NXT Series Dehydrator User Manual
Contents
1. Scroll Ahead SELE High pressus Alarm T XX X PSI Sa ER Scroll Ahead SELECT cr E Backup co ON Press EN XX X PSI kPa or Scroll Ahead SELECT Comp Overhaul Time XXXX HRS I ENTER y Scroll Ahead SELECT Y A Key Pad Inactivity XX MIN Y or Scroll Ahead SELECT Y or Enter New Password XXXX Figure 9 Continued 19 NXT SERIES DEHYDRATOR USER MANUAL To Record Change To Record Change To Record Change To Record Change To Record Change To Record Change To Record Change To Record Change To Record Change To Record Change 4 3 4 3 1 4 3 2 4 3 3 4 3 4 NXT SERIES DEHYDRATOR USER MANUAL Pressure Monitoring and Control Pressure Monitoring Points Dehydrator output pressure is monitored at the transmission line on all models by the Remote Sense port on the top ofthe unit CAUTION Do not operate the unit without the sense line connected this 4 4 may cause an over pressure condition that may damage the waveguide Dehydrator Duty Cycles The dehydrator is programmed at the factory to start when the output pressure 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 in2. eem vi 8 sari 9NMIM HOOQ 1 TE r 119 pe yov H3TIOH1NOO MOSS3HdWOO uc x 100 9002V f Loa MION3IOS A 3 LIM van zat MOTA MOTA 8 5 105 i k 7 wows ONVHO JUHM is ania ania NOE ama s ama NMOY8 MANSO 5 SISSVHO 180 z MVA E nouo HOUMS E E posti o 440 NO MOTIZAN3399 105 25 a urn E SNRIIM td SISSVHO TH A A O dT 7 OO ONIIM SISSVHO O TT LNW ALIHM HOSSIUANOI SUHM yov PE YAMOd SNIVIN N33u9 SISSVHO va 22 NXT SERIES DEHYDRATOR USER MANUAL HJTIOHLINOO HOSS3HdWOO 100 9002 V f L03V ta OI SNIVN en n t t L YO 8d d HOLO3NNOO LINN 431SVN NOYW SSS ai NANA eee g HOVE 3AB S XXXX0 n ual vy GION310S Y31714 GION310S LNv4 0V78 9 8 R m YOSSIYAN EN OSS oo 31IHM N33Y9 SISSVHD JONVUO xovi8 SUHM oe 2 9 sz zs E T i uy 9 v NMOS N 18 A L NMOY8 4409 YIMOd SNIVN NMOY8 pred HOLIMS
3. 35 kPa Some system components however have lower pressure ratings Using the procedures 4 5 described below DryLine NXT SERIES Series dehydrators can be programmed for any start stop pressure 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 dehydrator output pressure System Pressure 0 0 is the initial display as power is applied to the unit As shown in Figure 9 Main Menu pressing the SELECT 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 inside of the 20 door 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 the case of the excess run alarm the alarm must be cleared as described in the programming section Programming Procedure Use the SELECT key to advance through the series of prompts without changing the programmed values If y
4. 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 compressor 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
5. 0995 7 SISSVHO QNO MOTIBA N33HO ONIMIM SISSVH9 J 23 NXT SERIES DEHYDRATOR USER MANUAL Maintenance Section 6 6 1 The dehydrator reguires maintenance semiannually and after each 3000 hours of operation to ensure continued reliable operation Danger Service personnel should observe all safety regulations Do not perform maintenance on eguipment 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 gualified technicians should attempt to effect maintenance or repairs on electrical eguipment Semi Annual Maintenance The semi annual maintenance consists of a preventive maintenance inspection and replacement of the compressor air filter These tasks can be performed easily in the field as described below 3000 hour Overhaul A dehydrator overhaul is reguired after the compressor has run a total of 3000 hours as indicated on the compressor run time meter The dehydrator overhaul includes a compressor overhaul water filter high tempera ture tubing and hose clamps The dehydrator overhaul kit see Section 8 1 includes all the necessary parts and instructions Or if you prefer Andrew offers a dehydrator overhaul service Contact Andrew Technical Service Telephone numbers are listed on page 28 Refer to Sections 8 4 7 and 8 4 10 fo
6. MANUAL Additional Dehydrator Spare Parts Item Power Switch 230V Circuit Breaker 20 amp Compressor 230V NXT2000 NXT1000 Power Cable 230V Power Cable Strain Relief Heat Exchanger High Temperature Hose compressor to heat exchanger Low Temperature Hose heat exchanger to water filter Hose clamps high and low temp hose Water Filter complete assembly BGOO Water Filter Bowl All units Water Filter Element Coalescing Filter complete assembly Urethane tubing 1 4 OD water drain All units Evaporator Pan Tube Fitting Cooling Fan 230V 1 8 10 Clear Tubing sensor line Alarm Relay Board 3 8 OD Black Tubing Microprocessor Board with Display Fuse Holder Tube Clamp Compressor Control PCB Solenoid 230V Humidity sensor cable assy Pop Off Valve 16 PSI 28 QTY 1 1 1 1 1 1 1 2 5ft 0 762m 2 5ft 0 762m Za 4 5ft 1 372 1 1 4 5ft 1 372 1 5 ft TX gt gt gt A Part Number AE01J A0129 006 EBREK 12076 AE01J A1960 002 AE01J A1960 004 ECABP 25513 ECABB 27320 EHTEX 42200 EHOSE 21002 EHOSE 33002 ECLMP 20090 EFLTA 12204 EFLTA 94041 EFLTA 95045 EFLTA 12203 AE01J A1986 001 EFTGS 30223 AE01J A1965 002 ETUBE 20201 AE01A D1401 001 25435 5 AE01J A2007 001 EFUSH 14401 ECLMP 20040 AE01J A2006 001 163732 AE01C D0785 036 AE01J A0174 008 NXT SERIES DEHYDRATOR USER MANUAL Notes 29 8 1 8 2 8 3 8 4 8 5 NXT SERIES DEHYDRATOR USER MANUAL Parts Replaceme
7. Valves Wave Guide Dehydrator Output Line NXT Dehydrator CAUTION Note To provide extra overpressure protection Do not operate the Dehydrator with the system 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 isolation valves closed or with the remote sensing line disconnected Serious damage to the wave guide due to overpressure can occur 2 6 NXT SERIES DEHYDRATOR USER MANUAL Connect Alarm Wiring Open the front door and connect the alarm wiring to terminals shown in figure 2 See dal Pressure Normally Open AE below High Humidity Normally Open excess Ron common Upper terminal strip Excess Run Rormaly Open row Pressure row Pressure Normaly Oper common PowerFai Rormaty open If Normally Closed contacts are desired move the jumper on the PC boards to the N C position Jumper on positions A B for normally open position B C for normally closed All alarms are dry contacts and can be ganged together if a single alarm is desired See figure 3 Figure 3 Upper terminal strip Figure 2 Alarms Jumpers 8 NXT SERIES DEHYDRATOR USER MANUAL AAA AAA NXT Series System configuration diagram Multi Line This configuration shows proper hook up for systems when when more than a single wave waveguide is r
8. air Replace Water Filter Element 3000 hour Maintenance Replace the water filter after each 3000 hours of operation When ambient room air is compressed in the dehydrator 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 water filter to prevent water droplets from 8 11 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 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
9. 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 and oxygen from air by a pressure differential across semipermeable fibers The water vapor oxygen and a small amount of the air permeate through the filter walls leaving the exiting nitrogen with a reduced water vapor content of 60 C 76 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 Dehydrator Control The ultra dry nitrogen exits the dehydrator at the top of the unit Low pressure High pressure High Humidity and Excess run alarms are tapped into the air line within the dehydrator 21 NXT SERIES DEHYDRATOR USER MANUAL AA S IVNIWH31 Wav Tv MOVIE OF OF aay 6 6 NMONB 2 ama 9 9 S S AVEO momma zz 3nd LL TAL YOSNIS ALIQIANH 19352 XXXX6 9 5 tan TA anu id KAH Cid H3TIOHLNOO HOSSIIOUAONIIN 100 8661 WT LO3V la LES avasi sr VAN LOL 866LV LOV Avidsid _ fT TT 9NHMSISSVHo
10. 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 dehydrator 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 NXT SERIES DEHYDRATOR USER MANUAL In Case of Difficulty Note Run the dehydrator to dry it out prior to connecting it to the system Run it until zem y 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 If you experience difficulty with your dehydrator use the troubleshooting procedures described below Perform the tests inspections and corrective actions corresponding to the problem in the order listed See pages 7 10 for piping connections and Figure 10 for wiring Section 8 lists replaceable parts Caution High voltage exists inside the unit Disconnect the unit whenever performing troubleshooting operations Andrew Technical Service If you cannot correct the pr
11. of timer controlled heaters solenoid valves desiccant towers and associated wiring providing greater reliability The internal microprocessor control circuitry provides several major options including programmable alarms and operating thresholds 1 3 Introducing the DryLine Redundant Hot Standby Dehydrators The Andrew NXT Series DryLine Dehydrator provides a new level of transmission line system protection through the Redundant Hot Standby version In this configuration two NXT Series Dehydrators are connected together providing dry nitrogen distribution to one or more transmission lines and common control over the operation of both dehydrators The system also provides additional capacity for very large tight systems where the flow of a single dehydrator is not sufficient for purging and initial pressurization but is adequate for maintaining pressure once established NXT SERIES DEHYDRATOR USER MANUAL Installation Section 2 2 1 Unpack Dehydrator and Line Monitor and Inspect for Shipping Damage Carefully remove packing material Check the dehydrator and line monitor for shipping damage such as dents or loose parts Open the dehydrator front door and check for loose wires hoses or components If anything is loose refer to the piping schematic Figure 10 or the wiring schematic Figure 12 for proper placement Figure 1 If there is damage or if there are any other problems contact An
12. 480 1 240 GLW1700 1576 146410 70 04 35 02 3 200 1 600 GLW1750 1670 155143 74 24 37 12 3 36 1 68 Max Pressure Rating Ib in2 kPa uMx 459 5 35 Caution Maximum pressre ratings for reference uMx 459 465 611 and HPX12 6511C contact the antenna group for actual and P 186 Antennas have lower pressure ratings Specific feeds and pressure ratings than the Antennas pressure windows may have reduced as indicated in the chart below 13 pressure ratings NXT SERIES DEHYDRATOR USER MANUAL Controls and Displays indicates that an alarm condition exists The display is factory set for English language Section 3 and English units It can also be set for metric This section explains the functions of the controls and units displays used for operation and programming of the dehydrator 3 1 Dehydrator 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 display 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 wi
13. 5 0 for standard unit or 0 1 100 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 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 may enter a new password and depress ENTER or depress the SELECT button to cancel the change NXT SERIES DEHYDRATOR USER MANUAL N
14. 9 5444 Customer Service 24 hours North America 1 800 255 1479 U K 0800 250055 Europe Africa amp Middle East 44 1592 782 612 34 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 NXT SERIES DEHYDRATOR USER MANUAL ANDREW Andrew Corporation XTINXT Series Dehydrator System Three Year Limited Warranty Seller warrants that any Andrew XT1000 2000 4500 NXT1000 2000 and MT1000 2000 type DryLine Dehydrator 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 months 36 months from the date of installation or 3000 hours of actual run time except for the compressor which is for a period of twelve 12 months or 1000 hours whichever shall occur first such eguipment 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 at no cost to the Buyer provided that the cost of any transportation in connection with the return of the eguipment for the purpose of repair or replacement shal
15. Cooling Fan The cooling fan ventilates the dehydrator 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 NXT SERIES DEHYDRATOR USER MANUAL EEE IE II E 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 NXT SERIES DEHYDRATOR USER MANUAL Specifications Section 9 Specifications for Dehydrators NXT SERIES Specifications for Dehydrator NXT Series Output Pressure Range Adjustable 0 3 to 5 Psi NXT1000 1 0 SCFM 28 SLPM
16. Install Polyethylene Tubing Lines Output lines 4 with individual valves Pressure sense line Forthe Redundant version the slave unit sense line Connection Procedure Connect the Transmission Line Tubing Insert the tubing runs from the transmission lines into the fittings in the top panel marked Outlet Connect the Remote Sense Line Tubing Insert a single tubing run from the transmission line into the fitting in the top panel marked Remote Sense 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 Do not install the Remote Sense and Output lines into a Tee Fitting into one port on the transmission line The dehydrator will not operate properly CAUTION Do not operate the unit with the pressure sense line disconnected this may result in an over pressure condition Also be sure that any isolation valves are open before operating the unit NXT SERIES DEHYDRATOR USER MANUAL A TT NXT Series System configuration diagram Basic This configuration shows proper hook up for systems when only a single waveguide is reguired in the system Remote Pressure Sense Line Isolation Shut off Primary Large
17. NXT SERIES DEHYDRATOR Bulletin AE01B A0497 001 Rev A NXT SERIES DEHYDRATOR USER MANUAL TABLE OF CONTENTS SECTION 1 General Information Introduction Description SECTION 2 Installation Unpacking and Inspection Perform Pre System Startup Test Place the Dehydrator Install Polyethylene Tubing Lines Connection Procedure Connect Alarm Wiring Connect to Dry Air Cable System Caution Connect to Power Supply Test the Unit System Volumes Times to Purge and Pressurize SECTION 3 Controls and Displays Dehydrator Controls Microprocessor Control Keys Digital Display Window SECTION 4 Operation Control Status and Programming Main Menu Familiarize yourself with the Displays Program Mode Submenu Pressure Monitoring and Control Programming Procedure Shutdown Procedure SECTION 5 Theory of Operation Dehydrator Dehydrator Control Schematic 9XXXX Master Schematic Slave SECTION 6 Maintenance Semi Annual Preventive Maintenance Inspection SECTION 7 In Case of Difficulty NXT SERIES DEHYDRATOR USER MANUAL TABLE OF CONTENTS Parts Replacement and Dehydrator Overhaul Additional 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 Replace Heat Exchanger Replace Water Filter Element 3000 hour Maintenance Replace Coalescing Filter Element Replace C
18. NXT2000 2 0 SCFM 56 SLPM better than Output Dew Point 50 F 45 C at 92 RH at 104 F 40 C Operating Temperature 33 to 104 F 1 C to 40 C Low Pressure Alarm 0 1 to 0 3 Ib in2 6 7to Set point Range 201 mbar 3 0 to 6 0 Ib in2 b 201 to Set Point Range 403 mbar High Humidity Alarm Fixed 7 5 RH factory set xcess Run Alarm Set Range Adjustable to 255 min ower Fail Alarm oss of input power Alarm Contact Rating a N 230Vac 50 60Hz 0 03 Amps Standby Input Power 11 5 Amps Running 40 amps starting Output Air Connectors 3 8 poly tube compression fitting Remote Sensing input 3 8 poly tube compression fitting height 45 25 in 1150 mm Dimensions wath 16 5 in 420 mm depth 17 5 in 445 mm NXT1000 130 Pounds NXT2000 130 Pounds Over pressure limit internal 16 psi Pop off Valve Output Flow Rate nominal Weight net nominal Optional items System popoff valve 1 8 NPT 1 PSI AE01J 0174 009 System popoff valve 1 8 NPT 2 PSI AE01J 01 74 001 System popoff valve 1 8 NPT 3 PSI AE01J 0174 0011 Street Tee 1 8 NPT 3022 33 Section 10 NXT SERIES DEHYDRATOR USER MANUAL err Customer Support 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 34
19. drew Technical Service Telephone numbers are listed on page 34 If everything looks correct close the dehydrator front door 2 2 Perform Pre System Startup Test Make sure power switch is in the OFF position Plug the dehydrator into a proper electrical outlet Proper outlets are defined in the specifications Section 9 Do not connect the air lines on the unit at this time Within 30 seconds the display on the front panel will show a pressure reading of 0 0 and the compressor should start 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 pressure gauge at the top or bottom of the membrane tube Verify itis at 90 psi 5psi Adjust the valve if necessary to show 90 psi Check the air output port at the top 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 and close the dehydrator front door 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 2 3 2 4 2 5 NXT SERIES DEHYDRATOR USER MANUAL Place the Dehydrator The DryLine SERIES dehydrator is designed for to be floor standing The unit is shipped with the power cord and air lines placed through the top ofthe unit
20. en a surge is encountered Check fuse and replace if defective See Section 8 3 for replacements Disconnect unit from ac power open front door panel and check for loose connections refer to wiring diagram Caution High voltage is present inside the enclosure and On off switch lights display is blank on the power supply board at this point Check the voltage between pins 1 and 2 of TB2 on the power supply unit It should be 4 5 to 5 5 volts If not within this range replace power supply board see 8 4 18 for part numbers If it is within range and no loose connections are found contact Andrew Technical Service for assistance 25 NXT SERIES DEHYDRATOR USER MANUAL bef hi Check for leaks in the transmission lines or line tubing A M NI Check for kinks in line tubing Replace tubing where necessary sufficient line pressure i e a Check remote sense line Make sure any isolation valve is wide open Verify that the Low Pressure Alarm Set Point is below the compressor ON set point Isolate the low pressure condition by checking all fittings with soapy water Make sure that all system tubing is properly seated Low pressure alarm on display in the fittings Check for loose interface points and holes in the transmission lines Correct any conditions that exist where pressure is leaking If the condition persists call Andrew Technical Service for assistance Verify the compressor turn off and high pressure alarm
21. equired in the system For larger systems an 8 output manifold can be added This diagram can also be used for hooking DP 4A 001 or MN6600 Series Manifold to the system Remote Pressure Sense Line Isolation Shut off Primary Large Valves Wave Guide Dehydrator Output Line NXT Dehydrator Tee Fitting LM400 Line Monitor Any other Monitor or Manifold can be used in this location to Outputs to other expand the system Wave Guides CAUTION Note To provide extra overpressure protection Do not operate the Dehydrator with the system a secondary popoff valve may be added at this isolation valves closed or with the remote sensing point that is closely matched to the maximum line disconnected Serious damage to the wave system safe pressure See specification page for guide due to overpressure can occur options available NXT SERIES DEHYDRATOR USER MANUAL Ea A en il This configuration shows proper hook up for a redundant system configuration Dehydrator outputs connected 5VDC control cable with tee fitting Isolation Shut off Primary Large Valves Wave Guide Remote Pressure Sense Line NXT Redundant Slave NXT Redundant Master CAUTION Note To provide extra overpressure protection Do not operate the Dehydrator with the system a secondary popoff valve may be added at this isolation valves closed or with the remote sensing point that is closely matched to the maximum line disconnected Serio
22. he 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 Excess run time alarm on display Check system for leaks See troubleshooting section Low pressure alarm on display Dehydrator turns on for only a few seconds Ba Check the voltage supply to the unit 26 NXT SERIES DEHYDRATOR USER MANUAL Parts Replacement and Dehydrator Overhaul Section 8 Andrew dehydrators have been designed to provide many years of trouble free service and will reguire minimal maintenance The display panel contains as one ofthe standard features a reading of actual compressor run hours Notice To provide continuous reliable operation the dehydrator must be ovehauled every 3000 hours of compressor peration The dehydrator overhaul kit listed below contains all necessary parts Alternatively you may send your dehydrator to Andrew for overhaul Three Year Recommended Dehydrator Spare Parts Item Compressor Air Intake Filters bag of six Compressor Air Intake Filters complete assembly housing w filter Dehydrator Overhaul Kit Includes compressor overhaul kit high temperature hose clamps NXT1000 Dehydrator Overhaul Kit Includes compressor overhaul kit high temperature hose clamps NXT2000 27 QTY 1 Part Number 46173 1 46173 AE01K C0398 016 AE01K C0398 015 NXT SERIES DEHYDRATOR USER
23. 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 NXT SERIES DEHYDRATOR USER MANUAL System Volumes Times to Purge and Pressurize Time to Purge 1000 ft Time to Pressurize to 305 m in Hours Operating Pressure In Hours Line Type Volumes per 3 Volumes Per 1000 ft 305 m2 E A j ft per liters per 10000 0000 NXT1000 NXT2000 NXT1000 NXT2000 HELIAX Coaxial Cable Pressurized to 5 Ib in 35 kPa 3 36 7 3410 1 64 0 82 184 092 4 69 9 6494 3 12 1 56 352 176 5 117 0 10870 5 20 2 60 588 294 HELIAX Elliptical Waveguide Pressurized to 5 Ib in 35 kPa EW34 25 0 2323 1 112 0 556 0 124 0 062 EW28 36 0 3345 1 6 0 8 0 360 0 090 EW20 60 5 5621 2 688 1 344 0 304 0 152 EW17 71 0 6596 3 156 1 578 0 356 0 178 Circular Waveguide Pressurized to 5 Ib in 35 kPa WG269 39 5 3670 1 756 0 878 0 200 0 100 WC281 43 1 3746 1 916 0 958 0 216 0 108 Rigid Transmission Line Pressurized to 5 Ib in 35 kPa 3 1 8 48 7 4524 2 164 1 082 0 244 0 122 4 1 16 84 0 7804 3 732 1 866 0 424 0 212 6 1 8 194 0 18023 8 624 4 312 0 976 0 488 8 3 16 347 0 32236 15 424 7 712 1 748 0 874 Guideline Waveguide for UHF TV Pressurized to 2 Ib in 14 kPa GLW1350 994 92343 44 16 22 08 2 000 1 000 GLW1500 1227 113988 54 52 27 26 2
24. iners 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 Replace Circuit Breaker The circuit breaker is located on the upper front door of the dehydrator Disconnect the two 30 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 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 the
25. l be borne by Buyer Expressly excluded from the terms of this warranty are defects caused by faulty installation ii lack of proper inspection or maintenance iii and usage not in accordance with published ratings specifications or instructions The provisions of this warranty shall be applicable with respect to any eguipment Seller repairs or replaces pursuant to it SELLER MAKES NO WARRANTY EXPRESS OR IMPLIED OTHER THAN AS SPECIFICALLY STATED ABOVE EXPRESSLY EXCLUDED ARE ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PURPOSE THE FOREGOING SHALL CONSTITUTE 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 Rev 5 01 35 NXT SERIES DEHYDRATOR USER MANUAL Notes 36
26. ll 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 up and down arrow buttons may be used to browse the log VIEW o 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 Alarm Condition Display A flashing display 44 NXT SERIES DEHYDRATOR USER MANUAL Operation Section 4 4 1 4 2 4 2 1 Control Status and Programming DryLine NXT Series dehydrators have a microprocessor based control board for monitoring and control of the dehydrator and setting the programmable alarms It comes factory set for English language and English units Metric units can be set Figure 9 shows the various modes which may be viewed in the display window Main Menu displays are shown in 4 2 1 Program Mode Submenu displays are shown in 4 2 2 4 2 2 Familiarize yourself with the Displays The Main Menu First become familiar with the Main Menu Turn the dehydrator on In about 30 seconds the dehydrator will start and begin to pressurize the system Upon power up the system will do a se
27. ng 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 Up Arrow W 2 3 Down Arrow 415 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 value 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 10 11 12 13 14 NXT SERIES DEHYDRATOR USER MANUAL High Pressure Tank Set this value to NO unless the high pressure tank option was purchased Values Y or N 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 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 1
28. nt Procedures When the dehydrator 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 kit listed in Section 8 0 Following are procedures for replacement of 8 6 the parts listed in Section 8 Unit Shutdown and Removal In order to perform parts replacement on the DryLine Dehydrators it will be necessary to turn off the unit and remove them from service As this is done one or more of the alarms may be activated Personnel who may be monitoring these alarms should be informed prior to the units being turned off It will also be necessary to close off the transmission lines connected to the dehydrator to avoid losing 8 7 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 Caution Disconnect electrical power from the unit before removing the doors 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 Replace Power Switch Disconnect the four quick disconnect connectors from the power switch carefully noting the location of each wire Compress the reta
29. oblem or if there are other difficulties contact the Andrew Technical Service nearest you Telephone numbers are listed on page 34 Troubleshooting Procedure Check the breaker adjacent to the on off switch if tripped white indicator exposed then reset breaker Dehydrator on off switch does not light unit If on off switch light still fails to light make sure that unit is plugged in dase and the power outlet is operating 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 Disconnect ac power open front doors check for loose connections Dehydrator on off switch does not light unit refer to the wiring diagram for proper connections Replace cover and runs reconnect ac power Replace on off switch if condition persists Check ac voltage connection to the unit Check fuse and replace if defective See Section 8 3 for replacements If problem persists disconnect dehydrator from ac power open front door panel and check for loose connections refer to the wiring Dehydrator on off switch does not light and the diagram Close front door reconnect power and turn on unit if display is blank problem is not corrected contact Andrew Technical Service for assistance Note This problem can be caused by a lightning induced power surge The dehydrator is equipped with surge protectors which may cause the fuse to blow wh
30. 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 System may not be properly sized Or Leaks may exist Check using Snoop or detergent water Or Normal connector leakage may be greater than expected 11 During the off cycle the dehydrator is designed to allow a small amount of system nitrogen to bleed back through the membrane dryer This nitrogen maintains 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 inside of the unit Refer to the label on the alarm board or the schematic for the proper connections Connect to Power Supply The NXT Series can be plugged into a standard 20 amp power receptacle of the rated voltage Connect the dehydrator 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 f
31. ooling Fan Replace Microprocessor Board Specifications Specifications for Dehydrators NXT SERIES Customer Support 24 Hour Technical Service Hotlin Free Loaner Program Warranty NXT SERIES DEHYDRATOR USER MANUAL General Information Section 1 1 1 Introducing New DryLine Dehydrators The Andrew DryLine NXT1000 2000 4500 Dehydrators are a new generation of pressurization eguipment for antenna and transmission line systems They feature a new patented membrane separation drying technology for the industry s best performance and reliability plus many exclusive new features such as microprocessor control an guiet operation Each large DryLine dehydrator is a pressurization system built into a convenient chassis floor mounted package It is selfcontained unit containing many components which in other systems are typically pieced together on site This Manual contains the information you need to install operate and maintain your DryLine NXT Series dehydrator 1 2 Description DryLine dehydrators provide a source of dry nitrogen 45 C 50 F dew point or drier for pressurizing large antenna and transmission line systems Output pressure can be set and controlled within the range of 0 3 to 5 Ib in2 2 35 kPa Air pressure is generated by an air compressor and the dry nitrogen is produced by permeable separation of the water vapor and oxygen through a membrane cartridge eliminating the use
32. or the electric current This product is eguipped 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 Danger 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 serviceman if you have any questions regarding grounding or if in doubt as to whether the product is properly grounded Connection to a Halo Grounding System A 10 grounding stud is located at the inside power NXT SERIES DEHYDRATOR USER MANUAL EEE IEEE EI II AAS Aa entry area of the dehydrator chassis for direct connections to a halo grounding system where applicable Connect using a No 6 copper stranded wire terminated at the ground stud with a proper ring tongue crimp on terminal 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 9 Test the Unit Turn on the dehydrator The display should
33. otes 17 NXT SERIES DEHYDRATOR USER MANUAL Power Up Faut S ystem Default System Check Found Call Support M OK System Pressure A PSI or kPa Y Scroll N Ahead SELECT PROGRAM MODE or gt Password gt ENTER gt Enter y 0 1 2 3 4 5 6 7 8 9 or Y Scroll Use default 111111 Ahead SELECT Compressor Runtime ENTER HOURS Y or Scroll ES ru Count Record Ahead N Change i Y E Scroll Clear Runtime Alarm Hit or SELECT Enter to Clear jk ER piu Ahead or Y High A Tank oF 19 Saol Sei ect 9 N ENTER Record Ahead li Change L or Y Scroll N Ahead Record Change Scroll Ahead A To Record Change Scroll Ahead To Sel pate ygan A ENTER Record Change or Y Scroll N Ahead N mdi M Seb lime nour gt ENTER Y Reci lala Change or Y Scroll Ahead SELECT M Figure 9 18 Compressor ON XX X PSI a a or Set Time Minutes ENTER MM M or Y Scroll Ahead SELECT M or Comp Runtime Alarm ENTER XXX Minutes M or Y Scroll Ahead SELECT y AA 3 Scroll Ahead 5 Compressor OFF XX X PSI kPa N Scroll Ahead Low a Alarm XXX PSI y NTER
34. ou 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 proceed to the first programmable feature Shutdown Procedure When removing your dehydrator from service you may need a substitute dry air source Call Andrew Technical Service Telephone numbers are listed on page 28 Before turning off the unit notify personnel that alarms may be activated To shut down the NXT series unit turn the 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 top of the unit NXT SERIES DEHYDRATOR USER MANUAL Theory of Operation Section 5 5 1 5 2 Dehydrator The patented drying system begins at the compressor where filtered ambient air refer to piping schematic pages 7 10 is compressed The compressed air is then cooled and condensed in the heat exchanger after which water droplets are separated in the water filter The saturated air then passes through a coalescing filter for the removal of additional water and particulate and then into the patented membrane cartridge where the remaining water vapor is removed by pressure differential The water separated in the filters is blown to a pan on the head of the compressor
35. r procedures to replace water filter elements In Case of Difficulty If the dehydrator 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 24 6 1 1 6 1 5 Check Water Filter and Coalescent Filter and Elements Verify there is no water build up in the filter bowls If there is 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 corroded electrical connections A loose 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 dehydrator chassis The ground lug screw or stud nut must be tight to provide a proper ground Check Run Time Meter Check the run time meter to determine the duty cycle of the dehydrator If the dehydrator has been running more than 10 of the time check for system leaks Also check to see if it
36. se 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 compressor assembly should now be free of all tubing connections 8 8 8 9 NXT SERIES DEHYDRATOR USER MANUAL Compressor Remount and Reassembly Remove the bolts 6 NXT4500 4 NXT1000 amp NXT2000 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 dehydrator has been dropped or otherwise damaged such that the heat exchanger is leaking
37. settings as shown in sections 4 2 2 The High Presssure Alarm set point must be above the the compressor OFF set point Verify that the high Pressure Alarm set point is set above 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 High Pressure alarm on display Humidity alarm on display Check the dehydrator for build up of water in the filter bowls If there is a build up of water in the water filter bowl use a soapy water solution to check for leaky fittings in the dehydrator If no leak can be found the problem is probably with the compressor Rebuild kits for CAUTION each dehydrator are specified in section 8 The unit may also be returned to Andrew for repair Contact Andrew Technical Service for The humidity sensor is light sensitive further assistance DO NOT remove it from the brass Note fitting when the dehydrator is powered up Once the problem has been corrected run the dehydrator off line until the humidity alarm clears If the membrane dryer has been saturated this process can take up to 48 hours of continuous running Check the programming of the excess run time display as shown in section 4 2 2 The set point should be at least 50 above the normal run time T
38. t of internal diagnostics and meanwhile display as follows X controller revision XX X 1 If a power up test failure is detected the following is displayed system default call support In normal operating state with no alarms the 2 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 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 DryLine dehydrator is equipped with all options all of the screens shown in the flow chart will apply The modes pertaining to high pressure high humidity fixed at 7 5 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 prompti
39. us damage to the wave system safe pressure See specification page for guide due to overpressure can occur options available 2 7 NXT SERIES DEHYDRATOR USER MANUAL Connect to Dry Air Cable System Caution Check the system pressure rating before connecting the dehydrator to the transmission line system If the rating is below 5 Ib in 35 kPa the output pressure of the dehydrator should be adjusted See Section 4 To insure that all internal dehydrator components are properly dried operate the DryLine NXT Series 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 Determine total volume of the pressurized dry nitrogen cable system to be connected to the dehydrator Refer to Table 2 Times to Purge 2 8 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 dehydrator for purging Operate the dehydrator after the initial 45 minute drying period to deliver dry nitrogen 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
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