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EN

| User Manual

Annex with technical documentation

52

KA-MT 10-95/D3

Desiccant packs (complete dryer)

Typ

Order-ID.

Content

KA-MT 10

K-MT10DESMIX

Pakete mit ausreichend Trocken-
mittel um beide Behälter entspre-
chend der Wartungsvorschriften
vollständig zu befüllen.

KA-MT 15

K-MT15DESMIX

KA-MT 20

K-MT20DESMIX

KA-MT 25

K-MT25DESMIX

KA-MT 35

K-MT35DESMIX

KA-MT 45

K-MT60DESMIX

KA-MT 60

K-MT60DESMIX

KA-MT 75

K-MT75DESMIX

KA-MT 95

K-MT95DESMIX

Activated carbon packages

Typ

Quantity

Order-ID.

Content

KA-MT 10

1x

DESPAC10AK

Pakete mit Aktivkohle in ver-
schiedenen Gebindegrößen.
Ggf. kann es erforderlich sein
mehrere Pakete verschiedener
Gebindegrößen miteinander zu
kombinieren um die Aktiv-
kohlestufe vollständig zu be-
füllen. Beachten Sie hierzu die
jeweils erforderlichen Gebind-
etypen und deren Anzahl.

KA-MT 15

1X

DESPAC3AK

1X

DESPAC10AK

KA-MT 20

2x

DESPAC3AK

1X

DESPAC10AK

KA-MT 25

1x

DESPAC3AK

2X

DESPAC10AK

KA-MT 35

3x

DESPAC10AK

KA-MT 45

1x

DESPAC3AK

3x

DESPAC10AK

KA-MT 60

5x

DESPAC10AK

KA-MT 75

7x

DESPAC10AK

KA-MT 95

9x

DESPAC10AK

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Summary of Contents for KA-MT 10-95/D3

Page 1: ...KA MT 10 95 D3 Adsorption dryer Operating manual 30 02 2020 rev02 EN Cod 398H271980 Generation 3 ...

Page 2: ......

Page 3: ...ons for installation 18 Connect piping 19 Installing the electrical connection 20 Start up 22 Requirements for initial start up 22 Setting times of the operating phases 23 Overview of operating and control elements 23 Start up dryer 26 Changing cycle mode optional 28 Monitoring dryer operation 29 With dewpoint sensing control optional 29 Shutdown and restart dryer 30 Emergency shutdown 30 Depressu...

Page 4: ...r Manual 2 KA MT 10 95 D3 Annex with technical documentation 48 Technical data 49 Replacement and wear part list 50 Tightening torque values 52 Logic control diagram 53 Flow diagram 55 Dimensional drawing 56 ...

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: ...r 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...

Page 7: ...ch 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 specia...

Page 8: ...d 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 su...

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 d...

Page 10: ...r zones at the dryer Signs and instructions 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 the upstream filter Type plate of the dryer Vessel plate Type plate of the down stream filter ...

Page 11: ...s 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 of skidding caused by spilt drying agent 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 ...

Page 12: ...storage 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 d...

Page 13: ... 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 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 contac...

Page 14: ...h the upper pipe bridge and thus damage it Remove the packaging of the dryer Attach suitable lifting gear to the transport lugs of the vessels see figure I Raise the dryer see figure II and remove the transportation pallet Place the dryer at its installation site I Transport lugs on pressure vessel II Installing by crane Anchoring the dryer Use suitable attachment material to anchor the dryer to t...

Page 15: ...r 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 protect them again...

Page 16: ...w 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 ambient environment To this end the two chambers alternate between different operating modes Whilst in one vessel compressed air is de humidified adsorption i...

Page 17: ...e regeneration is subdivided into three phases expansion dehumidification and pres sure 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...

Page 18: ...ption 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 ...

Page 19: ...ntroller 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 control With a dewpoint sensin...

Page 20: ...n 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 from being exceeded The safety device must be i...

Page 21: ... connect the dryer to the compressed air system The following figure shows an installation example Compressed air system Item Component 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 10 Bypass...

Page 22: ...y 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 t...

Page 23: ...1 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 connecti...

Page 24: ...p the following preconditions must have been met The pipe system is free from contaminations scales thread abrasions welding beads and other contaminations All shutdown valves are closed of the compressed air inlet and outlet valves installed by the owner in the bypass line if available are closed The dryer is correctly sited and installed Checks before start up Ensure that all pipe cable and bolt...

Page 25: ...ax Overview of operating and control elements ON OFF switch The ON OFF switch 2 is located to the side of the switchbox 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 valves are V1 V2 are open while the expansion valves V3 V4 are closed This means that the air can circulate in the main processing direction even if the...

Page 26: ...ses of the dryer are indicated by means of 4 LEDs 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 details regarding the sequence of the individual processing steps and their duration pl...

Page 27: ...ected Sensor defective 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 Oil indicator The dryer is equipped with an oil indicator The indi cator allows for periodic measuring of the residual oil concentration in the purifi...

Page 28: ... on the size of the dryer and the compressed air network and the respective legal requirements in your country it may be necessary to perform initialisation according to the directive for pressure equipment Check the dryer regularly for externally visible damage and defects Any changes even in its operating behaviour must be reported immediately to the competent office or person In the event of an...

Page 29: ... the compressed air system downstream of the dryer is pressurised or that a start up device option see page 17 was installed into the compressed air system directly downstream of the dryer The importance of this increases with the size of the compressed air system downstream of the dryer Smaller compressed air systems can be pressurised also by means of compressed air fed through the dryer Slowly ...

Page 30: ...point 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 N...

Page 31: ...chbox shows the currently measured dewpoint The range of display is 100 C 148 F to 20 C 68 F If the set dewpoint is exceeded the system automatically completes a switchover between the chambers 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...

Page 32: ...tchover 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 ...

Page 33: ...ad 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 pressure in any circumstance If pressure drops too fast this may caus...

Page 34: ...age Open compressed air supply and switch on dryer a pagina 26 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 the dryer Close the compressed air inlet valve installed by the owner Switch off the dryer by setting the ON OFF switch to position 0 ...

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 ma...

Page 36: ... interval daily monthly 12 months 24 months 48 months See page Complete dryer Carry out visual checks and function checks 36 Vessel pressure gauge Check dam pressure For a dam pressure exceeding 0 3 bar Check muffler Check dust sieve Check drying agent 36 Oil indicator Measure the residual oil content and the residual capacity of the purifying agent Muffler Replace muffler after 1 year of operatio...

Page 37: ... the dryer is due for servicing The message appears flashing every 60 seconds once the preset number of operating hours e g 8000 oh has been reached After maintenance has been carried out you can use the dongle to reset 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 electri...

Page 38: ...th Clean the surfaces with a moist well wrung cloth Check dam pressure If following depressurisation of a vessel e g after the expansion phase the overpressure has not decreased to 0 bar then there is a residual pressure designated as dam pressure in the vessel Check for dam pressure if the dryer functions correctly the respective pressure gauge indicates 0 bar Then there is no dam pressure If the...

Page 39: ...he residual oil concentration 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 int...

Page 40: ... 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 41: ...uration 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 38 and determine the corresponding number of scale seg ments wit...

Page 42: ...he 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 ap...

Page 43: ...ugh 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 Depressurise the dryer and shut it down see page 30 Unscrew muffler as shown in the opposite figure Replace muffler and secure it Restart dryer see page 31 ...

Page 44: ...er 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 by turning the nut 2 Take the ...

Page 45: ...xpansion valves have to be re placed every 24 months as a precautionary measure Replacing solenoid coils Solenoid coils come with the 24 month service kits Replace them every 2 years Every 48 months In accordance with national regulations a pressure vessel inspection may be prescribed to be carried out at regular intervals by an independent supervisory office For an inspection of the pressure vess...

Page 46: ...he following table shows who is allowed to remedy a fault the owner s specialist personnel or the manufacturer s service engineer Table of possible faults Fault Possible cause Remedy Specialised personnel Service technician Excessive dam pres sure during regener ation Muffler or filter element of the muffler is contaminated Check mufflers or filter elements for contamination clean if nec and poss ...

Page 47: ...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 solenoid valve for contam ination clean or replace if necessar...

Page 48: ...ntial pressure on the upstream filter is too high Check differential pressure on the upstream filter if nec renew filter element Condensate trap on the up stream filter does not work Check function of the con densate trap if nec clean or renew Drying agent is contaminat ed or too old Check upstream filter for contamination if nec renew element Check drying agent for contamination if nec renew dryi...

Page 49: ...ed 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 orde...

Page 50: ...umentation 48 KA MT 10 95 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 51: ...perat C KA MT 10 105 1 AAP025EGFI AOP025EGMI 16 50 KA MT 15 145 1 AAP025EGFI AOP025EGMI 16 50 KA MT 20 200 1 AAP025EGFI AOP025EGMI 16 50 KA MT 25 255 1 1 2 AAP030GGFI AOP030GGMI 16 50 KA MT 35 350 1 1 2 AAP030GGFI AOP030GGMI 16 50 KA MT 45 420 1 1 2 AAP035GGFX AOP035GGMX 16 50 KA MT 60 620 2 AAP040HGFX AOP040HGMX 16 50 KA MT 75 750 2 AAP040HGFX AOP040HGMX 16 50 KA MT 95 940 2 1 2 AAP045IGFX AOP045...

Page 52: ...rdered always state the dryer type and the build no of the dryer These data are found on the type plate Service kits 12 and 36 months For model Mains voltage Order ID Scope of delivery KA MT 10 to KA MT 20 115V 230V SKK10 K20 D3 12 Reset module muffler filter elements pilot valves KA MT 25 115V 230V SKK25 D3 12 KA MT 35 115V 230V SKK35 D3 12 KA MT 45 115V 230V SKK45 D3 12 KA MT 60 to KA MT 75 115V...

Page 53: ...0V SKK35 D3 24 KA MT 45 115V SKK45 D3 24 115 230V SKK45 D3 24 KA MT 60 to KA MT 75 115V SKK60 K75 D3 24 115 230 V SKK60 K75 D3 24 KA MT 95 115V SKK95 D3 24 115 230V SKK95 D3 24 Additional spare parts Order no Maintenance interval Quantity Scope of delivery ZHM100 450 12 months 1 Dewpoint sensor LS5 ZR 12 months 1 Element fine filter muffler RK MANO 063SR0219 1 12 months 1 Vessel pressure gauge P02...

Page 54: ...KA MT 95 K MT95DESMIX Activated carbon packages Typ Quantity Order ID Content KA MT 10 1x DESPAC10AK Pakete mit Aktivkohle in ver schiedenen Gebindegrößen Ggf kann es erforderlich sein mehrere Pakete verschiedener Gebindegrößen miteinander zu kombinieren um die Aktiv kohlestufe vollständig zu be füllen Beachten Sie hierzu die jeweils erforderlichen Gebind etypen und deren Anzahl KA MT 15 1X DESPAC...

Page 55: ... 10 95 D3 53 Tightening torque values After the performance of maintenance activities reconnect the aluminum elbows indicated in the images to the valves blocks and to the vessels by applying to the screws a tightening torque between 8 Nm min and 10 Nm max ...

Page 56: ...EN User Manual Annex with technical documentation 54 KA MT 10 95 D3 Logic control diagram Adsorption in B1 and regeneration in B2 ...

Page 57: ...EN User Manual Annex with technical documentation KA MT 10 95 D3 55 Regeneration in B1 and adsorption in B2 ...

Page 58: ... Item Designation Item Designation 1 Dust sieve 8 Muffler 2 Check valve block V5 V6 9 Control system 3 Regeneration gas orifice plate 4 Upstream filter Optional devices 5 Downstream filter 10 Dewpoint sensing unit 6 Solenoid valve block V1 V4 11 Start up device 7 Oil indicator OP01 ...

Page 59: ...KA MT 15 G 1 1170 880 1750 490 400 60 1320 1320 193 KA MT 20 G 1 970 930 1530 490 400 60 1160 1160 193 KA MT 25 G 1 970 930 1760 530 400 60 1320 1320 234 KA MT 35 G 1 1260 1220 1810 585 400 60 1320 1320 283 KA MT 45 G 1 1290 1250 1820 605 400 80 1320 1320 334 KA MT 60 G 2 1350 1290 1870 635 500 80 1320 1320 428 KA MT 75 G 2 1500 1440 2000 640 500 80 1515 1515 555 KA MT 95 G 2 1550 1490 2020 670 50...

Page 60: ...enver Deutschland GmbH Argenthaler Str 11 55469 Simmern Deutschland Tel 49 0 6761 832 0 Fax 49 0 6761 832 409 Gardner Denver Ltd Redditch Worcestershire Claybrook Drive Redditch B98 0DS UK Tel 44 0 1527 838 200 ...

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