60Hz ONLY) and the compressor stops. When the
tank pressure declines to 25 PSIG (172 kPa), (20 PSIG
(138 kPa) on Model 7200/60Hz ONLY) and the com-
pressor restarts, the DRY-PAK® will resume cycling
in the same cycle phase as when it was interrupted.

Cycle phase 1..Right dehydration and left tower purge

..duration 25 seconds: (27 sec. for model 7200 60Hz
only)

The right purge solenoid valve is closed, the left is open,

venting the left desiccant tower to atmosphere. The
check balls are held against the left valve seats by the
higher pressure in the right desiccant tower. While most
Figure 3
of the air being dried by the right tower leaves the
DRY-PAK® Cycle
outlet, a portion of the high pressure dry air passes
through the orifice and expands at low pressure in the HEATLESS REGISTERED TRADEMARK / DIELECTRIC
U.S. PAT. 3323292
COMMUNICATIONS

left tower which was wetted in the previous cycle. Major details of construction:
The expanding air flow picks up the moisture and car- 1,2.... Left and right desiccant towers.
ries it through the open purge solenoid valve outlet to 3,4.... Inlet and outlet check balls.
atmosphere. At completion of cycle phase 1, the elapsed 5,6.... Left and right inlet valve seat.
cycle time is 25 seconds. (27 sec. for model 7200 60Hz 7,8.... Left and right outlet valve seat.
only) 9,10... Left and right calibrated purge air flow orifices.
11,12. Left and right purge solenoid valves.

3
 6.0 INSTALLATION AND START-UP
The left purge solenoid valve is closed, the right is open,
venting the right desiccant tower to atmosphere. The 6.1 Position the Model 5000 or 7200 as per section
check balls are held against the right valve seats by the 5.0. Open the cabinet front door. Remove the acces-
higher pressure in the left desiccant tower. While most sory kit from the cabinet.
of the air being dried by the left tower leaves the out- 6.2 Inspect for damage inside the cabinet (see 4.1).
let, a portion of the high pressure dry air passes through Verify that the Cabinet Ventilation Fan exhaust open-
the orifice and expands at low pressure in the right ing at the rear is not obstructed. Install the cabinet in-
tower which was wetted in the previous cycle. The take filter onto the dryer. Verify that electrical relays
expanding air flow picks up the moisture and carries it are seated into their sockets.
through the open purge solenoid valve outlet to atmo-
sphere. At completion of cycle phase 3, the elapsed 6.3 Remove the two shipping hold-down straps and
cycle time is 55 seconds.(57 sec. for model 7200 60Hz wooden spacer blocks from each compressor.
only)
6.4 Do not connect the air outlet to the cable system
Cycle phase 4..Left dehydration and right until the air dryer has been started and fully tested.
dwell..duration 5 seconds. (3 sec. for model 7200 60Hz
only) 6.5 Connect the proper power electrical plug to the
dryer power entrance cord. Provide the correct power
Both purge solenoid valves are closed and dry air con- to the dryer as stated on the dehydator electrical data
tinues to flow through the calibrated purge orifice until plate.
the air pressure in the right tower is equal to the air
pressure in the left tower. At completion of cycle phase 6.6 Select system "A" on the front panel and turn on
4, the elapsed cycle time is 60 seconds. the power switch on the front panel. Verify that sys-
tem "A" shows 60 to 65 PSIG (414 - 448 kPa), (50
4.0 RECEIVING AND INSPECTION PSIG (345 kPa) on Model 7200/60Hz ,back pressure
while the compressor is operating. If outside this pres-
4.1 Shipping damage is unusual but not totally avoid- sure range refer to: 8.2 Adjust Back-Pressure.
able. Open the shipping container upon receipt and in-
spect the contents for hidden damage. If damage is 6.7 Verify the purge cycling of the DRY-PAC® at
evident, promptly file a hidden damage claim with the the bottom of the door. When the compressor is oper-
delivering transportation company. ating a purge occurs at 30 second intervals, first from
one and then the other heatless dryer Purge Solenoid
5.0 SITE REQUIREMENTS
Valve. The purge air blast is audible and can be felt as
it escapes from the plastic silencer on the purge sole-
5.1 The Model 5000 and 7200 air dryers requires a
noid valve. After the initial purge blast, a steady flow
firm, level site with a minimum of 6 inches (150 mm)
of purge air continues for 25 seconds. After 5 addi-
clearance at the rear for ventilation. Front clearance
tional seconds, the opposite purge will occur. If the
should be at least 3 feet (one meter). The space above
cycling is not as described, refer to section 9.3 DRY-
the cabinet should be open. Do not stack objects on
PAK® Trouble Shooting. Close the cabinet door to
the cabinet or otherwise restrict the free flow of air
insure maximum ventilation. (27/3 sec. for model 7200
upward from the cabinet rear surface.
60Hz only)
5.2 The temperature at the installation site must be
6.8 A humidity alarm is a common condition at initial
within the range of 32° F to 120° F (0° C to 48° C)
BEST PERFORMANCE WILL OCCUR AT 68° F start-up. This is due to an extended period of dryer
inactivity, consequent to storage and shipping. The ini-
(20° C).
tial humidity alarm will normally clear automatically after
5.3 No water drain is required as purge moisture is several minutes of operation. For in depth information,
refer to 9.2 Humidity Alarm Trouble Shooting.
evaporated by cabinet air flow and normal operating
temperature.
5.4 The dryer location should be close to the cables 6.9 After the humidity alarm is cleared, push the low
to be pressurized. This will avoid unnecessary pres- outlet pressure requlator knob in. Adjust the low outlet
sure loss in the regulated pressure line. pressure regulator to allow air to escape the outlet air
4
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

fitting at a rate of approximately 1000 SCFD (28 7.3 At intervals of 1000 hours of operation: Verify
SCMD)as shown on the outlet air flow meter. Tempo- the adjustment of the Tank Pressure Switch. Refer to
rarily lock the regulator by pulling the knob out about section 8.1.
¼" to maintain this flow rate. When the tank pressure 7.4 At intervals of 1000 hours of operation: Verify
reaches 60 ± 2 PSIG (414±14 kPa), (50±2 PSIG the adjustment of the high and low line pressure alarm
(354±14 kPa) on Model 7200/60Hz ONLY) the comp- switches. Refer to section 8.3.
ressor will stop. The compressor will start again when
the tank pressure declines to 25 PSIG ± 2 (172±14 7.5 At intervals of 2000 hours of operation: Replace
kPa) PSIG, (20 ± 2 PSIG (138±14 kPa) on Model 7200/ the compressor inlet filter elements. Refer to section
60Hz ONLY). If the tank pressure range exceeds these 8.6.
limits refer to: 8.1 Tank Pressure Switch Adjustment.
NOTE: The humidity alarm may become active when 7.6 At intervals of 2000 hours of operation: Test the
the compressor is not operating. Operate the dehydra- humidity alarm circuit. Refer to section 8.7.
tor in this mode for not less than six hours after the 7.7 At intervals of 4000 hours of operation: Replace
humidity alarm remains permanently cleared. the compressor rings and valves. Refer to: 8.8.
6.10 Select system "B" mode and verify that the back
pressure settings and heatless dryer operation function 8.0 ADJUSTMENTS AND TESTS
as per paragraph 6.7, 6.8 and 6.9.
8.1 CHECK OR CHANGE TANK PRESSURE
6.11 Plug the air outlet fitting on the rear of the cabi- SWITCH SETTING ADJUSTMENT
net with your finger and increase the line pressure to
clear the low pressure alarm. Continue to increase the NOTE:
line pressure and note the pressure at which the High Acceptable tank pressure at compressor start is 25 ± 2
Line Pressure alarm becomes active. Lower the line PSIG (172±14 kPa) (20 PSIG (138 ±14 kPa) on
pressure and note the pressure at which the Low Line Model 7200/60Hz ONLY)and stop at 60 ± 2 PSIG
Pressure alarm becomes active. If you wish to change (414±14 kPa) (50 ± 2 PSIG (345±14) on Model
these factory settings refer to: 8.3 Check or change 7200/60Hz ONLY).
alarm pressure switch adjustment.
8.1.1 The Tank Pressure Switch has been factory ad-
6.12 Adjust the line pressure regulator to achieve the justed. Observe and record the start and stop pres-
desired pressure as indicated on the line pressure sures for reference before continuing.
gauge. When the line pressure is satisfactory, lock the TABLE III
setting by means of the regulator knob. MAINTENANCE CHART
6.13 Connect the remote alarm wires to the alarm ter- PR OCED UR E
R e f. 1000 2000 3000 4000
Para. Hrs Hrs Hrs Hrs
minal board on the rear of the cabinet. For alarm wir-
ing options, refer to: 8.5 Alarm Wiring Options. This Ve rify He atle s s
completes the start up procedure. D rye r Cycling
7.1 x x x x
Ve rify Back
7.0 GENERAL MAINTENANCE Pre s s ure
7.2 x x x x
Ve rify Tank
Periodic maintenance must be performed to insure Pre s s ure Switch 7.3 x x x x
Adjus tme nt
continued reliable and efficient operation of the
Models 5000 and 7200. Ve rify High & Low
Pre s s ure Switch
Adjus tme nt
7.4 x x x x
7.1 At intervals of 1000 hours of operation: Verify
that the DRY-PAK® is cycling correctly. Refer to: 8.9 R e place Inle t Air
7.5 x x
Filte r Ele me nts
DRY-PAK® Cycling Test.
Te s t Humidity
Alarm Circuit
7.6 x x
7.2 At intervals of 1000 hours of operation: Verify
that the back pressure regulator is correctly adjusted. R e place

Refer to section 8.2.

Compre s s or R ings
& Valve s
7.7 x

5
 WARNING! tank pressure varied from the specified range before
RISK OF ELECTROCUTION - Disconnect from you completed your observation, repeat 8.2.3.
electrical power before starting this procedure.
8.2.5 It is normal for the back pressure to rise slightly
8.1.2 The Tank Pressure Switch is located in the elec- before a purge, or to fall slightly when the purge oc-
trical compartment and is accessed through the top curs. If the back pressure is much more erratic than
cover of the Model 5000 or 7200 air dryer. The Tank (± 20 PSIG / ± 138 kPa) proceed to section 9.3.
Pressure Switch cover is held by a single 5/16 inch
hex nut. The cover can be seen just below the front 8.3 CHECK OR CHANGE ALARM PRES-
panel when the cabinet door is open. With the cover SURE SWITCH ADJUSMENT
removed, two adjuster screws are visible. To adjust
both the start and stop pressures (the total tank pres- 8.3.1 Both the High and Low line pressure alarm pres-
sure range) turn only the screw on the center adjuster. sure switches are located on the side wall of the elec-
About 21/8 FULL REVOLUTIONS of the adjuster nut trical compartment. Both may be adjusted while in nor-
changes the set-point 5 PSIG(35 kPa). Clockwise mal operation.
raises, counterclockwise lowers the setting. Replace
the switch cover after adjustment and close the cabi- 8.3.2 Test the alarm switch operation before making
net door. an adjustment. Close the air valve at the pipe panel or
meter panel supplied with dry air from the dryer. Re-
8.1.3 Connect the power cord to the electric outlet duce the line pressure and note the pressure at which
and restart the dehydrator. Again check the start and the low pressure alarm occurs. Increase the line pres-
stop pressure to verify the Tank Pressure Switch ad- sure and note the pressure at which the high line pres-
justment. sure alarm occurs. If either HIGH or LOW alarm switch
operating pressure is incorrect, proceed to 8.3.3. If no
8.2 CHECK OR CHANGE BACK PRESSURE adjustment is required, open the panel air flow valve.
REGULATOR ADJUSTMENT
8.3.3 The alarm pressure switches are identified by
8.2.1 PREPARATION: Adjust the back pressure labels. Use a small screw driver and turn the adjust-
regulator only -- WHILE THE COMPRESSOR IS OP- ment screw GENTLY clockwise to increase or coun-
ERATING AND THE TANK PRESSURE IS BE- terclockwise to reduce the pressure setting. Affirm the
TWEEN 29 AND 50 PSIG. (199 AND 345 kPa) adjustment by means of the line pressure regulator,
changing pressure slowly to obtain precision. Verify
Loosen the outlet air tube at the rear of the cabinet to that any or all panel flow valves are opened when ad-
increase the air flow rate. This will help to give more justment and tests are completed.
time to perform and validate the adjustment. Pull the
Back Pressure Regulator adjuster knob about 1/4 inch 8.4 DUPLEX RUN ALARM TIMER ADJUST-
to the unlocked position. MENT.
NOTE
The Dryer must be running in the "ALT" Mode.
8.2.2 Wait until a purge blast occurs from one of the 8.4.1 The Duplex Run Alarm Timer (TD3) is located,
purge solenoid valve silencers. Turn the adjustment knob and identified, in the Electrical Compartment. Before
clockwise to raise, or counterclockwise to lower the making adjustment, cause the dryer to run continually
Back Pressure. The acceptable adjustment range is and measure the duration time from compressor "A"
60 to 65 PSIG (414 - 448 kPa). or "B" start-up, to the Duplex alarm activation.

8.2.3 Continue to observe the back pressure gauge 8.4.2 The adjustment range and direction of increase/
for not less than one full minute more. The first purge decrease are shown on the timer label. Make only very
valve to purge after your adjustment will have purged minor adjustment at any one time and then check the
a second time. This assures that you have observed alarm delay as in 8.4.1. If the alarm does not function,
the full timing cycle of the DRY-PAK®. replacement of the delay timer is indicated.

8.2.4 If the compressor stopped operating, or, if the

6
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

8.5 ALARM WIRING OPTIONS 8.7 HUMIDITY ALARM MOISTURE TEST

8.5.1 ALARM oUTPUT oPTION 1: A summary “close in 8.7.1 Turn the dehydrator off and vent all the air
alarm” remote warning that one or more of the alarm pressure from the Sensor Manifold test valve. When
circuits is active. To utilize this option leave the alarm the back pressure gauge indicates 0 PSIG, remove the
terminal board as configured at the factory. Yellow jump sensor by turning the large hex nut at the top of the
wires connect “common” terminals in series, blue jump manifold counterclockwise. Remove the sensor care-
wires connect “close in alarm” terminals in series. Con- fully so that the sealing O-ring is not lost.
nect your remote alarm pair to terminals #1 and #24.
8.7.2 Wave the Sensor Element in the room air to
8.5.2 ALARM oUTPUT oPTION 2: Segregated alarms us- allow it to become moist and then return it to the mani-
ing a single common provide discrete indication of each fold. Be sure that the O-ring is in place, then hand-
alarm circuit, either close or open in alarm, but all at tighten the large hex nut (do not use a wrench).
one potential. To utilize this option remove the blue jumps
from the terminal board, leave the yellow jumps (which 8.7.3 Start the dehydrator and verify that the Humid-
connect commons in series) in place. Connect your ity Alarm is active and that air escapes through the
remote alarm common wire to terminal #1 and your open port (port 3) of the Humidity Bypass Solenoid
remaining remote alarm wires to selected “Close In Valve.
Alarm” or Open In Alarm” terminals as you prefer.
8.7.4 While the alarm is active, move the humidistat
8.5.3 ALARM oUTPUT oPTION 3: A summary “open in test toggle to “TEST CLEAR” for a few seconds.
alarm” remote warning that one or more of the alarm Verify that the humidity alarm clears until the test toggle
circuits is active. To utilize this option move only one is released. Close the cabinet door. After several min-
end of each yellow jump wire from its location in a utes of operation the alarm will clear automatically.
“common” terminal to the adjacent “open in alarm”
terminal as follows: yellow jump #1 to #4 becomes #2 8.8 COMPRESSOR REBUILD
to #4 and move the remaining yellow jumps to connect
#5 to #7, #8 to #10, #11 to #13, #14 to #16,#17 to #19, WARNING!!
and #20 to #22. Remove the blue jumps from the ter- RISK OF ELECTROCUTION - Disconnect from
minal board. Connect your remote alarm pair to termi- electrical power source: Before disconnecting
nals #1 and #23. compressor electrical quick-connect from cabinet
electrical harness.
8.5.4 ALARM oUTPUT oPTION 4: A completely segre-
gated alarm output wherein a separate voltage or fre- WARNING!
quency may be used for any or each alarm function. RISK OF BURNS - Normal compressor operation
Remove both the yellow and the blue jump wires from will cause head temperature to exceed 100°C. Be
the alarm terminal board. Connect your remote alarm very careful when handling a hot compressor.
wires to each alarm function terminal set to obtain
“Open In Alarm” or “Close In Alarm”, output as you
prefer. 8.8.1 To remove the compressor from the cabinet:

8.6 REPLACE COMPRESSOR FILTERS a.- Disconnect the flexible hose from the compressor
outlet using two wrenches (11/16 inch and 3/4 inch
8.6.1 Press the black filter cap towards the cylinder open end or comparable adjustable wrenches).
head and turn it counterclockwise. Remove the cap,
discard the old filter and wipe the cap clean with a rag. b.- Disconnect the electrical quick connect which joins
Install the new filter element and reassemble in re- the compressor electrical harness to the cabinet elec-
verse order. Each cylinder has one filter element. trical harness.

NOTICE - Do this only when compressor is not run- c.- Loosen the nuts from the four support-shock mounts
ning, otherwise it may ruin the valves. with a 1/2 inch open end wrench. Remove the nuts

7
and washers. 8.8.9 Install a new piston seal in one ring grove of
one piston and hold it in place by installing a piston ring
d.- Lift the compressor assembly free of the shock over the seal. Place the joint in the piston ring opposite
mounts and remove the compressor from the cabinet. to the joint in the piston seal. Be sure that the ring
covers the entire seal all around the piston. Repeat
8.8.2 Refer to Illustration 8, "COMPRESSOR - Ex- with each of the 3 remaining seals and rings. If the
ploded View" before disassembly of the compressor. joints of the piston rings on either piston are nearly
aligned, rotate one ring until its joint is not less than 45
8.8.3 DO NOT remove the inlet filter assemblies (1) angular degrees from the adjacent ring joint.
from the cylinder heads.
8.8.10 Place a Piston Rider Ring (31) on one piston
8.8.4 Loosen the four #2 Phillips screws and remove and slide a cylinder gently over the piston rings and
the plastic Compressor Fan Shroud (39). rider ring. Be sure that no part of the rider ring pro-
trudes from the cylinder, and that the cylinder will slide
8.8.5 Do not lubricate any part of the compressor. Do smoothly on the piston. Attach the cylinder to the mo-
not allow petroleum products, caustics or solvents to tor front bracket, using two screws. Tighten the screws
contact any part of the compressor. Parts may be ONLY FINGER TIGHT. Repeat for the opposite cyl-
cleaned with soap and water followed by wipe down inder of the compressor.
with a cloth dampened with clean water. Use a 3/4
inch open end wrench to loosen the manifold nuts (41) 8.8.11 Rotate the motor shaft and move the pistons
on the manifold tube (42) between the left and the right to the extreme outward position (top dead center).
cylinder heads (20). DO NOT REMOVE THE MANI- Move each cylinder so that it is even with the top of
FOLD TUBE UNTIL ONE HEAD HAS BEEN RE- the piston. Torque the cylinder screws to 150 pound-
MOVED! inches (18.44 Nm). Place a flat bar vertically across
the open cylinder. Rotate the motor shaft. The piston
8.8.6 Use a 3/16 inch Allen hex wrench to remove should contact the flat bar without lifting the bar from
the cylinder head and valve components (22, 23 and the cylinder surface. The cylinder gasket (25), when
24) from one cylinder. Next remove the manifold tube, added, will provide the correct piston-to-valve clear-
and then the opposite cylinder head. It may be neces- ance when the head assembly is secured.
sary to use a knife or razor blade to remove the gasket
material (21 and 25) from the head and cylinder. Be 8.8.12 The aluminum head, the head gasket and the
very careful not to scratch the aluminum surfaces. outlet valve, each have 4 bolt holes at the corners and
a single, smaller hole, (a “pilot” hole) for reference in
8.8.7 Remove the two Cylinder Screws (27) which aligning the components correctly. The aluminum valve
hold each Cylinder (26) and slide the cylinders out- plate, the inlet valve and the cylinder gasket each have
ward, over the Pistons (30). Remove the Piston Rings 4 bolt holes at the corners, and two smaller holes (“pi-
(28), Piston Seals (29) and Piston Rider Rings (31) lot holes”) for the same purpose.
from the pistons. NOTE!
The following procedure will assure that cylinder
heads and valve components are correctly posi-
NOTE!!! tioned during reassembly!
Do not lubricate any part of the compressor. Do not
allow petroleum products, caustics or solvents to 8.8.13 Hold the head in one hand, with its inside up,
contact any part of the compressor. Parts may be and with two head bolts protruding upward through the
cleaned with soap and water followed by wipe down head. Align the pilot hole in the head gasket and the
with a cloth dampened with clean water. outlet valve, with the pilot hole in the head and place
them on the head. The pilot hole in the head must still
8.8.8 Examine the heads, pistons and cylinders for be visible through the pilot holes in the components.
scratches or scars on working surfaces. Clean the parts The outlet valve has a “finger” on one side, an oblong
only with a cloth and soapy water if they are dirty or hole in the opposite side. The inside of the head must
greasy. Do not reuse scratched components. still be visible through the oblong hole in the outlet valve.

8
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

8.8.14 Place the aluminum valve plate on next, so one the purging valve silencer can be felt simultaneously.
pilot hole aligns with that in the head, the outlet valve 30 seconds later the opposite purge valve will provide
finger can be moved by pushing gently with a pencil the same indications. This is indication that the Heatless
through the outlet air passages of the aluminum plate dryer is cycling normally. If cycling is normal, tighten
and so that the inside of the head is still visible through the air outlet tube. If trouble shooting, refer to section
the inlet air passages of the aluminum plate. Next add 9.4.
the inlet valve so that its finger covers the inlet air pas-
sages and the outlet valve finger can still be seen and 9.0 TROUBLE SHOOTING
can be moved with a pencil through the outlet air pas-
sages. Add the cylinder gasket, then loosely connect 9.1 Trouble Shooting Low or High Pressure Alarm
the assembly to the cylinder. Loosely install the mani-
fold on the first head, after installing new Manifold 9.1.1 Perform adjustment procedures as per section 8.3
Sleeves (40). DO NOT TIGHTEN the head bolts at to verify that a malfunction exists. Close the valve or
this time. Repeat with the opposite head. valves at the meter panel (s) supplied by the dehydra-
tor.
8.8.15 Tighten the four Allen head screws of each
head finger tight. Torque the screws to 120 pound- a.- leave the dehydrator in normal operation and use
inches (13.83 Nm) using a 3/16 inch Allen hex wrench. the ohm-meter ONLY AT THE REMOTE ALARM
TERMINAL BOARD TB2, while the remote device
8.8.16 Install the Compressor Fan Shroud with the connection wires are DISCONNECTED.
four screws and washers previously removed.
b.- To check any of the alarm circuit except a. above,
8.8.17 Position the manifold and tighten the manifold TURN THE DEHYDRATOR OFF AND DISCON-
nuts with a wrench, 1/2 to 3/4 turns more than hand NECT FROM THE ELECTRICAL POWER
tight. SOURCE BEFORE USING AN OHM METER TO
NOTE! CHECK THE CAUSE OF MALFUNCTION.
Minor air leakage at the head-valve-cylinder
joints is normal. DO NOT SEAL the gaskets with c.- To check either alarm pressure switch: Remove
joint compound or sealant as damage to the as- the black wire terminal from the COMMON terminal
sembly will occur. Do not attempt to eliminate of the suspect pressure switch. If checking the Low
leakage by exceeding recommended torque val- Line Pressure Alarm switch, remove the violet (purple)
ues as distortion will result. wire terminal. If checking the High Line Pressure Alarm
switch, remove the gray wire terminal.
8.8.18 Carefully reinstall the compressor into the cabi-
net so that it rests on all four shock mounts. Install the 9.1.2 SYMPTOM: The (high or low) line pressure
four lock washers and nuts, tighten to not more than 70 alarm light (schematic symbol LT4 or LT5) on the front
pound-inches (8 Nm). Hold the outlet air fitting with a panel WILL NOT ILLUMINATE and the remote alarm
wrench while tightening the flexible hose nut. Recon- terminals (schematic symbol TB2-10,11,12 OR TB2-
nect the electrical quick-connect before restoring the 13,14,15) of the effected circuit DO NOT respond TO
cabinet power cord connection. SWITCH ADJUSTMENT:

8.9 DRY-PAK® CYCLING TEST CORRECTIVE ACTION: disconnect from

power and replace the effected pressure switch (P/N
8.9.1 The DRY-PAK® only cycles when the compres- 46752) and adjust per section 8.3.
sor is operating. Loosen the air outlet tube at the rear
of the cabinet, if necessary, to cause the dehydrator to 9.1.3 SYMPTOM: The (high or low) line pressure
continue operating for several minutes. alarm light (schematic symbol LT4 or LT5) on the front
panel REMAIN ILLUMINATED/WILL NOT
8.9.2 With the compressor operating and the back CLEAR and the remote alarm terminals (schematic
pressure adjusted as per section 8.2, an audible purge symbol TB2-10, 11, 12 OR TB2-13, 14, 15) of the ef-
should be heard each 30 seconds. A blast of air from fected circuit WILL NOT RESPOND TO SWITCH
ADJUSTMENT:

9
CORRECTIVE ACTION: Disconnect from ter a period of alarm free operation the humidity alarm
power and replace the effected pressure switch (P/N reoccurs. Refer to section 9.4.
46752) and adjust per section 8.3.
g:- If you have found and corrected an obvious cause
9.1.4 SYMPTOM: The (high or low) line pressure of the humidity alarm and yet the alarm persists, refer
alarm light (schematic symbol LT4 or LT5) on the front to section 9.4.
panel WILL NOT ILLUMINATE but the remote alarm
terminals (schematic symbol TB2-10, 11, 12 OR TB2- 9.2.2 Humidity Circuit Test
13, 14, 15) of the effected circuit DO RESPOND TO
SWITCH ADJUSTMENT: 9.2.2.1 When trouble shooting a humidity alarm, first
verify the operation of the humidistat, located on the
CORRECTIVE ACTION: Replace the effected front panel.
light.
9.2.2.2 If the humidity alarm is active and the amber
9.1.5 SYMPTOM: The (high or low) line pressure (yellow) LED ON THE HUMIDISTAT is lit, VERIFY
alarm light (schematic symbol LT4 or LT5) on the front THE ALARM by moving the test toggle to “Test Alarm”.
panel WILL ILLUMINATE AND CLEAR but the re- If this action temporarily clears an amber alarm, the
mote alarm terminals (schematic symbol TB2-10, 11, humidistat is operating correctly. Refer to 9.2.3 “Valid
12 OR TB2-13, 14, 15) of the effected circuit DO NOT Open Alarm”. If the test toggle will not temporarily clear
RESPOND TO SWITCH ADJUSTMENT: the amber LED when it is lit, replace the humidistat.

CORRECTIVE ACTION: First verify that the 9.2.2.3 If the humidity alarm is active and the red LED
alarm wires are connected to the correct terminals of ON THE HUMIDISTAT is lit: VERIFY THE ALARM
TB2. If the malfunction persists replace the effected by moving the test toggle to “Test Clear”. If this action
relay. temporarily clears the alarm, the humidistat is operating
correctly. Refer to 9.2.3: “Valid Humidity Alarm”. If
9.2 TROUBLE SHOOTING A HUMIDITY the test toggle will not temporarily clear the red LED
ALARM when it is lit, replace the humidistat.

9.2.1 The following is a list of conditions which can 9.2.3 Valid Open Alarm - If the amber LED on the
cause a humidity alarm and the order in which to pro- humidistat is lit and the test toggle will temporarily clear
ceed: it, (section 9.2.2.2) there is an open condition in the
sensor circuit. Check for a loose connection between
a: Test for faulty alarm circuit (section 9.2.2). the humidistat and sensor. If connections are OK, the
sensor itself has an open circuit and must be replaced.
b: Test for low back pressure (section 8.2). Do not test the sensor with a direct current ohm meter,
as sensor calibration will be destroyed.
c: Test for DRY-PAK® not cycling - refer to: 8.9 DRY-
PAK® Cycling Test. and to: 9.3 TROUBLE SHOOT- 9.3 TROUBLE SHOOTING DRY-PAK ® CY-
ING DRY-PAK® CYCLING INTERRUPTION. CLING INTERRUPTION

d: Back pressure falls to near 0 PSIG while compres- 9.3.1 Having found the dryer cycle to be interrupted
sor is operating. Refer to: 9.3.3 PRESSURE FLUC- (8.9), TURN THE DEHYDRATOR OFF AND DIS-
TUATION. CONNECT FROM POWER SOURCE BEFORE
CONTINUING! Disconnect both wire leads of each
e: Continual humidity alarm, but Heatless Dryer cycle, purge solenoid valve coil. Measure the resistance of
back pressure and operating duty cycle are normal. each coil with an ohmmeter. Normal coil resistance is
Refer to: section 9.3.4. 260 ± 30 ohms. If either coil is open or shorted, replace
the coil assembly. Be sure coil connections are secure
f: Intermittent humidity alarm. Humidity alarm clears when finished. If when the dehydrator is restarted, nor-
automatically after a period of continual operation. Af- mal cycling is resumed, proceed to 9.4, if not, to 9.3.2.

10
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

9.3.2 If cycle interruption continues, replace the timer. 9.4.2 If none of the above procedures solve the hu-
When cycling is restored, proceed to 9.4. midity alarm, replace the DRY-PAK®.

9.3.3 PRESSURE FLUCTUATION. If the back pres-

sure falls to 0 PSIG at any time when the compressor is
operating it indicates that one purge solenoid valve has
failed to close. This can be corrected by installing valve NOTES
repair kit P/N 0024815021. Install kits in both valves so
that both are in new condition. When the valve repair is
completed and cycling is restored, proceed to section
9.4.

9.3.4 If DRY-PAK® cycling and back pressure are

normal and if the dehydrator operates more than once
each hour, replace the purge mufflers. After installation
of new purge mufflers, if a noticable increase in purge
noise is noted, proceed to section 9.4. If all operational
checks reveal no reason for the alarm condition, but the
alarm persists, replace the sensing element. If the alarm
persists, go to section 9.4.

9.3.5 If the humidity alarm repeatedly occurs and

automatically clears after a period of continual opera-
tion, increase the back pressure regulator setting to 69
PSIG (476 kPa) (53 PSIG (365 kPa) on Model 7200/
60Hz ONLY). This type of humidity alarm is often the
result of an exceptionally high-capacity compressor or
of infrequent DRY-PAK® operation. In either case the
extra back pressure will eliminate the problem.

9.4 DRY-DOWN AFTER REPAIR

If the cause of a valid humidity alarm has been cor-

rected, the unit must operate after repairs are com-
pleted for perhaps an hour or more in order to dry the
desiccant towers and clear the humidity alarm. If a de-
fective sensor element was the cause of alarm, it will
normally clear after 5 to 15 minutes of operation with a
new sensor in place.

9.4.1 The desiccant used in the drying towers is mo-

lecular sieve, which has a normal useful life equal to
the dehydrator. Reduced service life can occur due to
air borne contaminants (hydrocarbons, acids etc.) which
may plug or degrade the desiccant. This is seldom the
cause of a high humidity condition, but if all other pos-
sible causes for a high humidity condition have been
ruled out, and especially after years of service, replace-
ment of the DRY-PAK ® desiccant towers is
recommened.

11
 TABLE IV
SPARE PARTS LIST FOR Model 7200 COMPRES-
SOR DEHYDRATOR
Item Part No. Description Quantity
1 41136 Light, Power On (Clear) 1
2 43137 Line Pressure regulator 2
3 44002 Filter Assembly (See Heatless Dryer Assy.- Fig.6) 2
3a 44177 Replacement Filter Element, 5 micron 2
4a 47116 Compressor Circuit Breaker - (Model 5000) 2
4b 44018 Compressor Circuit Breaker - (Model 7200) 2
5 44416/105139 Air Storage Tank ASME/CE Certified 1
6 44746 Heat Exchanger Assembly 2
7 0045024503 Flex Hose 2
8 46752 Line Pressure Switch - High or Low 2
9 47048 Humidity Bypass Solenoid Valve 2
9a 47317 Humidity Bypass Solenoid Valve Coil -
9b 0024815021 Humidity Solenoid Valve Repair Kit -
10 47097 Elapsed Timer (Hour Meter) 2
11a 60832 DRY-PAK® Assembly (Model 5000) 2
11b 60833 DRY-PAK® Assembly (Model 7200 - 50Hz) 2
11c 60834 DRY-PAK® Assembly (Model 7200 - 60Hz) 2
12 47217 Fan (220V/50Hz) 2
13 105149 Duplex Run Timer 1
14 0049983001 Outlet Air Flow Meter 1
15 34709 Humidistat 2
17 47053 Compressor Control Relay (3 pole, 220V/50Hz) 2
18 51627 Alternating Relay 1
19 51626 Relay (4 PDT) 3
21 0005390070 Line Pressure Gauge 200 Kpa (0 - 30 PSI) 2
22 0005390071 Tank Pressure Gauge 1100 Kpa (0 - 160 PSI) 1
23 89795 O-Ring, Sensing Element Nut Seal 2
24 14127 Relay Bracket Case (220V) 10
25 15688 Sensing Element 2
26 0017221082 Pressure Gauge (7000Kpa/100PSI) 2
27 0017495001 Schrader Valve 6
28 33384 Excess Run Timer 2
29 51625 Rotary Switch 1
30 0018568011 Shock Mount 8
31 0020523003 Back Pressure Regulator 2
32 105142 Tank Pressure Relief Valve ASME CE 1
33a 0023009026 Compressor (Model 5000 - 50Hz) 2
33b 0023009023 Compressor (Model 5000 - 60Hz) 2
33c 0023009029 Compressor (Model 7200 - 50Hz) 2
33d 0023009014 Compressor (Model 7200 - 60Hz) 2
34 30986 Sensor Plug 2
35a 34721 S.S. Timer (All Model 5000s and 7200/50Hz 2
35b 12441 S.S. Timer Model 7200/60Hz Only 2
37 36696 Brass Barb Connector (part of 46752) 2
38 37977 On-Off Control Circuit Breaker -.5 Amp, 2 pole 3
39 41135 Light, Alarm (Red) 7
40 51623 On / Off Switch 1
41 - Alarm Terminal Board ref.
42 0060353003 Start/Stop Pressure Switch 1
43 40151-2 Cabinet Filter 1

12
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

39 10 1 29 10 39 14

15
22
21
15
40

21

39

2
2
7
6
33
12

32 30

Figure 4
Model 7200 Air Dryer ( front view )

13
 41

43

Figure 5
Model 7200 Air Dryer ( rear view )

14
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

38 4 18

19

17
42
24

Figure 6
Model 7200 Air Dryer ( inside top view )

34

23
25
26
27
9
31

REF: ORIFICE

Figure 7
Humidity Manifold Assembly

15
 8 37 28

35

Figure 8
Electrical Compartment Wall (inside left)

24

13

Figure 9
Electrical Compartment Wall (inside right)

16
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

11,12
6a,b,9
13,14
5

10a,b 8

4 2,3

Figure 10
DRY-PAK® Assembly

1 Purge Valve -All 230/220v Models (2 required) 47046

2 Valve Repair Kit (mechanical parts-2 required) 0024815022
3 Purge Solenoid Valve Electric Coil 230/220v, 60/50 hz 47315
4 Purge Solenoid Valve Silencer (2 required) 0022646001
5 Ball Check (2 required) 0015903003
6a Top Ball Valve Seat with drilled orifice (5000 / 7200 ) 47314
6b Top Ball Valve Seat with drilled orifice (7200 - 60Hz only) 60841
7 Bottom Ball Valve Seat ( no orifice, 2 required) 37393
8 Center Block 37392
9 Valve Seat O-ring Seal 0014000115
10a Model 5000 Desiccant Cylinder Assembly (2 required) 47114
10b Model 7200 Desiccant Cylinder Assembly (2 required) 45992
11 Desiccant Cylinder Socket Head Cap Screws 0011032150
12 Lock Washer for item 18-11 0161000000
13 Filter Housing 47002
14 Replacement 5 micron Filter Element 44177

17
18
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

Figure 11
Electrical Schematic

19
 TABLE V
ELECTRICAL PARTS - LOCATIONS AND FUNCTIONS
CB 1 —10 amp / 7.5 amp, 2 pole Compressor “A” Circuit Breaker, located inside electrical compartment on rear CB Panel — provides
current to CB 3 and to Compressor A via K1 Contractor.

CB 2 —10 amp / 7.5 amp, 2 pole Compressor “B” Circuit Breaker, located inside electrical compartment on rear CB Panel — provides
current to CB 4 and to Compressor B via K2 Contractor.

CB 3 —0.5 amp, 2 pole CONTROL “A” Circuit Breaker, located inside electrical compartment on rear CB Panel — provides current to
“A” side Control Circuitry.

CB 4 —0.5 amp, 2 pole CONTROL “B” Circuit Breaker, located inside electrical compartment on rear CB Panel — provides current to
“B” side Control Circuitry.

CB 5 —0.5 amp, 2 pole Mode Control Circuit Breaker, located inside electrical compartment on rear CB Panel — provides current to
Mode Switch, Mode Controlling Relays, and Duplex Timer.

Comp A/Comp B —Oil Free Compressor/Motor Assembly, located in cabinet base on Air Storage Tank.

Fan “A”/Fan “B” —Cabinet Ventilation Fan, located on cabinet rear surface — powered by K9 and K15 Run “A” and Run “B” Relays.

Humidity Sensor —Located inside electrical compartment on Humidity Manifold “A” and “B”, left and right side wall — responds
electrically to any changes in moisture content of the dry air from the Heatless Dryer.

Hum “A”/Hum “B” —Humidistat, located on the front control panel — provides current to SV3/SV6 when clear or to K8/K14 if in alarm.

J1/P1-J5/P5 —Polarized Pin and Socket Connector, 3 positions - connects Cabinet Harness to Compressors Harness.

J2/J6 —Polarized Socket Connector, 9 positions - located on Humistats “A” and “B”.

J3/J7 —Non Polarized Connector, 3 position (center not used), located inside electrical compartment on Humidity Sensor Manifold —
connects to Humidity Sensor Plug.

ET “A”/ET “B” —Elapsed Timer (Hour Meter) located on front control panel — Shows the total hours of Compressor and Air Dryer
Operation

K1/K2 —Contractor “A” and “B”, located inside electrical compartment on Bottom Din Rail — provides current to Compressors and to
Excess Run Timers TD 1 and TD 2.

K3 —Relay, 4PDT 240/220 VAC Coil, located inside electrical compartment on Bottom Din Rail — provides current to “A” Mode Control
Circuitry.

K4 —Relay, 4PDT 240/220 VAC Coil, located inside electrical compartment on Bottom Din Rail — provides current to “B” Mode Control
Circuitry.

K5 —Relay, 4PDT 240/220 VAC Coil, located inside electrical compartment on Bottom Din Rail — provides current to Alternating Mode
Control Circuitry

K6 —Relay Alternating, located inside electrical compartment on Bottom Din Rail — alternates duty cycle between Compressor A and
Compressor B and Duplexes (Running Both Compressor) when excess flow demand exists.

K7 —Relay, DPDT 240/220 VAC Coil, located inside electrical compartment on Relay Bracket, right side wall — provides current to
Alternating Mode Control Circuitry.

K8/K14 —Relay, Humidity DPDT 240/220 VAC Coil, located inside electrical compartment on Relay Bracket, right side wall — provides
Remote Alarm Signal to TB2 for Humidity “A” and Humidity “B” Alarms.

K9/K15 —Relay, DPDT 240/220 VAC Coil, located inside electrical compartment on Relay Bracket, right side — provides “Run A” and
“Run B” Control Circuitry.

K10/K16 —Relay, Excess Run, 240/220 VAC Coil, located inside electrical compartment on Relay Bracket, right side wall — provides
Remote Alarm Signal to TB2 for Excess Run “A” and Excess Run “B”.

K11 —Relay, Power Failure, 240/220 VAC Coil, located inside electrical compartment on Relay Bracket, right side wall — monitors
incoming power and provides a Remote Alarm Signal to TB2 for power loss.

K12 —Relay, Low Pressure, 240/220 VAC Coil, located inside electrical compartment on Relay Bracket, right side wall — provides Remote
Alarm Signal to TB2 for Low Pressure Alarm.
20
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649

K13 —Relay, High Pressure, 240/220 VAC Coil, located inside electrical compartment on Relay Bracket, right side wall — provides Remote
Alarm Signal to TB2 for High Pressure Alarm.

LT1 —Power on Indicator (Amber), located on front control panel.

LT2/LT3 —Compressor RUN A and COMPRESSOR RUN B Indicator (Amber), located on front control panel — illuminates when
Compressor(s) Run.

LT4 —Low Line Pressure Alarm Indicator (Red), located on front control panel — illuminates when Low Line Pressure Alarm.

LT5 —High Line Pressure Alarm Indicator (Red), located on front control panel — illuminates when High Line Pressure Alarm.

LT6/LT7 —Excess run A and Excess run B Indicator (Red), located on front control panel — illuminates when Compressor exceeds 10
minutes of continuous operation.

LT8 —Duplex Indicator (Red), located on front control panel — illuminates when Single Compressor exceeds pre set Duplex Time (TD3)
for both Compressor to operator together.

PS 1 —Start/Stop Tank Pressure Switch, located inside electrical compartment on left side wall — provides current to Mode Relays K3, K4
and K7 which control Run Relay K9 and K15. Provides on/off cycling control of Compressors.

PS 2 —Adjustable High Line Pressure Switch, located inside electrical compartment on left side wall beside Start/Stop Pressure Switch —
provides current to HI Pressure Alarm Indicator (LT5) and Relay K13 when in alarm.

PS 3 —Adjustable Low Line Pressure Switch, located inside electrical compartment on left side wall beside Start/Stop Pressure Switch —
provides current to Low Pressure Alarm Indicator (LT4) and Relay K12 when in alarm.

T1/T2 —DRY-PAK® Timer “A” and “B”, located inside electrical compartment on left side wall — provides 25 seconds of current and 5
seconds of “dwell” (current interruption) alternately to SV1/SV2 and SV4/SV5 of the DRY-PAK®. L1 and L2 of T1/T2 are continually
energized when the Dehydrator is powered, providing the uninterrupted memory function which balances the work load on the desiccant
towers of the DRY-PAK®. (27/3 sec. for model 7200 60Hz only)

TD1/TD2 —Excess Run Time Delay “A” and “B”, located inside electrical compartment on left side wall — provides current to Excess Run
Relays K10/K16 after 10 minutes of continuous operation of Compressors “A” and “B”.

TD3 —Duplex Run Timer, located inside electrical compartment on right side wall below Relay Bracket — provides current to alternating
Relay (K6) after adjusted time delay causes Duplexing (both Compressors operating together) when unit in “Alt Mode”, also provides
current to Duplex Indicator and Remote Alarm Signal to
TB2.

SV1/SV2 —Normally closed Purge Solenoid Valve, located at base of Heatless Dryer, operating by T1-S1 and T1-S2.

SV3/SV6 —3 way Bypass Solenoid Valve, located outside the electrical compartment on Humidity Manifolds “A” and “B” (left and right
side walls) — when Humidity Alarm is clear, valve is energized allowing dry air to flow to storage tank. Vents wet air through port # 3 if in
Humidity Alarm.

SV4/SV5 —Normally closed Purge Solenoid Valve, located at base of DRY-PAK®, operating by T2-S1 and T2-S2.

SW1 —Main Power Disconnect Switch, located on front control panel — interrupts input power to air dryer on/off switch.

SW2 —Mode Selection Switch, located on front control panel — selection of “A” Mode, “B” Mode or Alternating Mode of Operation,
provides current to “Mode Relays”.

TB1 —Main Power Entrance Terminal Board, located inside electrical compartment on Bottom Back Shelf — wire termination for
incoming power cord.

TB2 —-Remote Alarm Terminal Board, located on rear back surface of Dehydrator — provides voltage free independent open or close
contracts for various alarm conditions.

21
 Figure 12
Compressor - Exploded View
TABLE VI - SPARE PARTS LIST FOR COMPRESSOR

Item Description Qty Part Number

1 Inlet Filter Assembly 2 0023601002
*3 Replacement Felt Element for Inlet Filter 2 0021990001
9 Pipe Plug 2 Reference
10 Safety Valve 1 0023630002
17 Manifold Elbow 2 Reference
18 Head Screw 8 Reference
19 Lock washer 12 Reference
20 Cylinder Head 2 Reference
*21 Head Gasket 2 Reference
*22 Valve, Outlet 2 Reference
*23 Valve Plate 2 Reference
*24 Valve, Inlet 2 Reference
*25 Cylinder Gasket 2 Reference
26 Cylinder 2 0023637001
27 Cylinder Screw 4 Reference
*28 Piston Ring 4 Reference
*29 Piston Seal 4 Reference
30 Piston Rod Assembly with eccentric 2 Reference
*31 Piston Rider Ring 2 Reference
38 Fan Blade 1 0023643003
39 Fan Shroud 1 0024398001
*40 Manifold Sleeve 2 Reference
41 Manifold Nut 2 Reference
42 Manifold Tube 1 Reference
*= Parts contained in Compressor Maintenance Kit P/N 0027406501

22
 Model 5000 / 7200 Compressor Dehydrator
Instruction Manual, IB-131 Rev.G Part Number 52649
GLOSSARY of TERMS

Altitude: The distance which the installation is above sea level expressed in feet, used interchangeably with
elevation.

Ambient: The environment surrounding the dehydrator. Ambient factors which can influence a dehydrator
include the temperature, the relative humidity, the atmospheric pressure and quantity of various pollutants which
are present.

Desiccant: The component within the dryer towers which is used alternately to retain, then to expel moisture from
the process air. Dielectric dryers employ desiccant which is totally inert, that is; it undergoes no chemical or physical
change in normal use.

Dew Point: Expressed in °F., the temperature at which dew or frost would form at 14.7 PSIA. The dew point of
a given air sample rises with increased pressure. In 1943 Dielectric established a dew point of -40°F as standard
for their compressor / dehydrators and for the pressurization of the communications equipment which is produced
at Dielectric. NOTE: -400 is the one point at which the Fahrenheit and Celsius scales are numerically equal.

DRY-PAK®: A patented dryer design and registered trade mark of Dielectric which describes the most simple
and efficient heatless air dryer. A Dry Pak consists of two desiccant towers, two maintenance free ball checks
and two direct acting solenoid valves controlled by a solid state timer. The main air flow is handled by the ball checks
without measurable pressure loss. Only the purge air flows through the two way solenoid valves, providing high
efficiency and long trouble free service.

Duplex: A mode of dryer operation where both dryer systems operate together. This mode of operation can only
occur when the dryer is operated in the automatic alternating mode.

Elevation: The distance which the installation is above sea level expressed in feet, used interchangeably with
altitude.

Line Pressure: The pressure of the low pressure outlet system, which is controlled by the adjustment of the Line
Pressure Regulator, is displayed on the Line Pressure Gauge, and is monitored by the adjustable Low and High
Pressure Alarm Switches.

PSIA/kPaa: Pounds per Square Inch / Absolute/Kilopascal Absolute. The measure of the pressure of a gas or
liquid, expressed in pounds per square inch, relative to a total vacuum. Standard atmosphere at sea level equals
14.7 PSIA (approx.).

PSIG/kPa: Pounds per Square Inch Gauge / Kilopascal. The measure of the pressure of a gas or liquid within
a component or system, to the degree it is greater than that of the surrounding atmosphere, expressed in pounds
per square inch. The internal pressure as shown on the gauges used on air dryers.

SCFD/SCMD: Standard Cubic Feet per Day/Standard Cubic Meters per Day. A rate of air flow measured in
cubic feet at 14.7 PSIA and 680 F. One SCFD when subjected to 10 PSIG (without temperature change) would
occupy a space equivalent to 0.6 cubic feet.

Segregated Alarm: An alarm circuit which provides separate terminations for each alarm function within the
dehydrator. Segregated alarms can provide to a remote location the information necessary for establishment of
maintenance priorities. Alarm terminations which either close in alarm or open in alarm, or dual function
terminations may be available, dependent on design parameters.

Std. conditions: Standard operating conditions imply a reasonably clean environment at 70°F.(21°C.) and sea
level. Ambient conditions impact dryer maintenance needs.

Summary Alarm: An alarm which does not identify an individual condition, but which can indicate an active state
of one or more alarm sensors within the dehydrator. Alarm terminations which either close in alarm or open in alarm,
or dual function terminations may be available, dependent on design parameters.

System Pressure: The pressure at which the compressors and the drying towers (desiccant towers) operate.
System Pressure determines the quantity of compressed air flow, the quantity of purge air and the moisture load
on the desiccant towers.
23
WARRANTY
The Manufacturer warrants that all goods supplied hereunder, whether or not of its own manufacture, will be of the kind described
herein or in any specification and drawing approved by the Manufacturer and free from defects in material or workmanship
under normal use and prescribed maintenance for a period of one (1) year, with the exception of air dryers utilizing water sealed
compressors as well as the compressors themselves which shall be for two (2) years. Neither this warranty nor any other, expressed
or implied, shall apply to goods delivered hereunder which have been damaged or subjected to alteration or negligence after
delivery. The Manufacturer’s only obligation for breach of this warranty shall be the repair, without charge, or the furnishing Ex Works
Raymond, Maine, of a similar part to replace any part which within one (1) year, with the exception as noted above, from date of
shipment is proven to have been defective, provided that (i) the Purchaser shall have notified the Manufacturer within ten (10) days
of the discovery of such defect and not later than ten (10) days after the last day of this warranty, and (ii) the Manufacturer shall have
the option of requiring the return of the defective material (transportation prepaid) to establish the claim. The Manufacturer shall not in
any event be liable for the Purchaser’s manufacturing costs, loss of profits, good will or any other special, consequential, incidental,
or other damages resulting from such defects. THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, WHICH
EXTEND BEYOND THE WARRANTY SET FORTH HEREIN.

Radiodetection (USA) 28 Tower Road, Raymond, Maine 04071, USA

Tel: +1 (207) 655 8525 Toll Free: +1 (877) 247 3797 Fax: +1 (207) 655 8535 [email protected] www.radiodetection.com
Radiodetection Ltd. (UK) Western Drive, Bristol BS14 0AF, UK
Tel: +44 (0) 117 976 7776 Fax: +44 (0) 117 976 7775 [email protected] www.radiodetection.com

© 2017 Radiodetection Ltd. All rights reserved. Radiodetection is a subsidiary of SPX Corporation. Dielectric is a trademark of Radiodetection in the United States and/or other countries.
Due to a policy of continued development, we reserve the right to alter or amend any published specification without notice. This document may not be copied, reproduced, transmitted,
modified or used, in whole or in part, without the prior written consent of Radiodetection Ltd.