ODPMT200 SERIES DryLine® DEHYDRATOR USER MANUAL
Contents
1. Andrew Solutions ODPMT200 SERIES DryLine DEHYDRATOR USER MANUAL Bulletin 01 0467 001 Rev E 2007 2013 CommScope Inc All rights reserved 01 13 ODPMT200 Series DryLine Dehydrator User Manual lO TABLE OF CONTENTS Section 1 General Information 1 1 INthOdUCHION as us Aad ete P awi __ 1 2 Description uc a W e cR sa ad ce 1 3 OperatlOni salik S la AM AW aoe 1 4 Triple Alarm Option Figure 1 Alarm Label SE Figure 2 Changing Alarm OU PU S gt si eee e ee en eene 1 5 Specifications LT Section 2 Installation 2 dise cse set aru awa fas naa via prp al mus Bebes ken 2 1 Inspection 2 2 Controls and Displays 2 3 Installing the Dehydrator DAN wis ints ME M 2 3 1 Slab Mounting lt kla aa lle xelk al a dk ton ohm 24 222 2 4 Power Connections k a ak W n 2 4 1 AC Power 2 5 Connecting the Low Pressure Alarm Output A 2 7 Connecting Dehydrator to the Transmission Line TII 2 8 Purging the Transmission Section 3 Main2. Com Grey 8 Low Press Alarm Orange Alarm Definitions Low Pressure If system pressure falls significantly below the low pressure trigger point the low pressure alarm sensor will activate an alarm contact This alarm is an indication of a significant system leak or a dehydrator failure Excess Run User settable run time to be set in accordance with the normal run time for the particular application Selectable times are 10 30 120 and 240 minutes See Figure 2 for location of JP3 Power Fail Activates when power is removed from the dehydrator This includes turning the power off at the switch High Humidity Activates when system or dehydrator output humidity rise above 7 5 relative humidity At initial installation this alarm will continue to alarm until the system has been properly purged ODPMT200 Series DryLine Dehydrator User Manual Alarm Reset Low Pressure Mains Power Excess Run High Humidity Figure 2 Changing Alarm Outputs Where To Factory setting Normally Closed N C Normally Open Alarm PCB Normally Open N O PCB Normally Open Alarm switch center term N O bottom term N C Power Fail Jumper JP6 on Jumper JP5 on Run Alarm Jumper JP4 on Alarm PCB 1 5 Specifications Output Pressure Constant Output capacity Output Dew Point Operating Temperature Range Low Pressure Alarm Electrical Input Output Connector
3. Dimensions 5 0 psig 12 0 SCFH 80liters h total approx 0 2 SCFH 1 5 liters m 49 F 45 or better 30 to 130 F 34 to 54 C 1 0 Ib in2 6 9 kPa 115 Vac 50 60 Hz 3 8 polytube compression 18 5 W x 32 0 H x 10 0 D Optional Alarms High Humidity Alarm Set Point Excess Run Alarm Set Point Power Fail Alarm 7 5 RH factory set 10 minutes factory set loss of input power ODPMT200 Series DryLine Dehydrator User Manual Section 2 Installation 2 1 Inspection Open carton Remove the top piece of corrugated packing Carefully remove the installation accessories and manual and dehydrator Check the dehydrator for shipping damage such as dents or loose parts 2 2 Controls and Displays Familiarize yourself with the controls and displays prior to installing or testing the dehydrator mmm comes from connects to the filter bowls Dehydrator Controls Displays Pressure Gauge indicates dehydrator output pressure in psig and kPa ON OFF Switch controls compressor and sensors Light indicates power switch is ON Circuit Breaker white tab indicates a circuit overload Push to reset ODPMT200 Series DryLine Dehydrator User Manual 2 3 2 3 1 2 4 2 4 1 0 0 0 0 548 HOURS 1 10 Un Time Meter provides a visual indication of the number of hours of compressor operation and provi
4. air outputs are provided with individual shut off valves on the front of the unit Make sure that the valve is open position for each transmission line connection If one of the outputs connection is not used close the valve and leave the port capped Note If the transmission lines have not been purged continue with section 2 8 Otherwise proceed to Section 3 Purging the Transmission Line Air in the transmission line system must be replaced with dry air to ensure satisfactory opera tion of the transmitted signal 1 Determine the total system volume 2 Divide the system volume by the flow rate of the dehydrator 12 CFH to determine the number of hours needed for the purge cycle 3 Open the far end of the transmission line 4 Operate the dehydrator for one purge cycle If it is not possible to open the far end of the transmission line 1 Connect the dehydrator to the trans mission line and pressurize the system 2 Wait 45 minutes while the air absorbs moisture in the system then disconnect the dehydrator from the transmission line and allow the air to vent 3 Repeat steps 1 and 2 three times to purge the system ODPMT200 Series DryLine Dehydrator User Manual Section 3 Maintenance 3 1 3 2 3 3 3 4 Maintenance The ODPMT200 Dehydrator requires relatively little maintenance to ensure satisfactory operation over long periods of time This section outlines the recommended annual pre
5. fax communication is received the CommScope staff will work with you to pinpoint the possible cause of trouble If the pressurization equipment is suspect they will e ask for your unit Model Number and Serial Number check the warranty status of the unit advise the availability of a loaner unit provide an estimate of the cost for inspection and repairs if the unit is out of warranty Return Material Authorization Sheet to you Repair Center Process A method of Payment must be provided prior to issuing of RMA regardless of warranty status IN WARRANTY REPAIR Most CommScope pressurization products carry a warranty of one to three years depending upon model number Warranty details are available on our web page If your unit falls within its warranty period inspection and repairs will be performed at no charge and the unit will be promptly returned to you If a warranty unit is deemed no problem found an inspection fee and freight will be charged to the customer OUT OF WARRANTY REPAIR We will inform you with the cost of repair and obtain your approval to proceed with repairs or if you elect not to have the unit repaired your instructions on disposition of your unit When repairs are 6 5 complete we will return your unit and invoice you for the inspection charge materials used for the repair and labor applied to complete the repair If you elected not to repair the unit we will invoice you for the
6. inspection and freight charge if unit is to be returned LOANER UNITS Loaner units are available from the repair center to maintain your system while repairs are being performed If you feel you need a loaner please contact us at at one of the numbers listed under contact numbers A for the full value of the unit must be issued prior to shipment Also contact us when the loaner is ready to be returned so that we 17 can issue a NEW RMA number to identify your return and create the appropriate credit to your account Damages to loaner will be deducted from the PACKING INSTRUCTIONS Pack your unit securely for shipment to the Repair Center If you received a loaner unit we suggest you use the box and packing materials to return your unit Otherwise we have factory packing materials available for a nominal fee Enclose a completed copy of this form inside the box and clearly mark your Company Name and RMA XXXXXXX on outside of the box Address the box to the following Ship To Address CommScope PRESSURIZATION SERVICE CENTER RMA XXXXXXX 11312 5 PIPELINE RD EULESS TX 76040 6629 Please note Units received with Biological animal contamination will be returned unrepaired or scraped after notification and you will be invoiced for inspection and freight CONTACT NUMBERS If you have any questions about the repair process or status of your unit please contact us directly through one of the following method
7. the run time meter Check the run time meter on the front panel to determine the duty cycle of the dehydrator 0 0 O 960 08 HOURS 1 10 If the dehydrator has been running for more than 10 15 of its installed time check the system for leaks Also check the time on the meter to determine if it is time to perform the 6000 hour overhaul Parts Replacement and Dehydrator Overhaul CommScope ODPMT200 Dehydrators are designed to give may years of trouble free service and require very minimal maintenance The dehydrator contains as a standard feature a run time meter that records compressor run hours To ensure continuous and reliable operation the dehydrator must be overhauled ODPMT200 Series DryLine Dehydrator User Manual every 6000 hours of compressor operation The kit listed below contains all of the necessary parts to perform this overhaul Maintenance Parts 1 Dehydrator Overhaul Kit 1 ea AE01K C0398 015 2 Compressor Air Intake Filter bag of 6 EFLTR 91101 Tools The following tools are used in the maintenance and overhaul procedures ballpoint adjustable wrench socket wrench with 7 16 inch or 11mm socket No 2 Phillips screwdriver a small flat blade screwdriver Overhaul Procedure When the ODPMT200 compressor run time reaches 6000 hours or a multiple of 6000 hours it is time to replace certain items in the comp
8. Line dehydrators while similar in moisture removal technology operates differently than the rest of the DryLine series of dehydrators In order to provide a constant supply of dry air to small air volume systems and to maintain an acceptable moisture level in the product air stream a high pressure reservoir tank is needed This reservoir tank is connected to a pressure regulator and orifice to yield a fixed output pressure of 5 0 psig and a nominal flow rate of 0 2 CFM In addition to supplying the output air the reservoir tank also provides the dry air for the feedback loop The feedback loop is necessary to maintain the dryness of the membrane cartridge During normal operation the bleed air in the feedback loop will cause the pressure to drop in the internal reservoir tank and the ODPMT200 compressor will cycle automatically These cycles will take place regardless of the system volume or condition of the transmission line the dehydrator is connected to The rate of these cycles however will vary During the purge cycle the dehydrator will cycle approximately every 2 to 4 minutes while showing 0 psig on the pressure gauge and providing a constant 0 2 SCFM of dry air When connected to a very tight system or the output is capped the dehydrator will cycle approximately every 60 to 90 minutes and maintain 5 0 psig system pressure while providing close to 0 CFM of dry air A system that leaks will have a cycle time some
9. des validation for the 3000 hour warranty Installing the Dehydrator Slab Mounting See the back of this manual page 21 for a drawing showing hole placement and overall size of the unit Power Connections Confirm your dehydrator electrical input matches the available power Ensure an electrical safety ground is installed on the ground stud located adjacent to the power input connector It is intended to be customer installed in the field to your halo grounding system 115 Vac ODPMT200 89015 ODPMT200 89315 AC Power AC units can be connected into a standard 15 amp power receptacle of the proper voltage Make sure the power circuit is properly grounded Verify the power switch is OFF Feed the power cable not supplied through the liquid tite fitting on bottom of unit Connect power cable to input terminal strip on unit Use a small flat blade screwdriver to tighten connections on the terminal strip After power connections are completed tie wrap power cable in place and tighten the liquid tite fitting around power cable See schematic on page 21 for input connections Proper electrical connection is required It is suggested a licensed electrician be contracted to connect the AC wiring to the unit if it is connected directly to the mains Failure to properly connect the power wires could result in a dangerous electrical shock hazard Test the Dehydrator Turn the dehydrator ON and check the output por
10. eck input power polarity and voltage per wiring diagram Check wiring connections per wiring diagram If breaker trips Circuit breaker tripped again replaces the breaker If the replacement breaker trips contact CommScope Customer Service See section 6 Assure that the drain line tubing exiting the bottom of the unit is not clogged When the compressor cycles off air and moisture should run out of the drain line See Figure 6 Pneumatic Diagram Filter bowls show excessive water 13 ODPMT200 Series DryLine Dehydrator User Manual ODPMT200 Series DryLine Dehydrator User Manual 5 p anbi4 WET 38156534 MADI JONWHO Pen 130055399 MOT 5532 3 BB N33HO H z Hiva uJ340d ano 14 LICHIATTTH 15 Cav n E Ima IHM NANOUS 34 ODPMT200 Series DryLine Dehydrator User Manual Section 5 Section 6 Replacement Parts Customer Service The following is a list of the replacement parts for the 6 1 Introduction ODPMT200 series dehydrators CommScope provides in warranty and out Description of warranty repairs as well as dehydrator and compressor overhauls from several Repair For units before Rev J mantain existing filters Centers Coordination of these services is Inlet Filter EFLTR 20201 provided through the nearest Sales Office or ODPMT200 8XXXX AE01J A0731 001 Customer Service Center The Center i
11. er element make sure the element is seated completely in the housing and then replace the cover If anew element is used discard the old element 3 8 Service Restoration RECOMMENDATION If the dehydrator overhaul process has taken more than a few hours it is recommended that the unit be run for one hour into the room to purge the membrane dryer and tank of any acquired moisture before reconnecting to the transmission line system Reverse the steps followed initially to remount the dehydrator To reconnect the dry air lines to reconnect the power and alarm cabling to turn the unit back on and finally to open the valves to the waveguide system so that the dehydrator is again providing dry air under pressure to the transmission line system 12 ODPMT200 Series DryLine Dehydrator User Manual Section 4 Troubleshooting If you experience difficulty with your dehydrator use the troubleshooting procedures described below Caution Electrical troubleshooting requires access to potentially dangerous voltages and should only be performed by a licensed electrician Problem Condition ___ Solution Check the breaker adjacent to the on off switch If the breaker is tripped white indicator exposed then the If the ON OFF switch light still falls to light make sure the unit Dehydrator on off switch does not light unit does 15 plugged in and power outlet is operating not run If you still have no li
12. ght unplug the unit remove the unit cover and check for loose connections Refer to the wiring diagram for proper connections See Figure 3 Summary Alarm Figure 4 Discrete Alarm Wire Diagrams Disconnect power remove cover check for loose connections per the wiring diagram Replace cover and reconnect input power If condition persists replace ON OFF switch Pressurize lines with the dehydrator turn shut off valve to the off position and observe pressure gauge The pressure gauge should read approximately 5 0 psig and the alarm should clear If alarm does not clear remove cover and verify wiring to low pressure alarm switch Dehydrator on off switch does not light unit runs If the pressure does not stay constant after shutting off the valve apply leak detector to isolate the leak in the dehydrator exercise care when applying solution not to wet wiring or electronics See Figure 6 Pneumatic Diagram Low pressure alarm activated With dehydrator isolated from transmission line observe pressure in transmission line If pressure drops use a leak detector solution to locate leaks in the transmission line Repair leaks if possible See section 6 If the problem persists contact CommScope Customer Service Check the breaker adjacent to the on off switch If the breaker is tripped white indicator exposed then reset the breaker Compressor does not Check power switch to make sure that it is on and lighted Ch
13. ormation 1 1 1 2 Introduction This manual contains the information you need to install operate and maintain your ODPMT200 Series DryLine dehydrator Please take the time to read this manual before attempting to operate or service the unit 1 3 ert Description ODPMT200 Series dehydrators provide dry air for pressurizing small up to 40 cubic feet or 560 liters in volume antenna and transmission line systems The dehydrators produce 499 459 dewpoint dry air at an output rate of 0 2 cubic feet 1 4 liters per minute Each dehydrator consists of an electrically driven air compressor a membrane dryer assembly an automatic transmission line pressure sensing system and a low pressure alarm output housed in a rigid metal chassis They are designed to mount to a slab floor Optional brackets are available for pole mounting capability Their front panels feature a pressure gauge an indicating on off switch a resettable circuit breaker and a run time meter For easy serviceability power connections alarm output connections and all filter elements are accessible from the front of the unit The ODPMT200 maintains transmission line pressures at 5 0 Ib in2 34 kPa It is intended for standard microwave antenna applications and any other transmission line pressurization requirement that supports a relatively high pressure limit Operation ODPMT200 Theory of operation ODPMT200 series of Dry
14. ressor and the air path of the dehydrator These include the piston cups piston seals and head gaskets of the compressor the filter elements in the water and coalescing filters and the tube section connecting the compressor output to the water filter input Unit Shutdown and Removal In order to perform an overhaul on the ODPMT200 the unit must be turned off and removed from service As this is being done the low pressure alarm may activate through a reporting alarm system Personnel monitoring such an alarm should be notified in advance So that they are aware of the fact that service is being performed It is also necessary to disconnect the dehydrator dry air output from the waveguide system during the overhaul 11 3 7 Dehydrator Filter Element Replacement Clean replace the air intake filter The air intake filter protects the compressor from contamination and dust Periodic cleaning replacement extends the life of the compressor The filter is made of open cell foam material It should be cleaned or replaced once a year or more frequently if the operating environment is very dusty Pull off the filter cover and remove the foam element The cover is held in place by two tabs Use a small screwdriver or a ballpoint pen to release them Wash the filter in running water squeezing it between the fingers ODPMT200 Series DryLine Dehydrator User Manual Do not apply oil or other chemicals to the filt
15. s In Case Of Difficulty If the dehydrator is not operating refer to the sections on installing and troubleshooting the unit 3 5 ODPMT200 Series DryLine Dehydrator User Manual Annual Maintenance Inspection includes checking for loose or damaged hoses fittings and electrical connections Open the front door and verify that there is no water build up in the two filter bowls located inside the front cover of the dehydrator There may be some droplets of water vapor in the filter bowls the lower portion of each bowl but there should be only a small amount of liquid in either bowl If there is excessive water refer to the troubleshooting section Replacement of the filter elements in the water filter and coalescing filter is covered in the overhaul section of this manual Check the electrical connections Check the screw in power input terminals to ensure that the AC power cord is securely terminated Check the screw in alarm terminals to ensure that all wire connections are tight 10 3 6 A loose or damaged connection may result in erratic operation and unnecessary downtime Refer to the troubleshooting section if an electrical problem is encountered Check the ground wire Check that an electrical safety ground is installed on the stud inside the front cover of the dehydrator This connection point is adjacent the power input connector It is intended to be customer installed in the field Check
16. s Telephone below TEL 817 864 4150 817 864 4155 FAX 817 864 4179 RoHS Inquiries For inquiries on RoHS please contact the following CommScope Inc Corke Abbey Bray Co Dublin Ireland Attn Legal Department ODPMT200 Series DryLine Dehydrator User Manual This page was left blank 18 ODPMT200 Series DryLine Dehydrator User Manual 5 ui u e ed ejoH 4 0581 0071 SCC 6ununoy Jo woog 00 8 005 Xv 19 ODPMT200 Series DryLine Dehydrator User Manual This page was left blank 20
17. s also Filter Bowl only AE01J A1978 101 prepared to help you with the following Water Filter Element AE01J A1978 203 0 01 micron Coalescent Element AE01J A1978 201 e Technical Assistance e Troubleshooting Overhual or Upgrade Repairs e Loaner Units For units before Rev J to bring them up to Rev J Upgrade Kit AE01K A0873 001 Spare Parts Installation Materials For units Rev J and above System Accessories Overhual Kit PMT200B KIT OVRHL Solenoid Kit PMT200B KIT SOLND 6 2 In Case of Trouble Filter Element Kit PMT200B KIT ELMNT Compressor AE01J A2022 001 The first step you should take if trouble develops using a dehydrator is to read the operators manual and follow the trouble isolating procedures given in it If the steps in the manual do not identify and remedy the problem then contact an CommScope Customer Service Center for 24 hour telephone assistance Record the Model Number e g ODPMT200 and Serial Number from the product label as you will be asked for these when you call Two main locations are currently available to help From North America Telephone 1 800 255 1479 Fax U S A 1 800 349 5444 International Telephone 1 779 435 6500 Fax Number 1 779 435 8579 Web Access Internet www commscope com email prc commscope com 16 6 3 6 4 ODPMT200 Series DryLine Dehydrator User Manual ee LL Initial Steps by CommScope When your call or
18. t inside the front cover to make sure air is flowing TT j k X 2 5 Connecting the Low Pressure Alarm Output To connect the low pressure alarm open the unit and locate the terminal block TB 1 HAW B 2 7 ODPMT200 Series DryLine Dehydrator User Manual Route the wires from the alarm control through the liquid tite fitting at bottom of unit into the chassis and up to the terminal block Tighten the screws on the terminal block tie wrap the alarm cable and tighten the liquid tite fitting When a low pressure alarm condition exists dry contacts are activated at terminal block TB 1 An alarm condition exists when pressure falls 2 8 below 1 0 Ib in2 6 9 kPa for all ODPMT200 models The relay contacts are rated at 2 A non inductive 30 Vdc Optional alarms if purchased will also be located on this terminal block The alarm connection label located inside of the front cover will provide terminal numbers for each additional alarm Connecting Dehydrator to the Transmission Line Check the antenna and transmission line system pressure rating before connecting the dehydrator to the system Insert one end of the 3 8 polytube feed line tubing into the compression fitting on the dehydrator inside wall or one of the similar fittings Tighten securely with a 9 16 wrench Be careful not to over tighten Connect the other end of the polytube to the transmission line Two
19. tenance 3 1 Maintenance 252555 E EY ee E deed E aede 3 2 Regular 4 4 3 3 Preventive Maintenance 3 4 6000 Hour Overhaul ina diana Mar dik BSS 3 5 Annual Maintenance 2 3 6 Replacement and Dehydrator Overhaul E AE AAN dm 3 7 Dehydrator Filter Element Replacement 71 3 8 Service Restoration 12 O WONNNNNDAD 0 69 Section 4 Troubleshooting oe Figure 3 F Jam Peed apa b m Figure 4 Alarm s xu a aa dba ER waa davoga dae TO Section 5 Replacement Parts 16 Section 6 Customer Service 16 6 1 Introduction s ics l xev TO 6 2 In Case of Trouble 16 6 3 Initial Steps by CommScope 17 6 4 Repair Center Process 17 6 5 RoHS Inquiries aoe ss Figure 5 Hole pattern for locateing J bolts i in cement slab Laat ite Menu ODPMT200 Series DryLine Dehydrator User Manual Section 1 General Inf
20. ventive maintenance for the unit and the suggested overhaul for every 6000 hours of compressor operation Regular Maintenance The ODPMT200 Dehydrator will perform at an optimum if it is routinely checked for correct performance This checking generally consists of an annual inspection of the condition of the air intake filter and an overhaul after every 6000 hours of compressor operation Performance of these measures is sufficient to ensure continued reliable operation Preventive Maintenance The annual maintenance of an ODPMT200 consists of a preventative maintenance inspection of the dehydrator and cleaning or replacement of the foam air intake filter These tasks can easily be performed in the field with the unit connected to the transmission line system and with only the front access door opened for maintenance 6000 Hour Overhaul A run time meter is provided on the front of the ODPMT200 to indicate the actual number of hours the compressor inside the dehydrator has run ENM 055090140 HOURS 1 10 The dehydrator overhaul kit includes parts to overhaul the compressor and critical components in the dehydrator that often become worn over time C 3 These include replacement water filter elements with new o rings and a length of white nylon tubing A compressor overhaul kit is also part of the dehydrator overhaul kit This kit contains a new cylinder and piston along with new gaskets and head screw
21. where in between depending on the severity of the leaks 1 4 ODPMT200 Series DryLine Dehydrator User Manual The pressure gauge will also reflect a pressure between 0 and 5 0 psig while the output flow is between 0 2 and 0 SCFM The pressure gauge senses pressure beyond the flow control orifice and will show the actual pressure in the waveguide During the initial pressurization of the transmission line the dehydrator will cycle every 2 to 4 minutes with the system at 0 psig pressure As the dehydrator pressurizes the system the cycle times will increase until the dehydrator output is balanced with the system leak at which point the cycle times will stabilize Triple Alarm Option This optional assembly is designed to provide the additional Excess Run High Humidity and Power Fail alarms to CommScope Dehydrators All alarms are Form C dry contacts and are factory set for continuity at alarm The external alarm monitoring system not included is connected to the terminal strip located behind the cover Asmall slotted screwdriver is necessary to make the connections The connection to the alarm strip is as follows and refer to Figure 1 for correct locations and colors of the wires on the terminal strip Figure 1 Alarm Label Term Function Wire Color 1 Power Fail Com Black 2 Power Fail Alarm Red 3 Humidity Com Green 4 Humidity Alarm Brown 5 Excess Run Com Blue 6 Excess Run Alarm White 7 Low Press
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