Parker Zander HDK-MT 10-100, Operating Instructions Manual

Page 1: ...High Pressure Dryer HDK MT 4 100 70 350 Operating Instructions Revision 04 2014 EN ...

Page 2: ...Lloyd s Register Quality Assurance GmbH Hamburg is available The quality assurance system is monitored by the service provider stated below Lloyd s Register Quality Assurance GmbH identification number 0525 Am Sandtorkai 41 D 20457 Hamburg The assembly consists of pressure appliances according to the classification list attached to the technical documentation provided by the manufacturer The follo...

Page 3: ...ot stated above to keep these appliance data up to date The above stated appliance data provide for a clear identification of the dryer and its components and significantly facilitate any service measures Further important data on the dryer such as the details on the permissible operating pressure and the electrical connection are found on the type plate for position of the type plate see page 9 ...

Page 4: ...o do in the case of transport damage occurring 18 Transporting and installing the dryer 19 Installing and anchoring 20 Storing the dryer 20 Installation 22 Preconditions for installation 22 Connect piping 23 Installing the electrical connection 24 Start up 26 Requirements for initial start up 26 Setting times of the operating phases 27 Overview of operating and control elements 27 Emergency shutdo...

Page 5: ...t weekly visual checks 39 Maintenance work to be completed every 12 months 40 Maintenance work to be completed every 24 months 41 Identify and eliminate faults 42 Summary of faults 42 Index 45 Annex with technical documentation 47 Technical data 48 Replacement and wear parts list 50 Logic control diagram 52 Flow diagram 54 Dimensional drawing 55 ...

Page 6: ...Manufacturer s details 6 HDK MT350_EN_04 General information Manufacturer s details Name and address ...

Page 7: ...r is used without prior approval and confirmation in writing by the manufacturer for purposes other than those specified in these operating instructions or contractually agreed If preset parameters e g on the control system etc are changed without prior approval and confirmation in writing by the manufacturer If the dryer is transported or stored incorrectly If the dryer is sited and installed inc...

Page 8: ...uch damage Danger These danger notes with a grey background warn against personal injury and or danger to life and limb danger notes help you to avoid serious or life threatening situations for yourself and or third parties Target group of these operating instructions These operating instructions are intended for all persons working on and using the dryer We assume that all such persons are specia...

Page 9: ...not used within its intended design specifications is repaired or maintained incorrectly Note For your own safety and to prevent machine damage please note the information and safety notes in these operating instructions when working with the dryer Signs instruction plates and danger zones at the dryer Signs and instructions Type plate of the filter Type plate of the dryer Front view Please note t...

Page 10: ...opened and maintained by authorized specialist personnel only Warning against overpressure The entire dryer is under pressure Before commencing any work the plant must be depressurised Warning against sudden air ejection When the vessels are depressurised air flows suddenly out of the sound absorber orber This causes a loud expansion noise Due to particles carried in the air flow there is a very c...

Page 11: ...uthorized and qualified specialist personnel may be tasked with the work on the dryer described in these operating instructions Conversions and modifications Without prior approval by the manufacturer no conversions and modifications must be made to the dryer Any non approved modifications may restrict the operational safety of the dryer and cause damage to property or personal injury Handling dry...

Page 12: ...roceed as described in the section on page 35 Monitor operation Warning against sudden air ejection During expansion the pressure is released suddenly through the muffler A loud expansion noise is caused which may damage your hearing Particles carried in the air flow act like bullets and can injure your eyes or skin Always wear eye and ear protection therefore when you are in the vicinity of the d...

Page 13: ...rnal damage on the dryer There is a risk of injury by slipping off the components components breaking off and expanding compressed air Never leave tools loose parts or cloths in at or on the dryer Following maintenance work always test all flange and bolt connections for leak tightness and secure seating Only use replacement parts that are suitable for the relevant function and meet the technical ...

Page 14: ...dries the compressed air supplied by the compressor and makes it available for industrial use Upstream filters clean the compressed air and remove dust dirt oil and water droplets before the compressed air reaches the dryer Thus an upstream filter is also used for extending the service life of the drying agent Downstream filters clean the compressed air from drying agent abrasions before it is fed...

Page 15: ... process the drying agent takes the moisture out of the air The downstream filter at the exit to the dryer filters any remaining solids from the flow of compressed air The dry compressed air is then supplied to the consumers via the network Regeneration running in parallel to the adsorption At the same time the other vessel is prepared for a renewed take up of humidity This process is called regen...

Page 16: ...me the air is not dried but flows through the bypass line past the dryer and through to the actual loads Filters in the bypass line are meaningful so that the actual loads are largely protected against dirt water and oil droplets even whilst maintenance is in progress Signalling contacts of the control system The control system is equipped with a digital input for the synchronised operation with a...

Page 17: ...able cycle the switchover is effected in relation to the dew point reached and the charging of the drying agent The adsorption time in the variable cycle is preset to 60 minutes Condensate drain systems for preliminary and afterfilter Condensate drain systems are installed to drain water that has collected in the preliminary or afterfilter from the filter There are two distinct types of condensate...

Page 18: ...ckaging Depending on the type of transportation the dryer is delivered in different types of packaging All transportation types the apertures of the dryer are closed off by means of plugs In addition when transportation is effected by air the dryer is packaged in a wooden box In addition when transportation is effected by ship the dryer is packaged in a film material and in a wooden box If the pac...

Page 19: ... the noise emission see also page 49 The installation area must be level firm and free of vibrations It must have the necessary carrying capacity for the weight of the dryer The weight of the dryer is specified in the technical data section of the annex The dryer should be installed with sufficient spacing at the top sides and rear in order to be able to carry out maintenance work and change the d...

Page 20: ...re drilled anchorage bores Use suitable attachment material to anchor the dryer to the floor see figure In the case of vibrating floors place the dryer on suitable vibration dampers Bores at the foot of the dryer Storing the dryer If the dryer is to be stored for an extended period of time the storage location must meet the following conditions The dryer must not be stored in the open air The stor...

Page 21: ...ct the dryer from the electrical power supply and all external lines Use film material or similar to close the compressed air inlet apertures and compressed air outlet apertures on the dryer in order to protect them against contamination If possible cover dryer with a protective sheet The dryer can now be stored for long periods Note If you wish to take the dryer back into service after an extende...

Page 22: ...e also page 16 Adjust the pressure maintaining valve to 10 15 bar below operating pressure Make sure the following minimum input pressures are permanently applied to the dryer HDK MT of pressure level 100 bar at least 50 bar HDK MT of pressure level 250 bar and 350 bar at least 100 bar All pipes couplings and connections must have the correct diameter and match the operating pressure Hazard caused...

Page 23: ...o connect the dryer to the compressed air system The following figure shows an installation example Compressed air system Item Component 1 Entry humid air 2 Compressed air inlet valve owner end 3 Upstream filter 4 Dryer 5 Downstream filter 6 Compressed air outlet valve owner end 7 Pressure maintaining valve 8 Bypass line option 9 Valve in bypass line option 10 Bypass filter option 11 Valve outlet ...

Page 24: ...ided by the customer Make the electrical supply cable to the dryer voltage free Secure the electrical supply cable to the dryer against switch on Undo bolt 1 on the connector and withdraw connector with seal from the switchbox Use a suitable tool to remove the terminal block from the connection box Undo the PG union and pull the cable through the aperture 3 The exposed phase ends should not be lon...

Page 25: ...the compressor is stopped the dryer regeneration also stops When the compressor is restarted regeneration also restarts If switch S1 is in the OFF position any regeneration process which has been started is always continued until completed To install the external line proceed as follows Connect the signalling line to the potential free busbar connection of the compressor to terminals 1 and 2 on th...

Page 26: ...e following preconditions must have been met The pipe system is free from contaminations All shutdown valves of the compressed air inlet and outlet valves installed by the owner are closed The dryer is correctly sited and installed Checks before start up Ensure that all pipe cable and bolt connections on the dryer have been retightened no pipes chafe against body edges all mountings are perfectly ...

Page 27: ...andby 50 min maximum Overview of operating and control elements ON OFF switch The ON OFF switch 2 is located to the side of the control cabinet and above the mains plug 1 see figure If it is set to 0 the power supply is disconnected and the dryer is switched off The main and expansion valves are normally closed This ensures that the main flow direction is blocked when the dryer is switched off If ...

Page 28: ...rating phases of the dryer are indicated by means of 4 LEDs Vessel B1 Vessel B2 Regeneration 1 Regeneration 2 Adsorption 1 Adsorption 2 Depending on the operating phase the following LEDs might be on simultaneously Adsorption B1 and regeneration B2 or regeneration B1 and adsorption B2 Digital display 3 The digital display shows the individual programme steps and the respective remaining time For d...

Page 29: ...r measuring range limit exceeded 999 Dewpoint sensor defective sens Dewpoint sensor not powered Cable defective or disconnected Sensor defective or 999 LED Economy cycle 4 This LED is only relevant in units that are equipped with the optional dewpoint sensing control The diode lights up when the dryer is switched on and in the standby phase and no regeneration air is required Pressure gauges Press...

Page 30: ... powerful the dryer is the more noise may be generated during operation Therefore the operator must provide suitable protective equipment e g ear protection Only operate the dryer within the permissible limits By operating the dryer in conditions for which it has not been designed functional faults may be caused Depending on the size of the dryer and the compressed air network and the respective l...

Page 31: ...intermediate step can be skipped Operating the dryer for the first time or after a change of drying agent separately Depending on the transportation and storage conditions the drying agent in the vessels can already be loaded with humidity from the environment At each first start up it makes sense therefore to operate the dryer from some time separately from the compressed air system This causes t...

Page 32: ...ryer has filled up completely only then should the valve be opened fully The dryer has then be taken into operation within the compressed air system In the event of a fault In the event of an emergency or if a safety relevant disruption occurs e g escaping compressed air defective component the dryer must be shut down immediately as described in the section on page 35 Then proceed as follows Remed...

Page 33: ... the control system remains on and the dryer is ready for the next switchover which is made as soon as the compressor is switched on With dewpoint sensing control optional Dryers equipped with dewpoint sensing control operated in variable cycle mode based on the measured dewpoint of the dried air at the compressed air outlet As soon as a certain dewpoint is reached as the drying agent in the absor...

Page 34: ...isplay is 100 C 148 F to 20 C 68 F If the set dewpoint is exceeded the system automatically completes a switchover between the vessels The dewpoint at which a switchover is made is preset at the factory After commissioning or extensive maintenance work check the dewpoint display at the dryer Under certain circumstances the desired dewpoint is only reached after prolonged operation Error messages I...

Page 35: ...n cycle is completed and that the pressure in both vessels is at the same level As soon as the dryer is switched on again the programme continues the cycle from the point at which it has been stopped Emergency shutdown In any emergency proceed as described in the next section Depressurising and shutting down the dryer In order to make the dryer safe follow the instructions in the next three sectio...

Page 36: ...oint sensing control is implemented If compressed air system and dryer have remained at operating pressure Ensure that the compressed air inlet valve provided by the operator is open Set ON OFF switch to I The programme continues the cycle from the point at which it was interrupted ON OFF switch Slowly open compressed air outlet valve Avoid a sudden drop in pressure in any circumstance If pressure...

Page 37: ...all maintenance work only when the plant has been shut down and depressurised Bolt connections must be undone with care Note ram pressure values Otherwise emerging media may cause personal injury Do not modify the factory settings of the control system in any way without prior consultation with the manufacturer Never carry out welding work on a vessel or modify the same in any way Following mainte...

Page 38: ...re gauge If the display does not drop to 0 bar after regeneration of a vessel Check muffler 40 Muffler Renew muffler 40 Dew point sensor with optional dew point sensing control Renew 41 Pilot valves Renew 41 Main valves Renew 41 Solids filters in the vessels seals drying agent Renew 41 Upstream and downstream filter With the differential pressure gauge option Check differential pressure on the ups...

Page 39: ...t the counter to 0 and delete the message from the display A dongle is enclosed with every service kit Each dongle can only be used once Switch off the controller Caution The electric line is still live Do not touch live parts Open the lid to the Multitronic controller The circuit board in housed underneath it Slot the dongle into the dongle interface X9 PC Press and hold the reset key S3 Switch o...

Page 40: ...ar we recommend that you replace the filter element see page 40 The filter elements must be replaced in any case every year Maintenance work to be completed every 12 months Renew filter elements on the filters The filter elements must be replaced if the differential pressure is more than 0 6 0 8 bar or at the latest after 1 year of operation Renew muffler The dryer is equipped with a muffler If th...

Page 41: ...are expendable parts and should be replaced every 24 months as a precautionary measure Replacing drying agent seals and solid filters Risk of skidding If drying agent has been spilt on the floor there is a risk of skidding caused by the drying agent beads The service life of the drying agent is usually approx 2 years However in favourable installation conditions the change of drying agent may be c...

Page 42: ...neer Table of possible faults Certain faults must be due to valves that are not properly opened closed For measures to be taken in such cases please refer to the bottom of the table Fault Possible cause Remedy Specialised personnel Service technician Dewpoint is not reached Operating pressure too low Increase operating pressure Excessive differential pressure at upstream filter Check differential ...

Page 43: ...1 Y2 or Y5 does not open properly see Excessive compressed air consumption Condensate trap optional at the upstream filter is not working properly Check condensate trap optional clean or replace if necessary Regeneration air setting too high Have adjusted Dryer fails to switch over Compressor is switched off Check compressor synchronisation Power supply interrupted cable broken Reconnect the unit ...

Page 44: ...nsor sens or 999 Sensor not powered or cable or sensor defective Sensor sensor cable or sensor adapter defective Visual inspection check power supply 24 V to terminals 4 and 6 Replace defective component s SEr Display for service interval Regular maintenance tasks must be carried out The display appears after every 8000 operating hours Inform the manufacturer s service staff and order the appropri...

Page 45: ...e 3 Detour line see bypass line Dew point sensor maintenance interval 38 Dewpoint sensing control 17 Digital display explanation 28 Documentation technical 47 Dongle use 39 Dryer maintenance interval 38 drying agent maintenance interval 38 service life 41 Drying agent charging 17 storage 21 drying agents handling 11 dust generation 11 dust mask 11 Dust sieves maintenance interval 38 E Ear protecti...

Page 46: ...7 Personnel qualification 7 9 11 39 Pressure build up sudden 31 pressure gauge maintenance interval 38 pressure vessel 13 37 Programme sequence steps 52 Protection class 49 R Regeneration explanation 15 Regulations for accident prevention 18 Replacement parts 13 37 Restart pressure conditions 36 S Safety notes 9 general 11 operating phases 11 Warning 8 Safety valves 22 26 seals maintenance interva...

Page 47: ...on HDK MT350_EN_04 47 Annex with technical documentation This annex comprises the following information and technical documentation Technical data Replacement and wear parts list Logic control diagram Flow diagram Dimensional drawing ...

Page 48: ...1645 340 130 19 4 HDK MT 40 100 400 570 1645 340 155 26 4 HDK MT 50 100 520 570 1845 340 170 31 8 HDK MT 60 100 590 570 2020 340 190 36 2 HDK MT 70 100 650 570 2145 340 210 39 6 250 bar HDK MT 4 250 60 570 1015 340 115 3 8 HDK MT 6 250 85 570 1025 340 120 4 0 HDK MT 10 250 120 570 1035 340 125 4 2 HDK MT 15 250 150 570 1045 340 130 4 4 HDK MT 20 250 230 570 1245 340 160 6 8 HDK MT 25 250 300 570 1...

Page 49: ...50 24 5 HDK MT 70 350 1180 570 2145 340 380 26 8 relative to 1 bar abs and 20 C 68 F at operating pressure and a feed temperature of 35 C 95 F Type HDK MT 4 100 70 350 Fluid group acc to PED 97 23 EG 2 max operating overpressure 100 250 350 bar Required permanent minimum input pressure HDK MT of pressure level 100 bar HDK MT of pressure level 250 bar and 350 bar at least 50 bar at least 100 bar mi...

Page 50: ...e part package for 12 months HDK MT12A Spare part package for 24 months HDK MT24A Repair set RKV HDK MT 230 Spare part packages 250 350 bar HDK MT 4 250 70 350 Spare part package for 12 months HDK MT12A Spare part package for 24 months HDK MT24A Repair set RKV HDK MT 230 Drying agent packages Type DESPAC01MS DESPAC04MS DESPAC015MS HDK MT 4 100 250 350 2x HDK MT 6 100 250 350 2x HDK MT 10 250 350 2...

Page 51: ...Annex with technical documentation HDK MT350_EN_04 51 Additional Spare parts Designation Order number Muffler SDD 15 600 AL Filter elements s enclosed Filter manual ...

Page 52: ...Logic control diagram 52 HDK MT350_EN_04 Logic control diagram Adsorption in B1 and regeneration in B2 ...

Page 53: ...Annex with technical documentation HDK MT350_EN_04 53 Regeneration in B1 and adsorption in B2 ...

Page 54: ... Item Designation Item Designation 1 Vessel 7 Pressure gauge 2 Upstream filter 8 Check valves 3 Downstream filter 9 Solenoid valves 4 Solid filter 12 Control cabinet 5 Lower valve block 21 Muffler 6 Upper valve block 22 Pressure maintaining valve ...

Page 55: ...x with technical documentation HDK MT350_EN_04 55 Dimensional drawing Type HDK MT 100 250 350 bar Dimensions mm 15 20 25 30 40 50 60 70 A 570 B 1045 1245 1445 1645 1645 1845 2045 2145 C 340 Connection G 3 4 ...