Model AIR 1500TML3

Operating Manual

OPERATING MANUAL

MODEL AIR 1500TML3-1D

MODEL AIR 1500TML3-2D
MODEL AIR 1500TML3-3D

AIR DRYER

Mail Address:
226A Commerce St.
Broomfield, CO 80020

Tel: 303- 465-3063

Fax: 303-465-9294
1

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual

TABLE OF CONTENTS
1.0
2.0
3.0
4.0
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
6.0
6.1
6.2
6.3
6.4
6.5
7.0

8.0

GENERAL ................................................................................................................ 3
SPECIFICATIONS ................................................................................................... 3
INSTALLATION AND START-UP PROCEDURES .................................................. 4
PRINCIPLES OF OPERATION................................................................................ 4
Figure 1 Air Flow Diagram .................................................................................... 5
COMPONENT DESCRIPTION ................................................................................ 5
AIR COMPRESSOR ................................................................................................ 5
HEATLESS DRYER ................................................................................................. 6
Figure 2 Heatless Dryer Operation ....................................................................... 7
HEATLESS AIR DRYER, CAPACITY CONTROL VALVE, & PRESSURESWITCH 7
Figure 3 Pressure Switch Adjustment Screws ...................................................... 8
HUMIDITY ALARM SYSTEM................................................................................... 8
LOW OUTLET PRESSURE REGULATOR & GAUGE ............................................ 9
OUTLET PRESSURE ALARMS .............................................................................. 9
COMPRESSOR POWER CONTACTOR ............................................................... 10
EXCESS COMPRESSOR RUN TIME ALARM CIRCUIT....................................... 10
CONTROL BOARD ................................................................................................ 10
MAINTENANCE ..................................................................................................... 11
SIX MONTH MAINTENANCE AND INSPECTION................................................. 11
ANNUAL MAINTENANCE AND INSPECTION ...................................................... 11
TWO YEAR MAINTENANCE AND INSPECTION ................................................. 11
AIR COMPRESSOR MAINTENANCE KIT P/N 9537 ............................................. 11
HEATLESS DRYER MAINTENANCE KIT INSTALLATION P/N 7595 ................... 11
PARTS IDENTIFICATION...................................................................................... 12
Figure 4 Front View ............................................................................................. 12
Figure 5 Wiring Diagram ..................................................................................... 13
Figure 6 Heatless Dryer Exploded View and Parts List ....................................... 14
DISCRETE ALARM BOARD .................................................................................. 15
Figure 7 Optional Alarm Board............................................................................ 15

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual

1.0

2.0

GENERAL
1.1

This manual covers the specifications, installation, start-up, operation, component description,
parts list, air flow schematic, wiring diagram and maintenance procedures for the Model
AIR 1500TML3 portable air dryers. This unit was designed as a portable dryer to provide a
continuous dry air flow at adjustable pressures of 0 2.7 PSIG for continuous feed pressure
cables, pipe systems and other systems requiring dry air.

1.2

The air dryer carries a One Year Warranty against defective workmanship and materials starting
from the date of shipment. Only parts are covered, labor to replace defective parts is not covered
by this warranty. All units are tested and inspected before shipment. Any damages incurred in
transit should be reported to the carrier immediately upon receipt. The manufacturer is not
responsible for damage caused during shipment.

SPECIFICATIONS

PART NUMBER
AIR 1500TML3-1D

AIR DRYER, 115V/60Hz

AIR 1500TML3-2D

AIR DRYER, 220V/50Hz

AIR 1500TML3-3D

AIR DRYER, 115V, WITH DISCRETE ALARM BOARD

NORMAL OUTPUT CAPACITY

1000 SCFD (28.3 Cubic Meters per Day)

EMERGENCY OUTPUT CAPACITY

1500 SCFD (42.6 Cubic Meters per Day)

COMPRESSOR MOTOR

115 Volts, 60 HZ -1/2 H.P., Rocking Piston Type.

220 Volts, 50 HZ -1/2 H.P., Rocking Piston Type

DELIVERED AIR HUMIDITY

Under 1% at 70F (21C)

DEWPOINT

-40F (-40C)

DELIVERED AIR PRESSURE

Adjustable, 0 - 2.7 PSIG

OPERATING TEMPERATURES

Standard: 115 Volts, Single Phase, 60 Hz., 5 Amps

Optional: 220 Volts, Single Phase, 50 Hz., 2.5 Amps
Minimum: 33F (0.5C)
Maximum: 20F (49C)

WEIGHT

96 Pounds (43.6 KG)

DIMENSIONS

20"wide (50.8 cm), 15"deep (38.1 cm), 25"high (63.5 cm)

POWER REQUIREMENTS

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual

3.0

4.0

INSTALLATION AND START-UP PROCEDURES

3.1

Rubber feet are provided for floor mounting, remove the shipping bolts from the wooden base,
remove the base, and discard. Install the rubber feet. The unit should be located in a wellventilated area that will allow for suitable air circulation.

3.2

The air dryer is designed to operate from a 115 volts, single phase, 60 Hertz power supply
(Optional 220 volts, single phase is also available). Connect the incoming power to the terminal
block located behind the electrical cover plate. The unit should be connected to a 15 Amp circuit.
Install control board module and connect the wire harness cable and the air sensor tube.

3.3

Check that the capacity control valve gauge reads 80 PSIG (+/- 2 PSIG) as soon as the air
compressor starts.

3.4

The system pressure should quickly rise to 80 PSIG (+/-2 PSIG) and the air compressor/heatless
air dryer system should shut off. Remove the black cover on the low pressure regulator. Using a
straight blade screwdriver and turn the knob clockwise to relieve air through the air outlet and
check that the compressor/dryer system starts when the system pressure drops to 30 PSIG (+/- 2
PSIG).

3.5

Allow the air dryer to run for 15 minutes then turn off the dryer and connect the cable/pipe system
to the air outlet of the air dryer using 3/8 plastic tubing.

3.6

Adjust the outlet pressure regulator to the desired cable pressure and allow the pressure in the
cable/pipe system to stabilize.

3.7

Once installation is complete and the start-up procedure has been performed, test for leaks at all
external air connections. Operate the unit for 24 hours and repeat the start-up procedure

PRINCIPLES OF OPERATION
4.1

An air flow diagram of the air dryer is shown in figure 1. The system supplying the dry outlet air
includes an air compressor, a pre cooler, an air filter, a heatless air dryer with a capacity control
valve and gauge, an air storage tank, an outlet regulator and a system control board.

4.2

Ambient air is drawn in through the intake filters into the air compressor where it is compressed to
80 PSIG. The hot, moist air then flows through the pre cooler where the air is cooled and then into
the air filter where any liquid water and particulates are taken out, the air is then directed to the inlet
of the heatless air dryer.

4.3

Moisture is removed from the air as it passes through the heatless air dryer. The dry air leaving the
heatless air dryer is routed through the capacity control valve, which functions as a check valve
and also maintains a constant 80 PSIG in the heatless dryer.

4.4

From the capacity control valve, the dry air flows into the air storage tank. The air pressure in the
air tank is monitored by the pressure switch, which turns on and off the air compressor to maintain
pressure between 30 and 80 PSIG in the tank. Air moves from the tank through the humidity tube
where the humidity sensor constantly monitors the humidity level of the air before passing the air
on to the outlet pressure regulator and to the air outlet.

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual
Figure 1 Air Flow Diagram
HEATLESS AIR DRYER

Figure 1 - Air Flow Diagram

CAPACITY
CONTROL
GAUGE

UNLOADER
VALVE
Dry Air

Humid Air

PRE-FILTER

PRE-COOLER

AIR COMPRESSOR

CAPACITY
CONTROL
VALVE

HUMIDITY BY-PASS
VALVE

TO CONTROL
LOW PRESSURE
BOARD
OUTLET
HI-LOW PRESSURE
REGULATOR
SENSOR

SAFETY RELIEF
VALVE

HUMIDITY
TUBE
AIR
STORAGE
TANK

DRY AIR
OUTLET

AIR COMPRESSOR
PRESSURE SWITCH

OUTLET
PRESSURE
GAUGE

5.0

SYSTEM
PRESSURE
GAUGE

COMPONENT DESCRIPTION
5.1

AIR COMPRESSOR
P/N 7932 (115 Volts)
P/N 7934 (220 Volts)
P/N 7614
P/N 7615
P/N 9632
P/N 8132
P/N B-431
P/N 7503 (115 Volts)
P/N 7511 (220 Volts)

AIR COMPRESSOR
AIR INTAKE FILTER
FILTER ELEMENT
SAFETY RELIEF VALVE
AIR PRECOOLER
FLEX LINE
UNLOADER

5.1.1

The air compressor is a rocking piston type, which is driven by a H.P. motor. It requires
no lubrication. The motor is equipped with built-in thermal overload protection. If the
overload shuts down the compressor due to a thermal overload, the motor will
automatically reset after cooling down.

5.1.2

An air intake filter is mounted in the inlet port of the cylinder head. The filter assembly has
a replaceable filter element that should be replaced every six months. To replace the
element, remove the filter housing from the compressor by holding the filter base and
turning the housing counter-clockwise. Then take the housing and turn each end in
opposite directions to separate the two housing halves. Remove the filter element out of
the housing. Clean the housing with a cloth and install a new filter element, then screw the
two halves back together.

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual

5.2

5.1.3

A safety relief valve is installed in the air compressor head to prevent the pressure in the
compressor from building to more than 125 PSIG.

5.1.4

The pre cooler is used to cool the hot compressed air to aid the drying process. It is
mounted between the air compressor/flex line and the pre-filter.

HEATLESS DRYER
P/N 12030-122 (115V)
P/N 12030-422 (220V)
P/N P4634
P/N P3197
P/N F18-02-SH00
P/N FRP-96-639
P/N 10040

HEATLESS AIR DRYER

CAPACITY CONTROL VALVE
CAPACITY CONTROL GAUGE
PRE-FILTER
PRE-FILTER ELEMENT
PURGE MUFFLER
5.2.1

The pre-filter with the auto drain removes liquid moisture and any particulate matter from
the air-cooled in precooler. The heatless air dryer removes virtually all moisture from the
supply air using desiccant and pressurization. The capacity control valve is used to
maintain a constant back-pressure in the heatless air dryer. It also prevents more than the
maximum emergency flow rate from flowing through the outlets and serves as a check
valve to prevent dry air from the air storage tank from flowing back through the heatless
dryer when the compressor shuts down.

5.2.2

Moist air entering the inlet of the heatless dryer manifold is routed into one of the two
desiccant chambers as determined by which one of the solenoid valves is energized. The
two solenoid valves are alternately energized and de-energized by the cycle timer at 30second intervals. As the air passes across the desiccant in the chamber, water vapor is
adsorbed and held on the desiccant. The dry air at the top of the desiccant chamber exits
down through a center tube to the purge orifice gland. The check valve ball just below the
gland is pushed downward which allows the dry air to enter the outlet passage in the
manifold. Most of the dry air is then delivered to the air storage tank through the capacity
control valve (See Heatless Dryer Operation - Figure 4).

5.2.3

While one of the desiccant chambers is drying the supply air, water vapor is being removed
from the desiccant in the other chamber. The solenoid valve associated with this chamber
is de-energized, which opens the chamber to atmosphere. A small portion of the dry air in
the outlet passage is routed through the orifice in the side of the purge orifice gland and is
expanded to just above atmospheric pressure. Because there is virtually no pressure in
the desiccant chamber, the spring below the check valve ball holds the ball against its seat
on the bottom of the purge orifice gland. This forces the dry air to pass up through the
center tube and then over the desiccant. As the expanded dry air passes across the
desiccant, it removes the water vapor and carries it out of the dryer through the solenoid
valve.

5.2.4

The above process reverses every 30 seconds.

5.2.5

The pressure in the heatless air dryer is critical to the drying process. It must be
maintained at 80 PSIG (+/- 2 PSIG) as read on the capacity control valve gauge whenever
the air compressor is operating. To adjust the capacity control valve, allow the system
pressure to drop to 30 PSIG and the air compressor to start. Pull the adjustment knob out
away from the valve body and turn the adjustment knob either clockwise to raise the
pressure or counterclockwise to lower the pressure. Once the adjustment has been made,
push the knob back towards the valve body to lock it.

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual

80 PSIG

0 PSIG

80 PSIG

Figure 2 Heatless Dryer Operation

5.3

HEATLESS AIR DRYER, CAPACITY CONTROL VALVE, & PRESSURESWITCH

SAFETY RELIEF VALVE
SYSTEM PRESSURE GAUGE
SYSTEM PRESSURE SWITCH

P/N 7321
P/N 9530
P/N 52096

5.3.1

The air storage tank is an ASME coded steel pressure vessel with a safety relief valve
installed to insure the pressure inside the tank does not exceed 80 PSIG. The system
pressure gauge reads the pressure inside the air storage tank.

5.3.2

The system pressure switch senses the pressure in the air storage tank and energizes the
air compressor and heatless air dryer (via the control board) when the system pressure
drops to 30 PSIG and de-energizes the power when the pressure reaches 80 PSIG.

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual
5.3.3

The system pressure switch is adjustable. Remove the cover and use the adjustment
screws as required. The cut-in pressure adjustment screw is used to raise or lower both
the energize pressure and the de-energize pressure together. The differential pressure
adjustment screw will change the differential between the two pressures.

DIFFERENTIAL
PRESSURE

CUT-IN PRESSURE

Figure 3 Pressure Switch Adjustment Screws

5.4

HUMIDITY ALARM SYSTEM

HUMIDITY SENSING TUBE
HUMIDITY SENSING ELEMENT
HUMIDITY TUBE O-RING
HUMIDITY TUBE HEX NUT
HUMIDITY TUBE PLUG ADAPTER
HUMIDITY BYPASS SOLENOID VALVE
MUFFLER

P/N
P/N
P/N
P/N
P/N
P/N
P/N
P/N

9162
P5000647D
5000-1-18C
5000-6-47J
7447
7509 (115V)
7515 (220V)
10040

5.4.1

The humidity alarm system prevents wet air from being delivered to the dry air outlet of the
air dryer. It diverts the wet air from the air tank out of the system and provides both a
visual alarm indication and a dry alarm contact closure when an alarm condition exists.

5.4.2

Air in the air storage tank is monitored by the humidity sensing element in the humidity
sensing tube. The sensing element is connected electrically to the sensor terminals of the
control board. If this sensor circuit becomes disconnected the open circuit alarm will be
activated (see section 5.4.7).

5.4.3

The humidity bypass solenoid is connected to the control board. Under normal operating
conditions, the solenoid valve is energized, allowing dry air to flow on through to the outlet
regulator.

5.4.4

If the air in the air storage tank exceeds an acceptable level of moisture, the sensing
element sends a signal to the control board. At this point, the board de-energizes the
humidity bypass solenoid valve (green diagnostic lamp LD8 will light on the control board).
When de-energized, the solenoid valve diverts the wet air from the system into the
atmosphere.
At the same time, the control board will energize the yellow humidity alarm condition lamp (
LD11) on the control board. If the humidity condition remains after one minute, the red
control board alarm lamp (LD4) and (LD1) will be activated, and the external humidity
alarm pair will be activated. If after 30 minutes the humidity level does not return to normal
then the air dryer will automatically shut itself down and the shut-down lamp (LD7) will be
energized. To clear the humidity alarm push the alarm reset switch located on the control
board.

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual

5.5

5.4.5

If exposed to high humidity conditions for an extended length of time the sensing element
can fail. Therefore, after the cause of high humidity condition has been repaired, the
sensing element should be replaced. It is also recommended that the humidity alarm
system be tested whenever routine maintenance is performed.

5.4.6

Test the humidity alarm system by removing the sensing element cable from the adaptor at
the top of the humidity tube and plugging in a humidity test plug (Pentras P/N 7508). Once
the cable is on the humidity test plug the humidity alarm conditions should follow as
outlined in 5.4.3 and 5.4.4. (Note: If the air dryer has just been turned on, all the alarms
are delayed for two minutes until the dryer is up to operating conditions. If the humidity test
plug is plugged in on start up, it will be two minutes before the (LD11) alarm is activated).
After testing, remove the humidity test plug and return the humidity sensing element cord
to the adapter on top of the humidity sensing tube.

5.4.7

The humidity system is also equipped with an open circuit alarm in the event the humidity
sensor cable is left unplugged. If the cable is unplugged the yellow diagnostic lamp (LD10)
will energize and after a one minute delay the red humidity/open circuit alarm lamp (LD4)
will energize as well as the humidity alarm lamp on the front panel and the alarm pair will
be activated.

LOW OUTLET PRESSURE REGULATOR & GAUGE

LOW OUTLET PRESSURE REGULATOR
LOW OUTLET PRESSURE GAUGE

5.6

P/N 9540
P/N 7984

5.5.1

The outlet pressure regulator and outlet pressure gauge are mounted on the outlet
pressure regulator. The regulator reduces the pressure of the air to the desired outlet
pressure. The maximum range of the regulator is 2.7 PSIG.

5.5.2

Remove the black cover on the regulator and using a straight blade screwdriver, turn the
knob clockwise to raise or counterclockwise to lower the pressure at the air outlet.

OUTLET PRESSURE ALARMS

5.6.1

The pressure at the outlet of the outlet pressure regulator is monitored by the outlet
pressure alarm circuit.

5.6.2

The high and low pressure alarm switches are mounted on the control board. They are
connected pneumatically via a pressure sensor tube (blue tubing) to the outlet of the outlet
pressure regulator

5.6.3

The alarm switches are factory set to provide an alarm when the outlet pressure drops to
0.1 PSIG or rises to 1.0 PSIG but can easily be reset to preferred alarm pressures.

5.6.4

Low outlet pressure alarm switch adjustment:

Using the outlet pressure regulator, lower the outlet pressure to the desired alarm pressure
point. With a screwdriver turn the dial on switch R2 slowly counterclockwise to reduce the
setting and clockwise to increase the setting. When the yellow diagnostic Low Set LED
light comes on, the point is set. After a one minute delay, the red alarm lamp (LD3) will
energize, as well as the front panel outlet pressure alarm lamp, and the alarm pair will be
activated. To reset the alarm push the reset switch located on the front display panel.

5.6.5

High outlet pressure alarm switch adjustment:

Using the outlet pressure regulator, raise the outlet pressure to the desired alarm pressure
point. With a screwdriver turn the dial on switch R1 slowly counterclockwise to reduce the
setting, and clockwise to increase the setting. When the yellow diagnostic High Set LED
light comes on, the point is set. After a one minute delay, the red alarm lamp (LD2) will
energize, as well as the front panel outlet pressure alarm lamp, and the alarm pair will be
activated. To reset the alarm push the reset switch located on the front display panel.

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual
5.7

COMPRESSOR POWER CONTACTOR

COMPRESSOR POWER CONTACTOR

5.7.1

5.8

5.9

P/N 11247 (115V)

P/N 7475 (230V)

Power to the air compressor and the heatless air dryer is supplied through the heavy-duty
30-ampere contacts in the compressor power contactor. The coil of the contactor is
connected electrically through the system control board to the pressure switch (section 5.3)
and is only energized when the contacts in the pressure switch are closed.

EXCESS COMPRESSOR RUN TIME ALARM CIRCUIT

5.8.1

The excess compressor run time alarm circuit provides an alarm signal in the event the
system pressure switch remains closed for more than approximately 12 minutes. An
excess run time alarm could be an indication of an air leak in the pressure system or
deterioration in the performance of the air compressor. Once a run time alarm is brought
in, it locks in, and must be manually cleared using the reset switch located on the control
board.

5.8.2

When the system pressure switch closes, a 12 minute timing cycle begins on the control
board. If the pressure switch opens before 12 minutes, the timing cycle ends. If the
pressure switch remains closed for the complete timing cycle, the delay relay energizes the
excess run time LED (LD5) on the control board and the alarm pair will be activated. Once
energized, the alarm must be manually reset by pressing the reset switch located on the
control board.

CONTROL BOARD
P/N 8115 (115V)
P/N 8116 (220V)
The air dryer is designed to operate from a 115 volts, single phase, 60 Hertz external
power source (Optional 220 volts, single phase, 50 Hertz power unit is also available)
Refer to Figure 6 on page 15, for a detailed electrical circuit diagram for the air dryer.
CONTROL BOARD

5.9.1

5.9.2

The control board monitors the system pressure and humidity levels controls the dryer
according to these inputs. It also manages all the air dryer alarms.

5.9.3

The control board holds all alarms for two minutes during initial power up of the dryer to
allow all systems to come up to operating conditions.

5.9.4

The control board diagnostic LEDs are identified as follows:

LD1 - Common Alarm

LD2 - High Pressure Alarm
LD3 - Low Pressure Alarm
LD4 - Humidity Alarm or Open Circuit
LD5 - Excess Run Time Alarm
LD6 - Auxiliary Alarm
LD7 - Shut Down Alarm
LD8 - By-Pass Valve
LD9 - Compressor Running
LD10 - Open Circuit Condition
LD11 - Humidity Condition
LD12 - Stand By Mode
LD13 - High Pressure Condition
LD14 - Low Pressure Condition
5.9.5

Energized with any alarm

Energized one minute after condition occurs
Energized one minute after condition occurs
Energized one minute after condition occurs
Energized approximately 12 minutes after continuous run
Not used on this dryer
Energized after 30 minutes of continuous humidity alarm
Energized immediately when by-pass valve is by-passing
Energized when the air compressor is running
Energized immediately when condition occurs--no delay
Energized immediately when condition occurs--no delay
Used with cycle kit when dryer is alternated with another
Energized immediately when condition occurs--no delay
Energized immediately when condition occurs--no delay

The alarm reset switch on the control board will clear all latched in alarms when pushed.

10

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual

6.0

MAINTENANCE
To extend the life of the air dryer and assure continued satisfactory operation, it is recommended that the
following inspection and maintenance procedures be performed at the scheduled intervals. Six air
compressor intake filter elements are supplied with this dryer. These are the only routine maintenance
parts required during the first year of operation. The Allen wrench supplied should be kept with unit for use
in performing the annual compressor maintenance.
6.1

SIX MONTH MAINTENANCE AND INSPECTION

6.1.1

6.2

Replace the air compressor intake filter elements. (section 5.1.2)

Check that the capacity control valve is adjusted properly. (section 5.2.4)
Check the operation of the humidity alarm system.
Check the system pressure switch setting. (section 5.3.3)

ANNUAL MAINTENANCE AND INSPECTION

6.2.1

6.3

Perform the following once every year or at 4400 hour intervals:

Perform the six-month maintenance and inspection procedures. (section 6.1)

Replace the pre filter element.
Install an air compressor maintenance kit. (section 6.4)

TWO YEAR MAINTENANCE AND INSPECTION

6.3.1

6.4

Perform the following every three months or at 1100 hour intervals:

Perform the following once every two years or at 8800 hour intervals:

Perform the annual maintenance and inspection procedures. (section 6.2)

Install a heatless dryer maintenance kit. (section 6.5)

AIR COMPRESSOR MAINTENANCE KIT

P/N 9537

Before performing any repairs or maintenance on the air dryer, disconnect the external power supply to the
unit. Refer to the maintenance kit instructions provided in the maintenance kit.
6.5

HEATLESS DRYER MAINTENANCE KIT INSTALLATION

P/N 7595

Before performing any repairs or maintenance on the air dryer, make sure to disconnect the external power
supply to the unit.
6.5.1

Disconnect the precooler line from left side of the pre-filter, disconnect the outlet hose to
the tank, and disconnect the power leads.

6.5.2

Loosen and remove the four mounting bolts that mount the dryer on the frame and remove
the dryer from the frame. Remove the bottom cover from the dryer by loosening the screw
on either side of the cover. Remove the purge mufflers from the solenoid bases.

6.5.3

Remove the solenoid coils and frames from the solenoid base assembly by removing the
retaining clip at the bottom of each base assembly. Remove the solenoid base assembly
from the manifold and discard. Remove the o-rings from the manifold and install new orings.

6.5.4

Install the new solenoid base assembly containing the new core into the manifold. DO
NOT OVER-TORQUE; tighten only until snug. Reinstall the old coil in the new frame using
spacers. Reinstall the retaining clip. Reinstall the cover and purge mufflers.

6.5.5

Remove the two desiccant towers, o-rings and purge orifices. Remove and discard check
valve balls and springs. Install new check valve balls and springs.

6.5.6

Reinstall purge orifices with new o-rings (lubricate threads with o-ring lube or petroleum
jelly).

6.5.7

Reinstall desiccant chambers with new o-rings (lubricate threads with anti-seize lubricant
or petroleum jelly). Reinstall dryer into unit and hook up outlet hose and pre cooler.

11

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual

7.0

PARTS IDENTIFICATION
14
13
15
1

3
4
5

6
7
8

16

9
10
11

17
18

12
Figure 4 Front View

INDEX
NO.

PART
NO.

DESCRIPTION

QTY.

7984

LOW OUTLET PRESSURE GAUGE

7932
7934

AIR COMPRESSOR (115 VOLTS)

AIR COMPRESSOR (220 VOLTS)

P3197
P4634
12030-122
12030-422
F18-02-SH00
7321
52096
9530
7509
7515
9162
2056
B-431
8132
7614
9540
9685-1
9685-2

CAPACITY CONTROL GAUGE

CAPACITY CONTROL VALVE
HEATLESS AIR DRYER (115VOLTS)
HEATLESS AIR DRYER (220 VOLTS)
PRE FILTER
SAFTEY VALVE
SYSTEM PRESSURE SWITCH
SYSTEM PRESSURE GAUGE
HUMIDITY BY-PASS VALVE (115V)
HUMIDITY BY-PASS VALVE (220V)
HUMIDITY TUBE
FLOOR VIBRATION MOUNTS
FLEX LINE
PRE-COOLER
AIR INTAKE FILTER
LOW OUTLET PRESSURE REGULATOR
REMOTE CONTROL BOARD MODULE (115 VOLTS)
REMOTE CONTROL BOARD MODULE (220 VOLTS)
REMOTE CONTROL BOARD MODULE (115 VOLTS) WITH
DISCRETE ALARM BOARD (FOR AIR 1500-1500TML3-3D)
DISCRETE ALARM BOARD ONLY (FOR AIR 1500-1500TML3-3D)

3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17A

9685-3

18

9521

12

1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1

P/N 9692 REV C, 04/23/13

11

13

Gn

T1

L1

T2

L2

10

Bk

LINE

AIR COMPRESSOR

Gn

C1

TERMINAL
BLOCK

NEU

Gn

12

SOLENOID
VALVE
#2

HEATLESS DRYER

SOLENOID
VALVE
#1

TIMER

POWER CONTACTOR

C2

GND

AC POWER IN
115V, 60Hz (or 230V, 50Hz)

9
10

FAN MOTOR

10

11

10

12

ALARM

SET

SET

LD1
LD2
LD3
LD4
LD5
LD6
LD7
LD8
LD9

TB-5

SENSOR

TANK

TB-8

TB-7

RESET
BUTTON TB-6

FRONT PANEL
DISPLAY

REMOTE ALARMS

LD10
LD11
LD12

LD13 HIGH

CYCLE KIT

LD14 LOW

CONTACTOR

BY-PASS VALVE

POWER

PENTRAS

18

17

TB-4

TB-3

TB-2

TB-1

CONTROL BOARD

STATUS PANEL ASSEMBLY

WIRING DIAGRAM
AIR 1500TML3

A
B

B
A

M
K

P2
MS3126F14-12S
J2
MS3122E14-12P
SUMMARY
FAULT

J1
MS3122E12-8P

HUMIDITY BY-PASS
VALVE

G
H

E
F

J2 P2

13

16

15

SYSTEM
PRESSURE
SWITCH

HUMIDITY SENSOR

14

LOAD

LINE

13

14

Model AIR 1500TML3

Operating Manual

Figure 5 Wiring Diagram

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual

Index
Number
1
2
3
4
5
6
7
8
9
10
11
12

Part Number

Description

Qty

Desiccant Chamber Assembly, 9"

O-Ring
O-Ring
Purge Orifice (Note: Purge orifices include items 3 and 5)
O-Ring
Hex Plug
O-Ring
Check Valve Ball
Spring
Manifold
Pipe Plug
O-Ring

2
2
2
2
2
1
1
2
2
1
2
2

13

12006
P400312924
P400313110
11663-22
P400312908
11397
P400312904
P400375
P300507
P300495
11399
103027
P400589DC1
P400589DC1

Solenoid Valve Assembly, 53 Volts DC (115V)

Solenoid Valve Assembly, 106 Volts DC (220V)

14
15
16

Not Sold Separately

7595
9680

Solenoid Valve Coil

Heatless Dryer Maintenance Kit
S.S. Timer (115V or 220V in, 53VDC or 106VDC out).

Figure 6 Heatless Dryer Exploded View and Parts List

14

P/N 9692 REV C, 04/23/13

Model AIR 1500TML3

Operating Manual

8.0

DISCRETE ALARM BOARD

8.1

An optional discrete alarm circuit board is available, if desired, from Pentras. Order P/N
9521 along with cable P/N 7449. This cable connects the alarm board to the control board.

8.2

With the discrete alarm circuit board, each individual alarm from the dryer can then be wired
from the alarm board to the remote monitoring system. These alarms can be wired as
normally open (N.O.) or normally closed (N.C.); however, the power failure alarm must be
wired opposite from the other alarms. So if the high pressure, low pressure, excess run
time and humidity alarms are wired as normally open (N.O.) then the power failure must be
wired normally closed (N.C.).

OPTIONAL ALARM BOARD HOOK UPS

This Alarm Not used on

1500 TM

Figure 7 Optional Alarm Board

15

P/N 9692 REV C, 04/23/13