Parker Zander K-MT 1/D3, Operating Manual

Page 1: ...K MT 1 4 D3 Adsorption dryer Operating manual Revisione 0 2018 EN Cod 398H272183 Generation 3 ...

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Page 3: ... 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 Depressurising and shutting down the dryer 31 ...

Page 4: ...EN User Manual 2 K MT 1 4 D3 Annex with technical documentation 46 Technical data 47 Replacement and wear part list 48 Logic control diagram 49 Flow diagram 51 Dimensional drawing 52 ...

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: ...Standard equipment Standard dryer consisting of 2 vessels filled with desiccant 1 upstream filter 1 downstream filter Piping and 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 supplementary documents Supplementary documents such as o...

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 supp...

Page 9: ...ries 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 dry...

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: ...Warning against sudden air ejection When the vessels are depressurised air flows suddenly out of the sound absorber This causes a sudden loud cracking noise Due to particles carried in the air flow there is a very considerable risk of eye injury When working on the dryer always wear eye and ear protection equipment Skid risk When emptying and filling the vessels with drying agent there is a risk o...

Page 12: ...orage 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 dry...

Page 13: ...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 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 manuf...

Page 14: ...s 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 profiles Rotat...

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: ... 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 ambient environment To this end the two chambers alternate between different operating modes Whilst in one vessel compressed air is de humidified adsorption in the other vessel the humid drying agent is...

Page 17: ... 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 right chamber is released via the muffler down to ambient pressure within just a few seconds The outflow of the compressed air becomes noticeable due to a sudde...

Page 18: ...tion 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 will be effected b...

Page 19: ...controller than the pressure dew point controller see below When both options are in place the compressor synchronisation controller 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...

Page 20: ...eneration air changes This effect may have a negative impact on the cost effectiveness of the dryer To prevent this it is possible to replace the built in regeneration air nozzle by a nozzle with a modified bore This replacement optimizes the regeneration air consumption and therefore restores the energy efficiency of the dryer To receive more information on this conversion please contact the manu...

Page 21: ...installed by the owner so that the dryer can be installed and maintained in a depressurised condition see also the installation example on page 20 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 from...

Page 22: ...ryer 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 option...

Page 23: ...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 tha...

Page 24: ... 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 25: ...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 26: ...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 dewpoi...

Page 27: ... 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 default data ...

Page 28: ...p 26 K MT 1 4 D3 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 ...

Page 29: ...r 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 Therefore the compressed air inlet valve must always be opened quite slowly Slowly open the compressed air inlet valve installed by the owner upstream of the dryer Switch on dryer to...

Page 30: ...f 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 compressed air outlet valve installed by the owner The pressure should not drop below the operating pressure if poss If necessary keep the compressed air outlet valve in a slightly open position until the compressed air system downstream of the d...

Page 31: ...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 32: ...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 31 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 33: ...h 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 cycle from the point at which it has been stopped Emergency shutdown To emergency shut down the dryer heed to the following instructions Close shut off valves upstream and downstream of the dryer ...

Page 34: ...ing control 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 ...

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: ...ask to be carried out Maintenance interval daily 12 months 24 months 48 months See page Complete dryer Carry out visual checks and function checks 35 Muffler K MT 1 2 Clean muffler replace if necessary 36 K MT 3 4 Mufflers must be replaced annually and after each desiccant change 36 Fine filter muffler option Replace silencer element annually and after each desiccant change 37 Sensor of optional d...

Page 37: ...nto 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 reset to 0 If the following appears in the display for a short time FAIL then flashing OFF this means that the dongle has already been used once and cannot be used again Switch off the controller again and ...

Page 38: ...T 1 2 Warning against sudden air ejection During expansion the pressure is released suddenly through the muffler A loud cracking noise occurs which can injure 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 dryer The correct procedures for all muffler versions are describ...

Page 39: ...o replace the dew point sensor every year This period depends howev er on the actual application and might thus be extended accordingly Dewpoint sensor 1 Warning The dew point sensor is a sensitive measuring device It can be damaged if subjected to forceful vibrations or shocks Therefore please handle the dew point sensor with great care at all times In order to limit the impact on the dryer opera...

Page 40: ...ou 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 visible Release pressure fro...

Page 41: ...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 32 Replace perforated plates demisters and drying agent To complete the following maintenance tasks you must di...

Page 42: ...art 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 order to avoid any eye irritations wear protective goggles In order to avoid any dust inhalation we...

Page 43: ...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 the chambers Slowly fill up with new drying agent in the...

Page 44: ... key to tighten the screws and take care to observe the following torques 25 Nm in the case of K MT 1 4 Tighten the screws crosswise in accordance with the sequence shown on the right Repeat the process once Restart the dryer see page 32 Check that the connection is leak tight Operate the dryer for two cycles then shut it down again Correctly affixing the check valve plate Replace sound absorber a...

Page 45: ...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 of possib...

Page 46: ...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 47: ...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 48: ...ocumentation 46 K MT 1 4 D3 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 49: ...Nominal2 pipe size Upstream filter Downstream filter Nominal Pressure in bare Nominal temperature C K MT 1 8 1 4 AAP010AGFI AOP010AGMI 16 50 K MT 2 15 1 4 AAP010AGFI AOP010AGMI 16 50 K MT 3 25 1 4 AAP010AGFI AOP010AGMI 16 50 K MT 4 35 1 4 AAP010AGFI AOP010AGMI 16 50 1 m3 h relating to 1 bara and 20 C at the compressor suction capacity Subsequently com pressed to 7 bare and 35 C inlet temperature to ...

Page 50: ...pe of delivery K MT 1 to K MT 4 12 and 36 months 115V 230V SKK1 K4 D3 12 Reset module muffler and filter elements K MT 1 to K MT 4 24 months 115V 230V SKK1 K4 D3 24 Reset module valve membranes muffler and filter elements K MT 1 to K MT 4 48 months 230V SKK1 K4 D3 48 Reset module valve membranes solenoid coils check valves demisters perforated plates muffler and filter elements 115V SKK1 K4 D3 48 ...

Page 51: ...EN User Manual Annex with technical documentation K MT 1 4 D3 49 Logic control diagram Adsorption in B1 and regeneration in B2 ...

Page 52: ...EN User Manual Annex with technical documentation 50 K MT 1 4 D3 Regeneration in B1 and adsorption in B2 ...

Page 53: ...al 70 Control system 10 102 Perforated plate 80 Upstream filter 10 107 Demister left 90 Downstream filter 10 108 Demister right 100 Muffler 10 109 Left perforated plate Optional devices 10 110 Conical pressure spring 110 Start up device 10 111 Right perforated plate 120 Regeneration gas return line 50 Regeneration gas orifice plate 701 Dewpoint sensing unit ...

Page 54: ...D3 Dimensional drawing Installation on floor F C D B A E Type BSP P NPT Dimensions mm Weight kg A B C D E F K MT 1 1 4 326 400 216 376 101 90 11 5 K MT 2 1 4 326 575 216 551 101 90 15 5 K MT 3 1 4 326 825 216 801 101 90 20 0 K MT 4 1 4 326 1075 216 1051 101 90 25 0 ...

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Page 56: ...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 ...