Parker Zander KA-MT 1, Operating Manual

Page 1: ...KA MT 1 8 D3 Adsorption dryer Operating manual 30 07 2020 rev02 EN Cod 398H272185 Generation 3 ...

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Page 3: ... for installation 19 Connect piping 20 Installing the electrical connection 21 Start up 23 Requirements for initial start up 23 Setting times of the operating phases 23 Overview of operating and control elements 24 Start up dryer 27 Changing cycle mode optional 29 Monitoring dryer operation 30 With dewpoint sensing control optional 30 Shutdown and restart dryer 31 Emergency shutdown 31 Depressuris...

Page 4: ... MT 1 8 D3 Identify and eliminate faults 49 Summary of faults 49 Annex with technical documentation 52 Technical data 53 Replacement and wear part list 54 Logic control diagram 58 Flow diagram 60 Installation on floor 61 ...

Page 5: ...these appliance data up to date The above stated appliance data provide for a clear identification of the dryer and its compo nents 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 8 ...

Page 6: ... of 1 double chamber hollow section vessel fillied with drying agent 1 single chamber hollow section vessel filled with purifying agent 1 upstream filter 1 downstream filter Muffler Control system Associated documents Operating instructions present Technical documentation see annex Circuit diagrams see separate document Operating manual for installed filters separate document Notes on supplementar...

Page 7: ...h 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 threa tening 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 special...

Page 8: ... A sudden escape of pressure may cause serious injuries Before carrying out any work on the dryer first depressurise the plant Risk of injury due to voltage carrying parts The electrical supply cable and external power lines are live even after the dryer is switched off and in the event of body contact may cause serious injury Before carrying out any work on the electrical system the electrical sup...

Page 9: ...dries compressed air for industrial use The dryer is designed for compressed air which is free from aggressive water oil and solid matter constituents As standard the dryer is intended to be sited within a building and protected against the weather The dryer may be operated only in accordance with the data on the type plate and in accord ance with the contractual conditions Suspected misuse The dr...

Page 10: ...as on the dryer Signs and labels Front view Please note the above plates and instructions attached to the dryer Ensure that they are not removed and are always readable Type plate of upstream filter Type plate of downstream filter Type plate of dryer Operating data plate ...

Page 11: ...e injury When working on the dryer always wear eye and ear protection equipment Risk of damage to eyes If not properly secured the indicator tube might be propelled out of its holder When the needle valve is opened the indicator tube is secured by a union nut If the union nut is not properly tightened or if the oil indicator has been interfered with there is a risk that the tube might be propelled...

Page 12: ...torage instruc tions on page 13 Information on transportation packaging Depending on the type of transportation the dryer is delivered in different types of packag ing 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 dr...

Page 13: ...yer 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 drying agent without any hindranc es see figure If in doubt the installation site must be inspect ed by specialists If you have any queries in this regard please contact the manufacturer see pag ...

Page 14: ...nchorage bores see figure Use suitable attachment material to anchor the dryer to the floor In the case of vibrating floors place the dryer on suitable vibration dampers Bores on the stand profiles Mount dryer on the wall The stand profiles can be rotated by 90 towards the rear side of the dryer and secured in this position see arrow in above figure Remove the screws at the muffler and the stand p...

Page 15: ...d by the owner and the installed compressed air outlet valve installed by the owner are both closed and that the dryer is depressurised Disconnect dryer from the compressed air system Disconnect 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 prote...

Page 16: ...nstalled downstream filters clean the compressed air from drying agent abrasions be fore it is fed into the compressed air system The two chambers of the hollow section vessel contain an extremely porous drying agent by means of which humidity is removed from the compressed air and stored just as in a sponge The stored humidity is then removed again from the drying agent and re introduced into the...

Page 17: ...newed take up of humidity This process is called regeneration The regeneration is subdivided into three phases expansion dehumidification and pressure build up With the dewpoint sensing control option the regeneration phase is followed by a standby phase Expansion phase During the expansion phase the pressure in the regenerating chamber is released via the muffler down to ambient pressure within j...

Page 18: ...ensing control option When in standby phase the fully regenerated vessel is ready for absorption operation The system is switched to this vessel as soon as the measured dewpoint at the compressed air outlet has reached the set dewpoint value for switchover Switchover When the drying agent in the adsorbing chamber has taken up a sufficient level of humidity then the switchover between the vessels w...

Page 19: ...is treated as the prime controller The control system can also be equipped with an optional operation signalling contact with which the dryer operation can be monitored from an external device Dryers with the optional dewpoint sensing control are equipped with such a contact as standard It is used for the transmission of operating signals and for the output of dewpoint alarms Dewpoint sensing cont...

Page 20: ... installed by the owner so that the dryer can be installed and maintained in a depressurised condition see also the installation example on page 19 All pipes couplings and connections must have the correct diameter and match the oper ating pressure Hazard caused by exceeding the limit values A safety device must be provided in order to protect against the maximum permissible operating pressure fro...

Page 21: ...dryer to the compressed air system The following figure shows an installation example Compressed air system Item Component 1 2 3 5 6 7 8 9 10 11 4 Example of an installation with bypass line 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 Outlet dry air 8 Bypass line option 9 Valve in bypass line optio...

Page 22: ... 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 th rough the aperture 3 The exposed phase ends should not be longer th...

Page 23: ... and 2 on the control board see circuit diagram Hinweis The compressor synchronisation controller is a higher level controller than the pressure dew point controller When both options are in place the compressor synchronisation controller is treated as the prime controller For operation monitoring system optional Operators have the option to connect the dryer to a fault signalling system connectin...

Page 24: ...sed the electrical connections are in safe contact and in good condition owner end and pressurised parts such as safety valves or other devices are not blocked up by dirt or paint all compressed air system parts which are pressurised valves hoses etc are free from wear symptoms and defects Setting times of the operating phases In its standard version the dryer is delivered with a time dependent co...

Page 25: ... dryer is switched off If the switch is set to I the dryer is switched on and begins to operate in fixed cycle mode i e time controlled If the switch is set to position II the dryer is switched on and begins to operate with compressor synchronisation in variable cycle mode i e dew point cont rolled Position II is only relevant for operation with the optional compressor synchronisation and or dewpo...

Page 26: ... seconds In this example step 2 is being completed whereby there are 215 seconds remaining SEr After 8000 operating hours SEr service is displayed for periods of 1 minute alternating with the default display Notify the service personnel of the manufacturer as a routine service is now due 25 With the dewpoint sensing control option the display shows the currently measured dewpoint instead of the de...

Page 27: ...indicator The dryer is equipped with an oil indicator The indi cator allows for periodic measuring of the residual oil concentration in the purified compressed air The residual oil content should only be measured at set intervals and the needle valve 1 at the indicator should be closed during normal operation For detailed instructions on the measuring procedure for residual oil please refer to the...

Page 28: ...ure that the compressed air inlet and outlet valves installed by the owner are closed see installation example on page 19 Ensure that the compressed air system upstream of the dryer is pressurised If necessary pressurise switch on compressor Slowly open compressed air inlet valve Avoid sudden pressure build up in any circumstance If pressure builds up too fast this may cause damage to the dryer Th...

Page 29: ...pressed air system downstream of the dryer Smaller compressed air systems can be pressurised also by means of compressed air fed through the dryer Slowly open compressed air outlet valve Avoid a sudden drop in pressure in any circumstance If pressure drops too fast this may cause damage to the dryer Therefore the compressed air outlet valve must always be opened quite slowly Slowly open the compre...

Page 30: ...oint sensing control With compressor synchronisation If compressor synchronisation is enabled the dryer can only be operated in conjunction with the compressor As soon as the compressor is switched off the dryer is automatically set to standby mode In standby mode the control system remains on and the dryer is ready for the next switcho ver which is made as soon as the compressor is switched on No...

Page 31: ...g escaping com pressed air defective component immediately close the compressed air supply line and set the ON OFF switch of the dryer to 0 in order to disconnect it from the power supply After wards depressurise the dryer see also chapter page 30 The unit may only be restarted after all defects have been eliminated With dewpoint sensing control optional Display of dewpoint If the dryer is equippe...

Page 32: ...chover Note If the unit is equipped with a compressor synchronisation system first switch off the compressor and then wait until the dryer has reached the standby phase before switching it off with the ON OFF switch This ensures that the regeneration cycle is completed and that the pressure in both chambers is at the same level As soon as the dryer is switched on again the programme continues the c...

Page 33: ...trol system it is depressurised gradu ally according to the read measuring current 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 Slowly open compressed air outlet valve Avoid a sudden drop in pressur...

Page 34: ...e goggles In order to avoid any dust inhalation wear dust mask Restart the dryer Switch on the dryer and pressurise as described in section Open compressed air supply and switch on dryer page 22 The compressed outlet valve must be closed and the downstream filter housing must be open Operate the dryer for approx thirty minutes blowing the dust particles off from the down stream filter Shut down th...

Page 35: ...of the dryer These data are found on the type plate Carry out all maintenance work only when the plant has been shut down and depressur ised 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 consulta tion with the manufacturer Never carry out any man...

Page 36: ...y 12 months 24 months 48 months See page Complete dryer Carry out visual checks and function checks 35 Oil indicator Measure the residual oil content and the resid ual capacity of the purifying agent Muffler KA MT 1 2 Clean muffler replace if necessary 40 KA MT 3 8 Mufflers must be replaced annually and after each desiccant change 40 Fine filter muffler option Replace silencer element annually and...

Page 37: ...y 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 on the controller The following appears in the display for a short time 0 SET then flashing OFF The service counter is then...

Page 38: ...ncentration proceed as described below A template of the measuring log used for this procedure is included in the appendix Risk of damage to eyes If not properly secured the indicator tube might be propelled out of its holder When the needle valve is opened the indicator tube is secured by a union nut If the union nut is not properly tightened or if the oil indicator has been interfered with there...

Page 39: ...1 15 1 35 1 55 1 85 12 5 0 18 0 37 0 57 0 70 0 85 1 08 1 25 1 45 16 5 0 13 0 27 0 45 0 57 0 65 0 80 0 90 1 08 25 0 09 0 18 0 30 0 38 0 45 0 60 0 65 0 75 33 0 07 0 12 0 19 0 30 0 32 0 42 0 50 0 55 50 0 045 0 090 0 130 0 180 0 225 0 300 0 350 0 400 56 0 040 0 080 0 110 0 155 0 195 0 275 0 300 0 350 63 0 036 0 070 0 105 0 145 0 180 0 225 0 275 0 300 72 0 032 0 062 0 095 0 128 0 155 0 190 0 245 0 275 ...

Page 40: ...ration at fixed intervals Choose a measuring interval e g 4 weeks and a duration of measurement e g 4 hours Determine the maximum admissible residual oil concentration in mg m3 for your specific application Divide this value by 1 2 in order to obtain the maximum admissible residual oil concentration in ppm Refer to the table on page 37 and determine the corresponding number of scale seg ments with...

Page 41: ...e indicator tube is properly tightened The colour change of the tube segments 2 is irre versible When all segments have changed colour the indicator tube must be replaced Ensure that the needle valve 1 is closed and that the indicator tube 2 is not under pressure To close the needle valve turn its handle clockwise To remove the indicator tube Loosen the reducer 4 below the union nut 3 using an app...

Page 42: ...articles 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 dryer The correct procedures for all muffler versions are described below Clean or renew standard mufflers Depressurise the dryer and shut it down see page 30 Unscrew muffler as shown in the opposite figures KA MT 1 2 Pos A KA MT 3 8 Pos ...

Page 43: ...hat you contact the manufacturer well in advance and order a new dewpoint sensor After receipt of the new pressure dewpoint sensor replace the sensor as follows Hold the box of the dewpoint sensor ready Release pressure from dryer and shut down the unit see page 30 Loosen the screw at the adapter 1 and disconnect signal cable with the adapter and seal Remove dewpoint sensor from the sensor cell 3 ...

Page 44: ...acture Only use approved climbing aids when disassembling the top plate To replace the purifying agent you must first remove the top plate Depressurise the dryer and shut it down see page 30 Loosen the screws at the top plate and lift off the plate Remove the perforated plate Remove the purifying agent from the single chamber vessel using an industrial vacuum cleaner Removing the top plate Caution...

Page 45: ...mbranes of solenoid valves You should replace the membranes of solenoid valves every two years Proceed as described in section Replace solenoid valves You must however replace the membranes only con tained in the Service Kit for 24 months Maintenance work to be completed every 48 months Replace check valves Check valves are wear parts and must thus be replaced every 48 months even if no damage is ...

Page 46: ...valve together with the solenoid and the diaphragm 4 Insert new diaphragm with guide 4 and secure it to the holder 3 Position new solenoid 1 onto the armature and secure it to the spring bracket 5 Solenoid valve If no other maintenance work is to be carried out Restart the dryer see page 31 Replace perforated plates demisters and drying agent To complete the following maintenance tasks you must di...

Page 47: ... Oil dust and dirt particles cover the drying agent surface and reduce its effective surface in part quite irreversibly If in doubt have a sample of your drying agent assessed by specialists Comply with the following safety notes when changing the drying agent Wear eye protection and dust mask due to increased dust generation When emptying the drying agent increased dust generation may occur In or...

Page 48: ...ise in accordance with the sequence shown on the right Repeat the process once Next the new drying agent should fill up Correctly affixing the solenoid valve plate Fill with new drying agent and remount check valve plate Risk of falls The dryer must not be misused as a climbing aid The components have not been designed for such loads and could fracture Only use approved climbing aids when filling t...

Page 49: ... secure them Reaffix the check valve plate Use a dyamometric key to tighten the screws and take care to observe the following torques 25 Nm in the case of KA MT 1 4 50 Nm in the case of KA MT 6 8 Tighten the screws crosswise in accordance with the sequence shown on the right Repeat the process once Restart the dryer see page 31 Check that the connection is leak tight Operate the dryer for two cycl...

Page 50: ...circuit defective fuse etc the expansion valve closes and the regeneration is interrupted In the case of some process faults the dryer will continue to operate for some time Other faults on the dryer become noticeable e g due to unusual noises and ran pressures The following table shows who is allowed to remedy a fault the owner s specialist personnel or the manufacturer s service engineer Table o...

Page 51: ...y Compressor might be off Check compressor synchro nisation circuit Error in control programme Restart programme No expansion Solenoid valve Y3 Y4 can not be opened Check supply voltage ca ble contacts and solenoid replace if necessary Solenoid valve Y3 Y4 can not be opened properly audible humming sound or valve flapping Check supply voltage Check spring and solenoid replace if necessary Check so...

Page 52: ...d Replace sensor sens o 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 com ponent s SEr Display for service interval Regular maintenance tasks must be carried out The display appears after every 8000 operating hours Inform the manufactur er s service staff and order...

Page 53: ...cumentation KA MT 1 8 D3 51 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 54: ... Nominal temperature C KA MT 1 8 1 4 AAP010AGFI AOP010AGMI 16 50 KA MT 2 15 1 4 AAP010AGFI AOP010AGMI 16 50 KA MT 3 25 1 4 AAP010AGFI AOP010AGMI 16 50 KA MT 4 35 1 4 AAP010AGFI AOP010AGMI 16 50 KA MT 6 52 1 2 AAP015AGFI AOP015AGMI 16 50 KA MT 7 72 1 2 AAP015AGFI AOP015AGMI 16 50 KA MT 8 86 3 4 AAP020AGFI AOP020AGMI 16 50 1 m3 h relating to 1 bara and 20 C at the compressor suction capacity Subsequ...

Page 55: ...24 months SKK6 K7 DA3 24 Reset module valve membranes muf fler and filter elements KA MT 6 to KA MT 7 48 months SKK6 K7 DA3 48 Reset module valve membranes sole noid coils check valves demisters per forated plates muffler and filter elements KA MT 8 12 and 36 months SKK8 DA3 12 Reset module muffler and filter elements KA MT 8 24 months SKK8 DA3 24 Reset module valve membranes muf fler and filter e...

Page 56: ...0 70 1 00 1 30 1 55 1 85 2 20 2 50 16 5 0 24 0 50 0 70 1 00 1 25 1 40 1 65 1 90 25 0 155 0 310 0 500 0 700 0 800 1 000 1 100 1 300 33 0 120 0 240 0 380 0 500 0 620 0 750 0 850 1 000 50 0 075 0 155 0 230 0 310 0 400 0 500 0 600 0 700 56 0 065 0 135 0 210 0 280 0 350 0 420 0 500 0 600 63 0 058 0 125 0 185 0 250 0 305 0 355 0 420 0 500 72 0 050 0 095 0 160 0 195 0 270 0 310 0 380 0 420 84 0 040 0 090...

Page 57: ...6 5 0 185 0 400 0 560 0 800 0 950 1 180 1 300 1 560 25 0 125 0 250 0 410 0 520 0 620 0 760 0 900 1 000 33 0 090 0 185 0 280 0 400 0 510 0 560 0 650 0 800 50 0 060 0 125 0 180 0 250 0 350 0 410 0 450 0 520 56 0 050 0 110 0 165 0 230 0 280 0 370 0 420 0 440 63 0 047 0 095 0 150 0 195 0 245 0 300 0 390 0 425 72 0 040 0 085 0 130 0 170 0 210 0 260 0 320 0 390 84 0 035 0 075 0 110 0 150 0 175 0 230 0 2...

Page 58: ... 05 1 29 1 48 1 65 16 5 0 16 0 35 0 49 0 55 0 81 0 95 1 08 1 20 25 0 10 0 21 0 35 0 48 0 52 0 55 0 70 0 85 33 0 07 0 16 0 22 0 35 0 40 0 49 0 60 0 66 50 0 05 0 10 0 17 0 21 0 27 0 35 0 38 0 48 56 0 04 0 09 0 16 0 20 0 22 0 27 0 34 0 38 63 0 036 0 082 0 120 0 165 0 210 0 250 0 280 0 355 72 0 035 0 070 0 110 0 160 0 200 0 210 0 270 0 280 84 0 033 0 065 0 090 0 120 0 160 0 200 0 210 0 250 100 0 025 0...

Page 59: ...EN User Manual Annex with technical documentation KA MT 1 8 D3 57 Logic control diagram Adsorption in B1 and regeneration in B2 ...

Page 60: ...EN User Manual Annex with technical documentation 58 KA MT 1 8 D3 Regeneration in B1 and adsorption in B2 ...

Page 61: ...forated plate 130 152 Top plate 10 107 Demister left 130 153 Bottom plate 10 108 Demister right 130 154 Seal 10 109 Left perforated plate 130 155 Perforated plate 10 110 Conical pressure spring 195 Oil indicator 10 111 Right perforated plate 50 Regeneration gas orifice plate Optional devices 60 Control unit 110 Start up device 70 Control system 701 Dewpoint sensing unit 80 Upstream filter ...

Page 62: ... BSP P NPT Dimensions mm Weight kg A B C D E F KA MT 1 1 4 459 400 216 376 101 101 15 0 KA MT 2 1 4 459 575 216 551 101 101 20 0 KA MT 3 1 4 459 825 216 801 101 101 28 0 KA MT 4 1 4 459 1075 216 1051 101 101 35 0 KA MT 6 1 2 683 1203 300 1097 132 132 68 0 KA MT 7 1 2 683 1428 300 1322 132 132 81 0 KA MT 8 3 4 683 1628 300 1522 132 132 92 0 ...

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Page 64: ...ico MI Italy Sede Operativa Gas Separation and Filtration Division EMEA Strada Zona Industriale 4 35020 S Angelo di Piove PD Italy tel 39 049 971 2111 fax 39 049 9701911 Web site www parker com hzd e mail technical support hiross parker com A division of Parker Hannifin Corporation ...