XC100 Series Monitor & XT300 Series Dehydrator User Manual
Contents
1. H3MOd SNIVW ls H2DV3H8 HOLMS z EC s ANE S IVNIWH3 L WV V ZAWOD 105 6d 8d dd 9d a ig TC MOVIE 0L 0L 88 vd 28 SISSVHO exi N n MOTISA 55 8 8 4 n gau ama 9 9 n ovis 8 8 2 5 AVHO v Vv n NYL i D Nid LUES MOTA 2 z Ln N3349 2 101 qaq a migz Tal as gee H3TIOH1NOO HOSS32OHdOHOIIN 3i 100 8661 V PL03V 5 28 ld zin mua aviasia ov HOSN3S zavo 318vo ALIGININH 2 Ua zd 7 QVdA39 101 8661 103 0081X 941614 aissvuo NVA 9 L4 L T8 LHM T8 LHM NYS I ANY L SAYNDIA AAS YOLOANNOO 138 I ts NI iT C S mmm aye 91 we gt HOLIMS 44O NO N Y N NYO 0 L qaq S2. clamps high and low temp hose 4 ECLMP 20090 9 Water Filter complete assembly 1 EFLTA 52100 ater Filter Element EFLTA 91010 oalescing Filter Element oalescing Filter complete assembly oly tubing 1 4 OD water drain All units 0 85 56 25436 4 13100 EFLTA 12203 vaporator Pan Tube Fitting ooling Fan 115V op Off Valve 16 PSI able Tie for membrane our Meter 115V vaporator Pan Spring A olm AE01J A0933 010 Ul ESPRE 35564 EFTGS 30223 I my AE01J A0933 001 I U gt oye poy N I Ay oy 1 4 4 1 4 1 4 1 m 29 8 1 8 2 8 3 8 4 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Parts Replacement Procedures 8 5 WARNING Disconnect electrical power from the unit before removing the doors and replacing Failure to comply may result in INJ URY or DEATH When the monitor run time reaches 3000 hours it will be necessary to rebuild the compressor and replace the hoses clamps water and coalescent filter elements The necessary parts and instructions are included in the over haul 8 6 kit listed in Section 8 0 Following are procedures for replacement of the parts listed in Section 8 Unit Shutdown and Removal In order to perform parts replacement on the XT DryLine Monitors it will be necessary to turn off the unit and remove them from service As this is don
3. Air INPUT from Dehydrator 5VDC Remote Cable XT300 Power Cord Figure 3 Transmission Line Connections 6 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL eT XC100 Series System configuration diagram Basic This configuration shows proper hook up for systems when only a single waveguide is required in the system Isolation Shut off Valves Dehydrator output line XT Dehydrator 5VDC Control Signal from XC100 XC100 Line Monitor Montor output line Primary Large Wave Guide Figure 4 XC100 Series System configuration diagram CAUTION Do not operate the Monitor with the system isolation valves closed or with the remote sensing line disconnected Serious damage to the wave guide due to overpressure can occur NOTE To provide extra overpressure protection a secondary popoff valve may be added at this point that is closely matched to the maximum system safe pressure See specification page for options available XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL 2 7 Connect Alarm Wiring Locate the terminal strip on the back of the line monitor and connect the alarm wiring to terminals shown in If Normally Closed contacts are desired move the figure 6 jumper on the PC boards to the N C position Jumper on positions A B for normanlly open position B C for normanlly closed All alarms are dry contacts and can be ganged together if
4. 2 14 318VO TWNDIS SISSVHO o XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL NIVHG XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL I I I I GREEN GND I I BLUE RED LINE BLACK ORANGE I I I I BRN i I MOTOR START CAP I I WHITE XXX1X ONLY Figure 12 XT300 Compressor Schematic for 115 VAC I I I I m GREEN ORANGE RED i BLUE BLACK i COMP I I I I BRN BRN MOTOR I I RET ONE START CAP o XXX2X ONLY Figure 13 XT300 Compressor Schematic for 230 VAC 24 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Section 6 Maintenance 6 0 6 1 6 2 6 3 The dehydrator requires maintenance semiannually and or after each 3000 hours of operation to ensure continued reliable operation WARNINGS Service personnel should observe all safety regulations Do not perform maintenance on equipment without first turning OFF the main power supply Under certain conditions dangerous potentials may exist when the main power supply controls are in the off position Only qualified technicians should attempt to effect maintenance or repairs on electrical equipment Semi Annual Maintenance The semi annual maintenance consists of a preventive maintenance inspection and replacement of the compressor air filter These ta
5. compressor assembly should now be free of all tubing connections 8 7 3 8 8 8 9 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Compressor Remount and Reassembly Remove the bolts 6 XT4500 4 XT1000 amp XT2000 which secure the compressor to the back mounting plate Carefully remove the compressor assembly from the chassis Mount the compressor assembly to the back mounting plate using the existing hardware Do not overtighten the mounting screws 8 10 Reconnect the hoses clamps as supplied with the compressor replacement kit and wiring Replace Heat Exchanger The heat exchanger is located at right side of the unit under the side panel Under normal conditions the heat exchanger should not need to be replaced Replace it if the monitor has been dropped or otherwise damaged such that the heat exchanger is leaking air Replace Waiter Filter Element 3000 hour Maintenance Replace the water filter after each 3000 hours of operation When ambient room air is compressed in the monitor compressor liquid water is formed This liquid water must be removed in order to allow the membrane dryer to function at its peak efficiency As the air exits the compressor it is cooled in the heat exchanger and then enters into the water filter The air swirls around the inside of the filter bowl separating the liquid water out on the sides of the filter bowl A 5 micron filter is also provided in the wat
6. 41 C to 40 230Vac 50 60Hz 0 03 Amps Standby Input Power Power True Watts 390 8 Amps Starting 115Vac 4 Amps Starting 230Vac Output Air Connector 3 8 poly tube compression fitting nput Air Connector 3 8 poly tube compression fitting height 12 22 in 310 mm Dimensions wid 16 84 in 428 mm depth 10 25 in 260 mm Weight net nominal 46 Pounds Over pressure limit internal 16 psi Pop off Valve Table 10 Optional items System popoff valve 1 8 NPT 1 PSI AE01J 01 74 009 System popoff valve 1 8 NPT 2 PSI AE01J 0174 001 System popoff valve 1 8 NPT 3 PSI AE01J 01 74 0011 Street Tee 1 8 NPT 3022 33 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL LSE ay 10 1 24 Hour Technical Service Hotline Andrew maintains a Technical Service Hotline for assistance with product repairs and service Andrew Corporation 10500 West 153rd Street Orland Park IL U S A 60462 www andrew com Telephone 708 349 3300 FAX U S A 1 800 349 5444 Customer Service 24 hours North America 1 800 255 1479 U K 0800 250055 Europe Africa amp Middle East 44 1592 782 612 10 2 Free Loaner Program Andrew maintains a repair center for pressurization equipment Free loaner units are available for use while your equipment is being repaired by Andrew Call our Technical Service Hotline for details 34 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Notes 35 XC100 S
7. blank corrected contact Andrew Technical Service for assistance NOTE This problem can be caused by a lightning induced power surge The monitor is equipped with surge protectors which may cause the fuse to blow when a surge is encountered Dehydrator starts and stops before reaching Check compressor ON and compressor off settings on line monitor sufficient line pressure Check for kinks in line tubing Replace tubing where necessary 26 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL High Pressure alarm on display Excess run time alarm on display Verify the compressor turn OFF and high pressure alarm settings as shown in Sections 4 2 2 The High Presssure Alarm set point must be above the the compressor OFF set point The High Pressure Alarm can be triggered by ambient temperature rises If this is a reoccurring problem the set points should be adjusted to increase the differential between compressor OFF and High Pressure Alarm values Contact Andrew Technical Service for further assistance Check the programming of the excess run time display as shown in section 4 2 2 The set point should be at least 5096 above the normal run time The unit is cycling ON and off at less than a 30 minute interval See troubleshooting section Dehydrator starts and stops before reaching sufficient line pressure Check system for leaks See troubleshooting section Low pressure alarm on display 27 XC100 SERI
8. port at the top or back of the unit to make sure that air is flowing out If problems exist review troubleshooting procedures in Section 7 or consult Andrew Technical Service If these items check out turn power switch OFF unplug the unit For the Redundant Hot Standby configuration there is a control line from the master unit which connects to the input line on the slave unit XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL 2 4 Place the Monitor and Dehydrator The DryLine XC100 Series monitor and XT300 dehydrator are designed to be rack mounted or shelf mounted 2 5 Install Polyethylene Tubing Lines Monitor input line marked INPUT from the dehydrator Monitor output line marked OUTPUT to the distribution panel and transmission lines Configuration diagrams are shown on pages 7 10 of this manual 2 6 Connection Procedure Connect the Transmission Line Tubing Insert the tubing run from the transmission lines or distribution into the fitting in the back panel of the monitor marked OUTPUT Install the isolation shutoff valves The valves when used on output lines allow the system to retain pressure while the system is removed for servicing Place each valve in line between each output and transmission line For Redundant Hot Standby use the Tee fitting optional to connect the output lines together from the master and slave units OUTPUT Waveguide XC100 Power Cord
9. rims hour oF HH ENTER or Y Scroll N Ahead SELECT I Y Figure 9 Program Mode Submenu 18 To Record Change To Record Change To Record Change To Record Change To Record Change To Record Change XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Y 1 J To Set k ENTER Record Change Scroll Ahead mE cT To Comp Runs Alarm XXX Minutes En Change Scroll Ahead SELECT To Conse ON 29 Record XX X PSI kPa eom Change or Y Scroll Ahead SELECT j Low Pressure Alarm NS d XX X PSI kPa Change or Y Scroll N Ahead SELECT Y High Pressure Alarm XX X PSI kPa Change or Y Scroll N Ahead SELECT j Y To Backup Comp ON Press Record XX X PSI kPa Change or Y Scroll 4 Y Ahead SELECT Y Comp Overhaul Time 5 d XXXX HRS Change or Y Scroll Ahead SELECT Y or Key jn ENTER Record Change or Y Scroll Ahead SELECT Y or 5 Enter New Password ENTER Record j Change Y or SELECT Figure 10 Figure 9 Program Mode Submenu Continued 19 4 3 4 3 1 4 3 2 4 3 3 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Pressure Monitoring and Control 4 4 Monitor Duty Cycles The monitor is programmed at the factory to start when the output pressu
10. shown in the flow chart will apply The modes pertaining to high pressure high humidity fixed at 7 596 R H and excess run time as well as multi channel manifold capability are options Press the key and proceed from system pressure to PROGRAM MODE Press the key and proceed to the Program Mode Submenu COMP ON 0 5 will now appear on the display At this point the display will be as follows prompting the user for a new password password 0 1 2 3 4 5 6 7 8 9 the default password is 111111 The following are used for password entry Select 0 1 W 2 3 Down Arrow 4 5 Enter 6 7 View Log 8 9 The following sections describe the various programmable functions and the associated sub functions in detail Compressor Count This valve is set to 1 for a single compressor up to 4 when used with multiple compressors in the Redundant Hot Standby mode Values 1 4 High Pressure Tank Set this valve to NO unless the high pressure tank option was purchased Values Y 10 11 12 13 14 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL SET DATE month 2 digits for month of the year values 01 12 SET DATE day 2 digits for day of the month values 01 31 SET DATE year 2 digits for year values 00 99 SET TIME hour 2 digits for hour of the day values 00 23 SET TIME minutes 2 digits for minutes of
11. ERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL pr ANDREW Andrew Corporation Dehydrator and Line Monitor System Three Year Warranty Seller warrants that any Andrew MT050 MT XT 300 600 or 1700 MR050 5050 PMT200 ODPMT200 series number Dehyarator and any Line Monitor System is transferred rightfully and with good title that it is free from any lawful security interest or other lien or encumbrance unknown to Buyer and that for a period of thirty six 36 months from the date of shipment or 3000 hours of actual run time whichever shall occur first such equipment will be free from defects in material and workmanship which arise under proper and normal use and service Buyer s exclusive remedy hereunder is limited to Seller s correction either at its plant or at such other place as may be agreed upon between Seller and Buyer of any such defects by repair or replacement with either a new unit or a factory reconditioned unit at no cost to the Buyer provided that the cost of any transportation in connection with the return of the equipment for the purpose of repair or replacement shall be borne by Buyer The provisions of this warranty shall be applicable with respect to any equipment which Seller repairs or replaces pursuant to it SELLER MAKES NO WARRANTY EXPHESS OH IMPLIED OTHER THAN AS SPECIFICALLY STATED ABOVE EXPRESSLY EXCLUDED ARE ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PURPOSE THE FOREGOING SHALL C
12. ES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Section 8 NOTICE iat provide continuous reliable operation the Pans dehydrator must be overhauled every 3000 Andrew dehydrators have been designed to hours of compressor operation The provide many years of trouble free service and monitor overhaul kit listed below contains will require minimal maintenance The display all necessary parts Alternatively you may panel on the monitor contains as one of the send your dehydrator to Andrew for standard features a reading of actual overhaul compressor run hours Table 5 Three Year Recommended Dehydrator Spare Parts Part Number Item Air Intake Filters EFLTR 91101 Compressor Air Intake Filters complete assembly housing w filter Dehydrator Overhaul Kit Includes compressor overhaul 1 _ kit high temperature hose clamps XT300 Table 6 XC100 Line Monitor Spare Parts Item Part Number Power Switch 1159 Power Swich 230V 3 cireuit Breaker 5 amp Microprocessor Controller PBC 115V Microprocessor Controller PBC 230V 6 Display PBC s Humidity Sensor Cable 45015227506 9 Monitor Dehydrator Signal Cable 28 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL ower Switch 1157 lt i e Fion Temperature Hose compressor to heat exchange ss 51517501 BEREE 8
13. ONSTITUTE ALL OF SELLER S LIABILITY EXCEPT AS TO PATENT INFRINGEMENT WITH RESPECT TO THE EQUIPMENT IN NO EVENT SHALL SELLER BE LIABLE FOR SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES INSTALLATION COSTS LOST REVENUE OR PROFITS OR ANY OTHER COSTS OF ANY NATURE AS A RESULT OF THE USE OF EQUIPMENT MANUFACTURED BY THE SELLER WHETHER USED IN ACCORDANCE WITH INSTRUCTIONS OR NOT UNDER NO CIRCUMSTANCES SHALL SELLER S LIABILITY TO BUYER EXCEED THE ACTUAL SALES PRICE OF THE EQUIPMENT PROVIDED HEREUNDER No representative is authorized to assume for Seller any other liability in connection with the equipment 36
14. Replace Compressor Control PCB The compressor control PCB controls the compressor ON OFF cycles solenoid drain valve timing and monitors the compressor current sensing To remove the control PCB open the front door of the unit Disconnect the cable connectors from the three locations on the PCB Remove the hardware which screw the control PCB to the door Install the replacment control PCB by reversing the above process Replace Compressor Disconnect Wiring With the side doors removed remove the cover plate on the compressor covering the electrical connections Remove the ground screw and remove the green wire from the connection box Using wire cutters cut the white and black leads as close to the butt splice as possible Trim 3 8 inch 10 mm of insulation from the wire s and install the replacement butt splice on these two wires leaving the compressor end of the splice uncrimped This will be used later to connect to the replacement compressor The compressor should now be free of any electrical connection to the unit Disconnect Tubing Remove the milky white hose which runs from the compressor outlet to the heat exchanger inlet Again it may be necessary to cut the clamp and hose to remove it from the heat exchanger Using the old tubing as a template cut the replacement tubing to length using a sharp knife Remove the drip pan assembly from the head of the old compressor and remount it to the replacement compressor The
15. XC100 SERIES MONITOR amp XT300 SERIES DEHY DRATOR USER MANUAL Bulletin 01 0510 001 Rev A Issue Date July 13 2004 NN 3 uy 14 1 SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL TABLE OF CONTENTS General Information Introducing New XC100 Monitors for use with the XT300 dehydrator Description Introducing the DryLine Redundant Hot Standby Setup Installation Unpacking and Inspection Perform Pre System Startup Test Place the Monitor and Dehydrator Install Polyethylene Tubing Lines Connection Procedure XC100 Series System configuration diagram Basic Connect Alarm Wiring XC100 Series System configuration diagram Multi Line Connect to Dry Air Cable System Purging Procedure Connect to Power Supply Grounding Instructions Plug and Outlet Configurations Test the Unit System Volumes Times to Purge and Pressurize Controls and Displays Monitor Controls Microprocessor Control Keys Digital Display Window Operation Control Status and Programming Familiarize yourself with the Displays Main Menu Program Mode Submenu Pressure Monitoring and Control Monitor Duty Cycles Display of System Pressure Alarm Conditions Programming Procedure Shutdown Procedure Theory of Operation Dehydrator Dehydrator Control XC100 Schematic XT300 Schematic XT300 Compressor Schematic XC100 SERIES MONITOR
16. ________________________ _ _ 8 12 Replace Microprocessor Board The microprocessor board assembly includes the display the microprocessor compressor pressure sensor the processor containing the microprocessor programming as well as other electronic components A component failure on the microprocessor circuit card will necessitate replacement of the entire circuit board assembly To remove the microprocessor circuit board assembly open the front door on the unit Disconnect the wiring from the microprocessor circuit board being careful to note the location of each wire as it is removed Remove the hardware which secures the board to the door panel and remove the microprocessor circuit board Install the replacement microprocessor circuit card assembly by reversing the above process 32 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Sea e Section 9 Specifications Table 8 Specifications for Monitor XC100 Series Output Pressure Range Adjustable 3 to 15 Psi 110 150 bi High Pressure Alarm to 15 0 Ib in High Humidity Alarm Fixed 5 RH factory set xcess Run Alarm Set Range djustable to 240 min ower Fail Alarm oss of input power sions inal Alarm Contact Rating 4 sut Power 115Vac 230Vac 50 60 2 P 1 amps starting Dimen depth 12 5 in 318 mm 0 3 SCFM 6 5 better than Output Dew Point 50 F 45 C at 92 RH at 104 F 4 40 C Operating Temperature 104 F
17. a single alarm is desired See figure 5 D lt e ener ee e nz 2 ESFi 27 79 Uu 2 zu Figure 6 Terminal strip gt 2 LIE a 2 0 0 10 a 9 16 2 H H PF High Pressure Normall Open m 2 JP2 5 EN High Humidity Normally Open aee i JP4 c n ch 1 Figure 5 Alarm Jumpers ormally Open s XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL ET XC100 Series System configuration diagram Multi Line This configuration shows proper hook up for systems when when more than a single wave waveguide is required in the system For larger systems a second LM400 monitor or additional MN6600 Distribution Maniflods can be added Figure 7 This diagram can also be used for hooking DP 4A 001 or MN6600 Series Manifold to the system Isolation Shut off Valves Dehydrator output line XC100 Line Monitor XT Dehydrator 5VDC Control Signal from XC100 output line OUTPUT LM400 or MN6600 or DP 4A 001 Outputs to transmission Lines Figure 7 XC100 Series System configuration diagram Multi Line CAUTION Do not operate the Monitor with the system isolation valves closed or with the remote sensing line disconnected Serious damage to the wave guide due to overpressure can occur Note To provide extra overpressure pr
18. amp XT300 SERIES DEHYDRATOR USER MANUAL TABLE OF CONTENTS Maintenance Semi Annual Preventive Maintenance Inspection In Case of Difficulty Semi Annual Preventive Maintenance Inspection Check Water Filter and Coalescent Filter and Elements Check Electrical Connections Check Ground Wire Check Run Time Replace Compressor Air Filter Carefully pull off the filter In Case of Difficulty Parts Replacement and Monitor Overhaul Three Year Recommended Dehydrator Spare Parts XC100 Line Monitor Spare Parts XT300 Dehydrator Spare Parts Parts Replacement Procedures Unit Shutdown and Removal Door and Panel Removal Replace Power Switch Replace Circuit Breaker Replace Compressor Control PCB Replace Compressor Disconnect Wiring Disconnect Tubing Compressor Remount and Reassembly Replace Heat Exchanger Replace Water Filter Element 3000 hour Maintenance Replace Coalescing Filter Element Replace Cooling Fan Replace Microprocessor Board Specifications Specifications for Monitors XC100 Series Specifications for Dehydrator XT300 Series Optional items Customer Support 24 Hour Technical Service Hotlin Free Loaner Program Warranty XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Introducing New XC100 Monitors for use with the XT300 dehydrator The Andrew XC100 Monitors are a new generation of pressurization control equipment for antenna and transmission line systems They feature enhanc
19. ceman if you have any questions regarding grounding or if in doubt as to whether the product is properly grounded XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL aiwu a nss ft f Connection to a Halo Grounding System A 10 grounding stud is located at the inside power entry area of the dehydrator chassis and on the back of the monitor for direct connections to a halo grounding system Connect using a No 6 copper stranded wire terminated at the ground stud with a proper ring tongue crimp on terminal 2 9 2 Plug and Outlet Configurations Make sure that the units are connected to an outlet having the same configuration as the plug Do not modify the plug If it will not fit the outlet have a proper outlet installed by a qualified electrician Do not use an adapter If the product must be reconnected for use on a different type of electric circuit qualified service personnel should make the reconnection 2 10 Test the Unit Turn ON the monitor and dehydrator The display should indicate 0 0 pressure within thirty seconds The humidity alarm low pressure alarm pressure reading and eventually the excess run time alarm if so equipped should flash in sequence in the display window The alarm conditions exist because the unit is not connected to the system 12 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Time to Purge 1000 ft Time to Pressurize to 305 m in Hours Operating Pressure I
20. drator components are properly dried operate the unit for at least 45 minutes prior to connecting the output air line to the primary waveguide If the transmission lines have not been purged take the following steps to dry the system otherwise proceed to Section 3 Controls and Displays Purging Procedure 2 9 Determine total volume of the pressurized dry air cable system to be connected to the monitor Refer to Table 2 Times to Purge and Times to Pressurize Remember if the Redundant Hot Standby option is used these times can be cut in half approximately Open the opposite end of the cable system from the monitor for purging 2 9 1 Operate the monitor after the initial 45 minute drying period to deliver dry air into the pressurized air system until a total of 3 volumes have been pumped through the entire system Check the humidity in the system using the humidity alarm if so equipped Perform this check after the far end of the system has been closed and the system has been stabilized for at least 5 hours Check cycle timing Compressor on time should be no more than 10 of off time for maximum life If not 1 System may not be properly sized 2 Leaks may exist Check using Snoop or detergent water 3 Normal connector leakage may be greater than expected 11 During the OFF cycle the dehydrator is designed to allow a small amount of system air to bleed back through the membrane dryer This air mainta
21. e one or more of the alarms may be activated Personnel who may be monitoring these alarms should be informed prior to the 8 7 units being turned OFF It will also be necessary to close off the transmission lines 8 71 connected to the monitor to avoid losing pressure in these lines Once these steps have been taken turn OFF the power to both units disconnect the alarm connections and unplug the unit The units can now be moved to a suitable work table for parts replacement Door and Panel Removal Carefully loosen the screws in the front doors and swing them open Loosen the screws in the side panels and remove the side panels by lifting them away from the unit 8 7 2 Replace Power Switch Disconnect the four quick disconnect connectors from the power switch carefully noting the location of each wire Compress the retainers on the switch and push the switch out the front of the chassis It may be necessary to rock the switch from top to bottom to remove it Replace switch by snapping it in place Reconnect the four wires 30 Replace Circuit Breaker The circuit breaker is located on the upper front door of the monitor Disconnect the two quick disconnect connectors from the circuit breaker carefully noting the location of each wire To remove the circuit breaker compress the retainers on both sides and push it through the front panel opening Replace circuit breaker snapping it in place Reconnect the two wires
22. ed programmability and controls with a bright new display and keypad The dehydrator features a patented membrane separation drying technology for the industry s best performance and reliability plus many exclusive new features such as microprocessor control and quiet operation This Manual contains the information you need to install operate and maintain your DryLine dehydrator and XC100 Series monitor Description The XC100 Series monitor are designed to control all functions of the DryLine XT300 Series dehydrators The XC100 includes a microprocessor control circuit along with a membrane touch tactile keypad and a vacuum fluorescent display An infrared IR interface is now included which allows direct programming and status reviews using a PDA or laptop computer A new event log is also recorded to assist with system status with system status and cycle analysis 1 3 Figure 1 XT300 with XC100 on top Introducing the DryLine Redundant Hot Standby Setup The Andrew XC100 Series Monitor with XT300 dehydrator provides a new level of transmission line system protection through the Redundant Hot Standby version In this configuration two XTC100 Series dehydrators are connected together providing dry air distribution to one or more transmission lines and common control over the operation of both dehydrator The system also provides additional capacity for very large tight systems where the flow of a single
23. er filter to prevent water droplets from exiting the filter This 5 micron filter also filters out any dust particles or other contaminants which would lessen the efficiency of the membrane dryer 8 11 To replace the filter element twist and remove the filter bowl from the cast housing Unscrew the filter element from the cast filter housing and replace with a new filter Do not attempt to clean the filter element If it is necessary to clean the filter bowl use a mild soap and water solution and rinse with water Do not use solvents Reassemble the unit by reversing the above procedure Check for leaks by turning the unit ON and applying a dilute detergent and 31 water solution at the bowl housing seal and at the hose fittings which were reconnected If no leaks are found the unit is ready to return to service If leaks are located repair the leak and recheck for additional leaks Leaking fittings must be repaired or the unit will not function properly and can result in damage to the transmission line system Replace Coalescing Filter Element The coalescing filter is located downstream from the water filter Its function is to remove any water fog which may still be present in the air leaving the water filter The coalescing filter traps any fine liquid water particles including aerosols and causes them to coalesce into larger droplets These droplets fall to the bottom of the bowl and are blown out and carried to the c
24. he water filter The saturated air then passes through a coalescing filter for the removal of additional water and then into the patented membrane cartridge where the remaining water is removed by pressure differential The water separated in the filters is blown to a pan on the head of the compressor and is evaporated by the heat of compression The flow of the water is controlled by a timer controlled solenoid The membrane tube separates moisture from air by a pressure differential across semipermeable fibers The water vapor and a small amount of the air permeate through the filter walls leaving the exiting air with a reduced water vapor content of 45 C 50 F dewpoint The air that permeates through the fibers purges the water vapor out of the tube s vent ports This patented drying process contains no moving parts thus reducing maintenance and increasing reliability 5 2 Dehydrator Control The ultra dry air exits the dehydrator at the top or back of the unit Low pressure High pressure High Humidity and excess run alarms are tapped into the air line within the dehydrator 21 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL OOLOX 01 941014 HOLO3NNOO H3TIOHLNOO HOSS3HdWOO OL 3unss3ud H3AO GION310S MONIA MOTIIA S5 3dund 15 ama s j SISSVHO 199 5
25. ins the dryness of the membrane dryer As system air bleeds back through the dryer additional system moisture is continually removed lowering the system dew point even further Your system is now up and running at the factory programmed settings To become familiar with the microprocessor controls and to change the settings proceed to Section 3 Controls and Displays Connect the alarm wiring to the terminals on the back of the XC100 Refer to the label on the alarm board or the schematic for the proper connections Connect to Power Supply The XC100 Series and XT300 Series can be plugged into a standard 15 amp power receptacle of the rated voltage Connect the monitor to a properly grounded power outlet Power is specified in Section 9 Physical Specifications Grounding Instructions This product should be grounded In the event of an electrical short circuit grounding reduces the risk of electric shock by providing an escape path for the electric current This product is equipped with a cord having a grounding wire and a grounding plug It should be plugged into a properly installed outlet that is grounded in accordance with all local codes and ordinances WARNINGS Improper installation of the grounding plug can result in a risk of electric shock If repair or replacement of the cord or plug is necessary do not connect the green grounding wire to either flat blade terminal Check with a qualified electrician or servi
26. ive actions corresponding to the problem in the order listed See pages 7 10 for NOTE Run the dehydrator to dry it out prior to connecting it to the system Run it until the high humidity alarm clears if so equipped The drying process should take about 45 minutes if the membrane dryer was not saturated If the membrane dryer was saturated drying may take up to 48 hours piping connections and Figure 10 for wiring Section 8 lists replaceable parts Andrew Technical Service If you cannot correct the problem or if there are other difficulties contact the Andrew Technical Service nearest you Telephone numbers are listed on page 34 Check the breaker adjacent to the ON OFF switch if tripped white indicator exposed then reset breaker by depressing If ON OFF switch light still fails to light make sure that unit is plugged Monitor or dehydrator ON OFF switch does not in and the power outlet is operating light unit does not run If you still have no light unplug unit open the front door panel and check for loose connections Refer to wiring diagram for proper wire connection Check ac voltage connection to the unit Check circuit and breaker push to reset If problem persists disconnect monitor from ac power open front door panel and check for loose connections refer to the wiring diagram Monitor ON OFF switch does not light and the Close front door reconnect power and turn ON unit if problem is not display is
27. larm must be cleared as described in the programming section 20 Programming Procedure Use the SELECT key to advance through the series of prompts without changing the programmed values If you change a value and want to save it to memory use the ENTER key which will also advance you to the next feature With the PROGRAM MODE prompt displayed in the display window press the key to precced to the first programmable feature Shutdown Procedure When removing your monitor or dehydrator from service you may need a substitute dry air source Call Andrew Technical Service Telephone numbers are listed in Customer Support section 10 Before turning OFF the unit notify personnel that alarms may be activated To shut down the XC100 Series unit first turn the dehydrator power switch to the off position turn the monitor ON OFF power switch to the OFF position and close the isolation shutoff valves located in the output input lines to retain System pressure Disconnect by unscrewing the poly tube compression fittings located at the back or top of the units XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Section 5 Theory of Operation 5 1 Dehydrator The patented drying system begins at the compressor where filtered ambient air refer to piping schematic Figures 4 7 and 8 is compressed The compressed air is then cooled and condensed in the heat exchanger after which water droplets are separated in t
28. lay scrolls ahead to the SELECT next display or program mode without changing the values in the microprocessor memory Enters into the microprocessor memory ENTER the values displayed in the window and advances display scrolls ahead to the next program or display mode Numerically increase displayed settings in display window When depressed longer than 1 2 second scrolling will occur at a faster rate Numerically decrease displayed settings in display window When depressed longer than 1 2 second scrolling will occur at a faster rate Used to allow the user quick access to the system event log After depressing this button the most recent event will be displayed The upand down arrow buttons may be used to browse the log VIEW O 3 Digital Display Window The window displays three types of information System Status Information Displays system pressure and total run time Program Control Prompts Used for setting duty cycle ON OFF pressures and alarms 14 Alarm Condition Display A flashing display indicates that an alarm condition exists The display is factory set for English language and English units It can also be set for metric units XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Section 4 Operation 4 1 4 2 4 2 1 Control Status and Programming 3 XC100 Series monitors have a microprocessor based control board for monitoring and control of the monito
29. monitor is not sufficient for purging and initial pressurization but is adequate for maintaining pressure once established XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Unpack Dehydrator and Line Monitor and Inspect for Shipping Damage Carefully remove packing material Check the monitor and line monitor for shipping damage such as dents or loose parts Open the covers and check for loose wires hoses or components If anything loose refer to the piping schematic Figure 10 or the wiring schematic Figure 12 for proper placement If there is damage or if there are any other problems contact Andrew Technical Service Telephone numbers are listed in Customer Support Section 10 If everything looks correct close the covers Perform Pre System Startup Test Make sure power switch is in the OFF position Plug the monitor and dehydrator into proper electrical outlets Proper outlets are defined in the specifications Connect the 5VDC control signal cable from the monitor to the dehydrator Connect the dehydrator output air line to the monitor input Do not connect the air lines to the transmission lines at this time After turning the power switches ON within 30 seconds the systems will start and the display will read SYSTEM PRESSURE XXX X PSI or KPa As the unit warms up check the filter bowls See Figures 1 to ensure condensate is being released and not building up in each bowl Check the air output
30. n Hours Line Type Volumes per 3 Volumes Per 1000 ft 305 m2 22 J ue eas ft per liters per 3090 XT300 XT300 3 36 7 3410 5 46 613 4 69 9 6494 10 4 1 173 5 117 0 10870 17 33 1 960 EW34 25 0 2323 3 70 413 EW28 36 0 3345 5 33 1 200 EW20 60 5 5621 8 96 1 013 EW17 71 0 6596 10 52 1 187 WG269 39 5 3670 5 85 667 WC281 43 1 3746 6 38 720 3 1 8 48 7 4524 7 21 813 4 116 84 0 7804 12 44 1 413 6 1 8 194 0 18023 28 74 3 233 8 3 16 347 0 32236 51 41 5 826 uMx 459 5 35 CAUTION Maximum pressure ratings for reference contact the uMx 459 465 611 and HPX12 6511C and P antenna group for actual pressure ratings Specific 186 Antennas have lower pressure ratings feeds and pressure windows may have reduced than the Antennas as indicated in the chart pressure ratings below 13 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Section 3 Controls and Displays This section explains the functions of the controls and displays used for operation and programming of the monitor 3 1 Monitor Controls ON OFF Double pole power switch controls both sides of the line Built in light indicates power is ON Circuit White tab indicates overload condition Breaker Resettable Fuse On front door 3 2 Microprocessor Control Keys Advances disp
31. ompressor head where they evaporate To replace the filter element twist and remove the filter bowl from the cast housing Unscrew the filter element from the cast filter housing and replace with a new filter Do not attempt to clean the filter element If it is necessary to clean the filter bowl use a mild soap and water solution and rinse with water Do not use solvents Reassemble the unit by reversing the above procedure Check for leaks by turning the unit ON and applying a dilute detergent and water solution at the bowl housing seal and at the hose fittings which were reconnected If no leaks are found the unit is ready to return to service If leaks are located repair the leak and recheck for additional leaks Leaking fittings must be repaired or the unit will not function properly and can result in damage to the transmission line system Replace Cooling Fan The cooling fan ventilates the monitor enclosure thus cooling the compressor and the heat exchanger Failure of a fan can result in saturation of the membrane dryer and damage to the compressor To remove a fan disconnect the fan leads and remove the mounting hardware Install the replacement fan using the existing hardware Orientation of the ac power leads is not critical XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL ____________________________ _______________________________________________________________________________________________________
32. otection a secondary popoff valve may be added at this point that is closely matched to the maximum system safe pressure See specification page for options available XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL This configuration shows proper hook up for a redundant system configuration Figure 8 Transmission Line Dehydrator outputs connected with tee fitting To distribution LM400 MN6600 or DP 4A 001 OUTPUT XC100 Redundant Line Monitor XT XT Redundant Redundant Dehydrator Dehydrator 5VDC control Signal from XC100 5VDC control Signal from XC100 Figure 8 XC100 Series System configuration diagram Multi Line CAUTION Note Do not operate the Monitor with the system To provide extra overpressure protection a isolation valves closed or with the remote secondary popoff valve may be added at this point sensing line disconnected Serious damage that is closely matched to the maximum system to the wave guide due to overpressure can safe pressure See specification page for options occur available 2 8 2 8 1 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Connect to Dry Air Cable System CAUTION Check the system pressure rating before connecting the dehydrator monitor to the transmission line system The pressure settings must be adjusted to match the ratings of the waveguide components See Section 4 To insure that all internal dehy
33. r and setting the programmable alarms It comes factory set for English language and English units Figure 9 shows the various modes which may be viewed in the display window Main Menu displays are shown in the first column Program Mode Submenu displays are shown in the second column 4 2 2 Familiarize yourself with the Displays The Main Menu First become familiar with the Main Menu Turn the monitor In about 30 seconds the monitor will start and begin to pressurize the System Upon power up the system will do a set of internal diagnostics and mean while 1 display as follows X controller revision XX X If a power up test failure is detected the following is displayed system pressure XXX X PSI kPa Press the button and the display will indicate PROGRAM MODE Press the button again and the Total Run Time will appear as XXXX X HOURS and indicate total hours since initial turn ON Note for the Redundant Hot Standby version the button can be pressed 3 again and total run time will appear as XXXX X hours B and indicate total Dehydration B hours since initial turn ON 15 Press and you will return to system pressure or if the excess run alarm has been purchased CLEAR RUN TIME will appear This feature is used to clear the alarm by pressing the key and proceeding back to COMP 5 0 PSI The Program Mode Submenu If your monitor is equipped with all options all of the screens
34. re of the dehydrator drops to 5 Ib in 3 kPa and stop when the pressure reaches 5 Ib in 35 kPa That is the recommended pressure range for most antenna and transmission line components which have a rating of at least 5 Ib in 35 kPa Some system components however have lower pressure ratings Using the procedures described below XC100 Series monitors can be programmed for any start stop pressure 4 5 combination in the 0 3 15 0 Ib in 2 103 kPa range For the Redundant Hot Standby version the master unit is programmed to operate at 1 0 PSI 7 kPa and the slave unit is programmed to start at 0 5 PSI 3 5 kPa Both units are set to stop at 5 0 PSI 35 kPa Display of System Pressure The monitor output pressure SYSTEM PRESSURE 0 0 PSI is the initial display as power is applied to the unit As shown in Figure 9 Main Menu pressing the Key will display PROGRAM MODE on the display window Alarm Conditions Alarm conditions except high humidity are defined by the programmed settings entered into the microprocessor as described below Alarm contacts are included in the unit and wiring terminals are located on the back of the monitor When an alarm condition exists the normally open contacts are closed thereby activating a remote alarm not included Also the alarm condition will flash continually on the display window until the alarm condition is corrected In the case of the excess run alarm the a
35. rroded electrical connections Aloose terminal can cause erratic operation and unnecessary downtime Check the screw on and push on terminals and tighten as required Check Ground Wire Check for proper ground wire connection to protect operations personnel A green ground wire is attached between the power terminal strip and the monitor chassis The ground lug Screw or stud nut must be tight to provide a proper ground Check Run Time Check the run time on the monitor to determine the duty cycle of the dehydrator If the monitor has been running more than 10 of the time check for system leaks Also check to see if it is time to schedule the 3000 hour maintenance Replace Compressor Air Filter The air filter protects the compressor from contamination and extends the service life of the compressor It is made of open cell material and should be replaced every six months or more often if the unit is located in a dusty environment Carefully pull off the filter cover and remove the filter element Install the new filter element and replace the filter cover being certain that it is completely seated To replace the filter housing unscrew the housing from the compressor head and replace with new filter housing XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL If you experience difficulty with your monitor or dedydrator use the troubleshooting procedures described below Perform the tests inspections and correct
36. sks can be performed easily in the field as described below 3000 hour Overhaul A monitor overhaul is required after the compressor has run a total of 3000 hours as indicated on the compressor run time meter The monitor overhaul includes a compressor overhaul water filter high tempera ture tubing and hose clamps The monitor overhaul kit see Section 8 1 includes all the necessary parts and instructions Or if you prefer Andrew offers a monitor overhaul service Contact Andrew Technical Service Telephone numbers are listed on Section 10 Refer to Sections 8 4 7 and 8 4 10 for procedures to replace water filter elements In Case of Difficulty If the monitor will not operate or if there are other problems refer to the troubleshooting procedures in Section 7 Semi Annual Preventive Maintenance Inspection Inspection includes checking for loose or damaged hoses fittings and electrical connections Check the following items 25 6 3 1 6 3 2 6 3 3 6 3 4 6 3 5 Check Water Filter and Coalescent Filter and Elements Verify there is no excessive water build up in the filter bowls If there is excessive water refer to the troubleshooting procedures in Section 7 for corrective action Replacement of the water filter and coalescent filter and their associated elements and bowls is covered in the parts replacement section of this manual Refer to Section 8 Check Electrical Connections Check for loose or co
37. the hour values 00 59 COMP RUN TIME ALARM Set this to a time above the normal runtime on the system values 5 240 COMPRESSOR ON Set this the desired start pressure in PSI or kPa format is XXX X PSI Values 0 3 15 0 for standard unit or 0 3 100 0 for the high pressure option COMPRESSOR OFF Set this the desired start pressure in PSI or kPa format is XXX X PSI Values 0 3 15 0 for standard unit or 0 3 100 0 for the high pressure option LOW PRESSURE ALARM Set this the desired low pressure alarm threshold Format is XX X PSI kPa Values 0 1 15 0 NOTE Must be set below compressor ON set point Recommended setting is at least 0 3 PSI below compressor ON values HIGH PRESSURE ALARM Set this to the desired high pressure alarm threshold Format is XX X PSI kPa Values 0 1 16 0 NOTE Must be set above compressor OFF set point Recommended at least 0 3 PSI above OFF value 16 15 16 17 18 19 BACKUP COMP ON PRESS Used only with multiple compressor systems set to operate in redundant hot standby mode This is set to the desired start pressure for the backup compressor s Format is XXX X PSI kPa Values 0 3 15 0 NOTE Must be set below primary compressor ON set point COMP OVERHAUL TIME Factory only setting 3000 hours KEYPAD INACTIVITY Format is XX seconds Factory set for 45 seconds SYSTEM PRESSURE HI RES If set to YES
38. this setting will display system pressure two decimal places of resolution Set to NO except when system pressures are very low or the ON and OFF pressure differential is very small ENTER NEW PASSWORD The factory set password is 111111 User many enter a new password and depress ENTER or depress the SELECT button to cancel the change XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Notes 17 XC100 SERIES MONITOR amp XT300 SERIES DEHYDRATOR USER MANUAL Power Up Y System Check System Pressure A XXX X PSI or kPa Fault Found ENTER Y Scroll N Ahead SELECT PROGRAM Y Scroll Ahead SELECT Compressor Runtime XXXX X HOURS Y Scroll N Ahead SELECT j Clear Runtime Alarm Hit or N 10 t ENTER Cancel Enter to Clear Alarm or Scroll Ahead SELECT 4 Ya Password 0 1 2 3 4 5 6 7 8 9 Use default 111111 Y ENTER or Compessor Count ENTER 1 m Scroll 7 Ahead SELECT High Pressure Tank 9r 9 dw ENTER Scroll N Ahead SELECT Set month ENTER or Y Scroll N Ahead SELECT Set day meV N Db gt p ENTER or Scroll N Ahead SELECT Set Ds year or N ENTER or Y Scroll Ahead SELECT Set
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