MT500A SERIES DEHYDRATOR USER MANUAL
Contents
1. Rack Mounting wall mounting or set on shelf Power Connections Confirm your dehydrator electrical input matches the available power 115 VAC 230 VAC 50 60 Hz auto detecting MT500A 81015 MT500A 81315 AC Power AC units can be connected into a standard 15 Amp power receptacle of the proper voltage Make sure the power circuit is properly grounded Two power cords are supplied one 115 VAC American and one 230 VAC International with striped leads CAUTION Proper electrical connection is required It is suggested a licensed electrician be contracted to connect the AC wiring to the unit if it is connected directly to the mains Failure to properly connect the power wires could result in a dangerous electrical shock hazard 2 5 2 6 Test the Dehydrator Turn the dehydrator ON and check the output port on the rear of the unit to make sure air is flowing Connecting the Alarm Outputs To connect the alarms locate the terminal block TB 1 on the rear of the unit Place alarm connection wires in proper terminals an tighten the screw on the terminal block The relay contacts are rated at 2 A non inductive 30 VDC Optional alarms if purchased will also be located on this terminal see section 1 4 for terminal numbers Connecting Dehydrator to the Transmission Line CAUTION Check the antenna and transmission line system pressure rating before connecting the dehydrator to the syste2. Specifications MT500A Dehydrator Output Pressure 0 35 kPa 2 0 5 0 psig Output capacity 14 0 SLPM 0 5 SCFM total approx Output Dew Point 45 C 50 F or better Operating Temperature Range 1 to 40 C 33 to 104 F Low Pressure Alarm 6 9 kPa 1 0 psig Electrical Input 115 230 VAC 50 60 Hz auto detecting Output Connector 3 8 polytube compression Dimensions 43 2 cm H x 26 4 cm W 32 cm D 17 W x 10 4 H x 12 6 D Weight 16 55 kg 36 1 2 Ibs Optional Alarms High Humidity Alarm Set Point 7 5 RH factory set Power Fail Alarm loss of input power MT500A SERIES DEHYDRATOR USER MANUAL Installation Section 2 2 1 Unpacking and Inspection Open carton Mode 1 Displays pressure and total run hours Remove the top piece of closed cell foam packaging Carefully remove the installation accessories and manual and dehydrator Check the dehydrator for shipping damage such as dents or loose parts 2 2 Controls and Displays Familiarize yourself with the controls and Mode 2 Displays pressure and total run hours displays prior to installing or testing the flashes current condition dehydrator ON OFF MODE Switch Switch Mode 3 Displays last ON and last OFF times ON OFF Switch Toggles unit condition ON and OFF Mode Switch Toggles between display modes 2 3 2 3 1 2 4 2 4 1 MT500A SERIES DEHYDRATOR USER MANUAL Installing the Dehydrator 19
3. the overhaul 11 MT500A SERIES DEHYDRATOR USER MANUAL Notes MT500A SERIES DEHYDRATOR USER MANUAL If you experience difficulty with your dehydrator use the troubleshooting procedures described below If the display light fails to light make sure the unit is plugged in and power outlet 15 operating If you still have no light unplug the unit remove the unit cover and check for loose connections Refer to the wiring diagram for Dehydrator display does not light unit does not run proper connections Check to assure that the fuse 15 OK on the controller Check to assure that proper AC voltage is being supplied to the input Check the display on the controller Toggle the ON OFF switch Compressor does not turn OFF left of the display Check input power polarity and voltage per wiring diagram MT500A SERIES DEHYDRATOR USER MANUAL ule 32 plouajos puno19 SLEL8 VOOSLIN Aogz due 8 asn y JOU9S 5 998J 19 U 14 MT500A SERIES DEHYDRATOR USER MANUAL S1018 WOOS _LIN puno19 10 indu A UIEN 991 19101140 LIN 998J19 u plouajos Jossaidwog 15 MT500A SERIES DEHYDRATOR USER MANUAL Notes MT500A SERIES DEHYDRATOR USER MANUAL The following 15 a list of the replacement kits for the MT500A Series dehydrators Overhaul Kit MT500A KIT OVRHL Filter Ele
4. 2 Description MT500A Series dehydrators provide dry air for pressurizing medium up to 120 cubic feet or 2830 liters in volume antenna and transmission line systems The dehydrators produce 50 F 45 C dew point dry air at nominal rate of 0 5 standard cubic feet 14 liters per minute SCFM Each dehydrator consists of an electrically driven air compressor a membrane dryer assembly an automatic transmission line pressure sensing system and alarm outputs housed in rigid metal chassis It is designed to mount directly to the rack directly on a wall or as a free standing unit The front panel features a control interface with display for alarms and pressure For easy serviceability power connections alarm output connections and all filter elements are accessible from the outside or through easy to access service panels The MT500A maintains transmission line pressures from 2 0 to 5 0 psig 14 34 kPa It is intended for standard microwave antenna applications and any other transmission line pressurization requirement that supports a medium pressure limit Theory of operation The MT500A series of DryLinee dehydrators while similar in moisture removal technology operates differently than some of the DryLinee series of dehydrators In order to maintain a positive constant level of pressure to medium air volume systems and to maintain an acceptable dryness level in the product air stream a downstream pressure s
5. HYDRATOR USER MANUAL Alarms The MT500A offers Low Pressure Compressor Pressure and Power Fail alarms as a standard feature Alarm conditions are indicated on the display Alarms are output as alarm conditions are indicated on the display Alarms are output as a common summary alarm with a form C dry contact The alarm 15 set for continuity on alarm Multiple Alarm Option This optional assembly is designed to provide the additional High Humidity alarm to Andrew Dehydrators All alarms are Form C dry contacts and are factory set for continuity at alarm mains power fail alarm opens at alarm This optional assembly will also indicate discrete alarms on the display and provide individual contacts and connections for discrete alarms The external alarm monitoring system supplied by others is connected to the terminal strip located on the rear of the cabinet small slotted screwdriver 15 necessary to make the connections Term 1 2 3 4 5 6 T 8 Figure 1 Function Wire Color Power Fail Com Black Power Fail Alarm Red Humidity Com Green Humidity Alarm Brown Dryer Press Com Blue Dryer Press Alarm White Low Press Com Gray Low Press Alarm Orange Alarm Definitions Power Fail Activates open when power is removed from the dehydrator This includes turning the power off at the switch High Humidity Activates when system or dehydrator output humidity rise above 7 5 relative humidity At initial
6. MTSOOA SERIES DEHYDRATOR USER MANUAL Bulletin AE01B A0529 001 Rev Date 17 July 06 MT500A SERIES DEHYDRATOR USER MANUAL SECTION 1 General Information Introduction Description Theory of operation Alarms Specifications dd SECTION 2 Installation Unpacking and Inspection Controls and Displays Installing the Dehydrator Power Connections Connecting Alarms Output Connecting Dehydrator to the Transmission Line Purging the Transmission Line O A AA YA O OO SECTION 3 Maintenance 9 Maintenance 9 Preventive Maintenance 9 Dehydrator Filter Element Replacement 9 Annual Inspection 9 0 1 Parts Replacement and Dehydrator Overhaul 1 Service Restoration Recommendation 1 SECTION 4 Troubleshooting 13 Problem Solution Table 13 Schematic Diagram with All Option 81315 14 Without Alarm Schematic Diagram 81015 15 SECTION 5 Replacement Parts 17 Overhaul Kit 17 Element Replacement 17 Filter Bowls 17 Filter Bowls and Dryer Tube Replacement 17 Solenoid Replacement SECTION 6 Customer Service 17 Introduction 17 In Case of Trouble 17 Initial Step 18 Return Goods Instruction 18 Repair Center Process 18 Loaner Units 18 Warranty 19 1 1 MT500A SERIES DEHYDRATOR USER MANUAL Introduction This manual contains the information you need to install operate and maintain your MT500A Series DryLinee dehydrator Please take the time to read this manual before attempting to operate or service the unit 1
7. aner unit of the same type was supplied by Andrew use the loaner unit box to return the original dehydrator Repair Center Process The Andrew Dehydrator Repair Center will receive your unit and inspect it for any transport damage The unit will then be analyzed for troubles using the description you have supplied and the specialized experience the Repair Center staff have with dehydrators If the unit is in warranty repairs are made at no charge and the unit will be returned to you by the same mode of transport as it was received If the unit is in warranty but no problems are found the unit will be thoroughly tested before being returned to you Anominal inspection fee will be charged for this service If your unit is out of warranty it will be inspected and repaired for the quoted fee Loaner Units The Andrew dehydrator Repair Centers stock a limited number of loaner dehydrator units of both current and discontinued products These units while not new are still in excellent working order Loaners are available on a first come first served basis They are issued in conjunction with the original RGN and are invoiced at a nominal price You will need to request a second RGN to return the loaner unit A credit memo is issued by the Repair Center when a loaner is returned MT500A SERIES DEHYDRATOR USER MANUAL AS ANDREW Andrew Corporation Small and Medium Capacity Dehydrator and Line Monitor Syst
8. ax only in Europe 44 1592 782380 Fax only any Location to USA 708 349 5410 Fax only Initial Steps by Andrew 6 4 When your call or fax communication 15 received the Andrew staff will work with you to pinpoint the possible cause of trouble If the pressurization equipment is suspect they will ask for your unit Model Number and Serial Number e check the warranty status of the unit e advise the availability of a loaner unit provide of the cost for inspection and repairs if the unit is out of warranty e Return Goods Authorization Sheet to you Return Goods Instructions After you have contacted Andrew and received a 6 5 Return Goods Authorization Number RGN you will need to take the following steps to send the faulty unit to a Repair Center make a copy of the Return Goods Authorization Sheet that was faxed to you write a brief description of the trouble you are encountering and attach this to the copy of the sheet pack the unit with at least 4 inches of protective packaging on all sides enclose the authorization sheet and trouble description within the box enclose a purchase order or other method of payment for non warranty repairs 18 mark the outside of the box with the RGN return the box to the Repair Center address listed on the authorization sheet If you have saved the original packaging that came with the unit use it to return the dehydrator for repair If a lo
9. ed time check the systems for leaks Also check the time on the meter to determine if it is time to perform the 6000 hour overhaul Parts Replacement and Dehydrator Overhaul Andrew MT500A Dehydrators are designed to give many years of trouble free service and require very minimal maintenance The dehydrator contains as a standard feature an hour meter that records compressor run hours To ensure continuous and reliable operation the dehydrator must be overhauled every 6000 hours of compressor operation The kits shown in Section 5 contain all of the necessary parts to perform this overhaul The dehydrator overhaul kit includes parts to overhaul the compressor and critical components in the dehydrator that often become worn over time N CASE OF DIFFICULTY If the dehydrator is not operating refer to Section 2 on Installation and Section 4 on troubleshooting the unit Tools The following tools are used in the maintenance and overhaul procedures Adjustable open end wrench Allen wrench 5 32 2 Phillips screwdrivers Small flat blade screw driver MT500A SERIES DEHYDRATOR USER MANUAL Overhaul Procedure Unplug the unit from the power supply When the MT500A compressor run time reaches Follow the instructions included in the 6000 hours or a multiple of 6000 hours it is compressor overhaul kit When the overhaul time to replace certain items in the compressor is complete reinstall Complete overhaul can and the air path
10. em Three Year Warranty Seller warrants that any Andrew MT050 MT XT300 MT XT500 MR050 PMT200 and ODPMT200 series number 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 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 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 Expressly excluded from the terms of this warranty are defects caused by i 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 equipment Seller repairs or replaces pursuan
11. ensor is utilized for controlling the operation of the unit This feedback controlled sensor prompts the unit to engage at 2 0 psig and shut down at 5 0 psig In addition to monitoring the downstream flow the system is also set up to utilize the downstream flow to provide the dry air for the feedback loop The feedback loop is necessary to maintain the dryness of the membrane cartridge and will consume a small percentage of the air supplied by the dehydrator During normal operation the bleed air in the feedback loop will cause the pressure to slowly drop in the downstream air flow and the MT500A compressor will cycle automatically These cycles will take place regardless of the system volume or condition of the transmission line the dehydrator is connected to The rate of these cycles however will vary When connected to a normal system the dehydrator s duty cycle should not exceed 10 and will maintain the system pressure between 2 0 psig and 5 psig If the duty cycle significantly exceeds 10 check the system for leaks When open to atmosphere the dehydrator will run continuously and provide approximately 0 5 SCFM The display will also reflect a pressure between O and 5 0 psig while the output flow is between 0 and 0 5 SCFM The pressure sensor measures pressure beyond the flow control orifice and will show the actual pressure in the transmission lines or to the distribution manifold 1 4 1 4 1 MT500A SERIES DE
12. installation this alarm will continue to alarm until the system has been properly purged Compressor Pressure X R If upstream pressure drops below 35 psig during operation of the compressor the system will display a Dryer Pressure low message If this condition lasts for longer than 30 seconds the alarm contact is triggered alerting the alarm relay of the issue This alarm can be reset by resetting the power of the unit Low Pressure Alarm Summary Alarm Alarm Low Pressure Mains Power Dryer Press High Humidity If system pressure falls below the low pressure trigger point the low pressure alarm sensor will activate an alarm contact This alarm is an indication of a significant system leak or a dehydrator failure Changing Alarm Outputs Factory setting Where To Reset TB3 on Control Board Normally Open N O Multiple Alarms Factory setting Where To Reset Normally Low Pressure Open N O jumper JP4 on A B alarm PCB Normally Power Fail Closed N C Jumper JP3 on B C Alarm PCB Normally Jumper JP1 on Open N O Run Alarm A B PCB Normally Jumper JP2 on Open N O Alarm PCB A B MT500A SERIES DEHYDRATOR USER MANUAL 1 5 J2 J4 J5 JP2 Press Switch PS2 Humidity Sensor Main Power Power Selector Input A B DC B C JP1 Compressor Excess Alarm Timer 10 min J3 Timer Connection JP3 Compressor Voltage Timer Set 120V JP4 Aux A N O
13. l Inspection Inspection includes checking for loose or damaged hoses fittings and electrical connections Open the top cover and front door and verify that there is no water build up in the two filter bowls located inside the front cover of the dehydrator There may be some droplets of water in the filter bowels the lower portion of each bowl but there should be only a small amount of liquid in either bowl MT500A SERIES DEHYDRATOR USER MANUAL If there is excessive water refer to the troubleshooting section Replacement of the filter elements in the water filter and coalescing filter is covered in the overhaul section of this manual 34 Check the electrical connections Check the screw at the power input connector to ensure that the AC power cord 15 securely terminated Check the screw in alarm terminals to ensure that all wire connections are tight A loose or damaged connection may result in erratic operation and unnecessary downtime Refer to the troubleshooting section if an electrical problem is encountered Check the ground wire Check that an electrical safety ground 15 installed on the stud on the rear of the dehydrator This connection point is adjacent to the power input connector It is intended to be customer installed in the field 10 Check the hour meter on the front panel to determine the duty cycle of the dehydrator f the dehydrator has been running for more than 10 of its install
14. m Using included Teflon tape pneumatic thread sealant screw one of the included 3 8 compression fittings into the output bulkhead There is an elbow and a straight compression fitting included with the unit Insert one end of the 3 8 poly tube feed line tubing into the compression fitting on the dehydrator output port Tighten securely with a 9 16 wrench Be careful not to over tighten Connect the other end of the poly tube to the transmission line MT500A SERIES DEHYDRATOR USER MANUAL Note If the transmission lines have not been purged continue with section 2 7 Otherwise proceed to section 3 2 1 Purging the Transmission Line Air in the transmission line system must be replaced with dry air to ensure satisfactory operation of the transmitted signal 1 Determine the total system volume 2 Divide the system volume by the flow rate of the dehydrator 30 SCFH to determine the number of hours needed for one purge cycle 3 Open the far end of the transmission line 4 Operate the dehydrator for no less than three purge cycles If it is not possible to open the far end of the transmission line follow these steps 1 Connect the dehydrator to the transmission line and pressurize the system The system pressure should reach 5 0 Psig 2 Wait 15 minutes while the air absorbs moisture in the system then disconnect the dehydrator from the transmission line and allow the air to vent 3 Repeat
15. ment Replacement Kit MT500A KIT ELMNT Filter Bowl Assemble Replacement Kit MT500A KIT FLTRS Filter Bowl Assemble and Dryer Tube Replacement Kit MT500A KIT DRYER Solenoid Replacement Kit MT500A KIT SOLND 17 Introduction Andrew provides in warranty and out of warranty repairs as well as dehydrator and compressor overhauls from several Repair Centers Coordination of these services is provided through the nearest Sales Office or Customer Service Center The Center is also prepared to help you with the following Technical Assistance Troubleshooting Repairs Loaner Units Spare Parts Installation Materials System Accessories In Case of Trouble The first step you should take if trouble develops using a dehydrator is to read the operators manual and follow the trouble isolating procedures given in it If the steps in the manual do not identify and remedy the problem then contact an Andrew Customer Service Center for 24 hour telephone assistance Record the Model Number e g MT500A and Serial Number from the product label as you will be asked for these when you call Two main locations are currently available to help in North America 1 800 255 1479 in Europe 44 1592 782612 any Location to USA 708 349 3300 6 2 6 3 MT500A SERIES DEHYDRATOR USER MANUAL If you find it easier to describe your troubles by Fax then the following numbers are also available in North America 1 800 349 5444 F
16. of the dehydrator These include be done without removing the compressor the piston cups piston seals and head gaskets from the chassis The compressor head of the compressor the filter elements in the air filter output port and relief valve can all be water and coalescing filters and the tube section removed though top panel When the overhaul connecting the compressor output to the heat is complete reinstall exchanger 3 5 Service Restoration RECOMMENDATION In addition if the unit gives the dryer pressure alarm the compressor may be in need of an If the dehydrator overhaul process has taken overhaul This does not always coincide with more than a few hours it is recommended the 6000 hour time frame If the dryer pressure that the unit be run for one hour into the alarm is triggered check the system for leaks If room to purge the membrane dryer of any no leaks are detected the compressor will need acquired moisture before reconnecting to the to be overhauled transmission line system Unit Shutdown and Removal In order to perform an overhaul on the MT500A the unit must be turned off and removed from service As this is being done the low pressure alarm may activate through a reporting alarm system Personnel monitoring such an alarm should be notified in advance so that they are aware of the fact that service is being performed It is also necessary to disconnect the dehydrator dry air output from the waveguide system during
17. steps 1 and 2 twelve times to purge the system 3 0 3 1 MT500A SERIES DEHYDRATOR USER MANUAL Maintenance The MT500A Dehydrator requires relatively little maintenance to ensure satisfactory operation over long periods of time This section outlines the recommended annual preventive maintenance for the unit and the suggested overhaul for every 6000 hours of compressor operation Preventive Maintenance The annual maintenance of a MT500A consists of a preventative maintenance inspection of the dehydrator and replacement of the foam air intake filter These tasks can easily be performed in the field with the unit connected to the transmission line system and with only the front and side access doors opened for maintenance In addition to the annual inspection a complete overhaul 15 recommended every 6000 hours or sooner if local conditions warrant 3 2 Dehydrator Filter Element Replacement Replace the air intake filter The air intake filter protects the compressor from contamination and dust Periodic replacement extends the life of the compressor To gain access to the element push in on the cover and rotate the house approximately 1 4 turn CCW The filter is made of a fibrous material It should be replaced once a year or more frequently if the operating environment is very dusty 3 3 Make sure the element is seated completely in the housing and then replace the cover Discard the old element Annua
18. t 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 THE EQUIPMENT MANUFACTURED BY 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 2 0706 MT500A SERIES DEHYDRATOR USER MANUAL D REW One Company A World of Solutions Andrew Corporation Customer Support Center All designs specifications and availability of products and services presented in this 10500 W 153rd Street From North America bulletin are subject to change without notice Orland Park IL 60462 USA Telephone 1 888 889 9485 Bulletin AE01B A0529 001 6 06 International 2006 Andrew Corporation Orland Park IL 60462 USA Telephone 1 708 873 2307 Fax 1 708 349 5663 Internet www andrew com
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