Parker K-MT 10-95 Operating Instructions Manual

Adsorption dryer

K-MT 10-95

Dokument-ID: DMN-K-MT10-95/R02

Operating instructions

Revision 02 — 2016/EN

Cod: 398H272167

Declaration of Conformity

Parker Hannifin Manufacturing Germany GmbH& Co. KG

Gas Separation and Filtration Division EMEA

Im Teelbruch 118

D – 45219 Essen Kettwig

hereby declares with sole responsibility, that the products

compressed air adsorption dryer

K-MT 10–95

assembly type: assembly acc. to Art. 4 No. 2b,

which this declaration refers to, conform to Directive 2014/68/EU and were
subjected to a conformity assessment according to Annex III Modules B + D (for
assembly assessment).

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).

Pressure vessel

Dryer Quantity Allowable

pressure (PS)

Volume

[l]

Category

(PED)

Module

K-MT 10

2

16

20

II

B + D

K-MT 15

2

16

24

II

B + D

K-MT 20

2

16

36

II

B + D

K-MT 25

2

16

45

II

B + D

K-MT 35

2

16

55

II

B + D

K-MT 45

2

16

70

III

B + D

K-MT 60

2

16

105

III

B + D

K-MT 75

2

16

132

III

B + D

K-MT 95

2

16

175

III

B + D

Piping

Dryer Allowable

pressure (PS)

Dimensions

(DN)

Category

(PED)

Module

K-MT 10

16

DN25

Art.4.3

Art.4.3

K-MT 15

16

DN25

Art.4.3

Art.4.3

K-MT 20

16

DN25

Art.4.3

Art.4.3

K-MT 25

16

DN40

Art.4.3

Art.4.3

K-MT 35

16

DN40

Art.4.3

Art.4.3

K-MT 45

16

DN40

Art.4.3

Art.4.3

K-MT 60

16

DN50

Art.4.3

Art.4.3

K-MT 75

16

DN50

Art.4.3

Art.4.3

K-MT 95

16

DN65

I

A

Filter

Dryer Filter Quantity Allowable

pressure (PS)

Volume

[l]

Category

(PED)

Module

K-MT 10

GL 9 2 16

1,1

Art.4.3

Art.4.3

K-MT 15

GL 9 2 16

1,1

Art.4.3

Art.4.3

K-MT 20

GL 9 2 16

2

Art.4.3

Art.4.3

K-MT 25

GL 11 2 16

2

Art.4.3

Art.4.3

K-MT 35

GL 11 2 16

2

Art.4.3

Art.4.3

K-MT 45

GL 12 2 16

6 I B+D

K-MT 60

GL 13 2 16

6 I B+D

K-MT 75

GL 13 2 16

6 I B+D

K-MT 95

GL 14 2 16

6 I B+D

The following standards / technical specifications were used:

 harmonized standards: DIN EN ISO 12100:2011-03, DIN EN 61000-6-2,

DIN EN 60204

The following other EC directives were used

 2014/30/EU
 2014/35/EU

Essen,

19.07.2016

Datum / Date i. V. Dr. Jürgen Timmler

Leiter Technik und Entwicklung /

Manager Engineering and Development

Machine passport

Type designation K-MT ___

Order no.

Order ID.

Build no.

Vessel no.

Vessel no.
Year of manufacture

It is the responsibility of the owner,

 to enter for the first time any appliance data not 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 11).

Table of contents

General information ............................................................................................ 8

Manufacturer's details ............................................................................................................ 8

Details on the dryer ................................................................................................................ 8

About these operating instructions.......................................................................................... 9

For your own safety .......................................................................................... 10

General safety notes ............................................................................................................ 10

Signs, instruction plates and danger zones at the dryer ........................................................ 11

Intended use of the dryer ...................................................................................................... 13

Transportation, installation and storage ......................................................... 14

Information on transportation packaging ............................................................................... 14

What to do in the case of transport damage occurring? ........................................................ 14

Transporting and installing the dryer ..................................................................................... 15

Storing the dryer ................................................................................................................... 17

Technical product description ......................................................................... 18

Summary Drawing Standard Dryer ....................................................................................... 18

Function description ............................................................................................................. 19

Available options .................................................................................................................. 21

Installation .......................................................................................................... 23

Preconditions for installation ................................................................................................. 23

Connect piping ..................................................................................................................... 24

Installing the electrical connection ........................................................................................ 25

Start-up ............................................................................................................... 27

Requirements for initial start-up ............................................................................................ 27

Setting times of the operating phases ................................................................................... 28

Overview of operating and control elements .........................................................................

28

Emergency shutdown ........................................................................................................... 31

Start up dryer ....................................................................................................................... 31

Changing cycle mode ........................................................................................................... 33

Monitoring dryer operation ............................................................................... 35

With dewpoint-sensing control (optional) .............................................................................. 35

Shutdown and restart dryer .............................................................................. 36

Emergency shutdown ........................................................................................................... 37

Depressurising and shutting down the dryer ......................................................................... 37

If work is to be carried out on the electrical system ............................................................... 37

Restart ................................................................................................................................. 38

Maintenance and repair of the dryer ................................................................ 39

Notes on maintenance ......................................................................................................... 39

Regular maintenance intervals ............................................................................................. 40

Instructions for use of the dongle ......................................................................................... 41

Daily maintenance tasks ...................................................................................................... 42

Maintenance work to be completed every 12 months........................................................... 42

Notes on further maintenance work ..................................................................................... 45

Identify and eliminate faults ............................................................................. 46

Summary of faults ................................................................................................................ 46

Index ................................................................................................................... 49

Annex with technical documentation .............................................................. 51

Technical data ..................................................................................................................... 52

Replacement and wear parts list .......................................................................................... 53

Flow diagram ....................................................................................................................... 55

Logic control diagram ........................................................................................................... 56

Dimensional drawing............................................................................................................ 58

8 K-MT10-95_EN_02

General information

Manufacturer's de tails

Name and address

Details on the dryer

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(separate document)
 Operating manual for installed filters (separate document)

Notes on supplementary documents

Supplementary documents such as operating manuals for options or pertaining
components must always be heeded. They contain additional information, e.g.
regarding maintenance, and are therefore necessary for safe operation of the plant.

∗

Planned dryers may be equipped with special components

K-MT10-95_EN_02 9

About these operating instructions

These operating instructions contain basic information on the safe use of the
dryer.

Characters and symbols used

► Work steps that you have to carry out in the sequence stated are marked by

black triangles.

Lists are marked by a small box.

Note:
These notes provide you with hints and information on the safe and

efficient handling of machines and devices.

Warning!
These safety notes warn against damage to property and help you to

avoid such 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.

T arget 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 specialist personnel, e.g. fitters
or electricians.

Operating instructions: handling

These operating instructions must be continuously available at the site where the
dryer is used. We recommend to prepare a copy and to keep the same in a safe
and freely accessible place next to the dryer. Keep the original document in a
safe place.

10 K-MT10-95_EN_02

For your own safety

The dryer has been built in accordance with the state of the art and the
recognized technical safety regulations. Nevertheless, there is a risk of personal
injury and damage to property when the dryer is used, if

it is operated by non-qualified personnel,
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.

General safety notes

Warning against sudden air ejection
When the hollow section 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.

Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way, for as

long as the plant is still pressurised! 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 supply
cable and all external power lines must be made voltage-free!

Personnel qualification

Only authorized 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.

K-MT10-95_EN_02 11

Handling drying agents

The drying agents are perfectly safe when in an unused condition. However,
when filling and emptying the vessels with drying agents, increased dust
generation may occur. Please comply with the following instructions:

When filling drying agents into the vessels, wear a dust mask and eye protection!
If a spillage occurs, any spilt drying agent must be taken up immediately. There is a

risk of skidding!

Disassembly and disposal

Dispose all parts of the dryer, the drying agent, and all other operating materials in
an environmentally safe way and in accordance with all current statutory regulations.

Signs, instruction p lates and danger zon es at th e d r yer

Signs and instruct ions

Type plate

of the

dryer

Type plate of the

downstream filter

Type plate of the

upstream filter

Vessel plate

Front view Rear view

Please note the above plates and instructions attached to the dryer. Ensure that
they are not removed and are always readable.

12 K-MT10-95_EN_02

Hazard areas on the dryer

Hazard caused by electrical voltage

Hazard caused by overpressure

Hazard caused by sudden air ejection during

expansion

Hazard area

Symbol in
operating
instructions

Warning against hazardous electrical voltage

Different parts of the dryer carry electrical current. These parts may be
connected, 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:

 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 of
skidding caused by spilt drying agent.

K-MT10-95_EN_02 13

Intended use of the dryer

The dryer is exclusively intended for drying compressed air. Depending on
defined input conditions, it 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 accordance with the contractual conditions.

Suspected misuse

The dryer must not be misused as a climbing aid! Pipes, valves, and similar
fittings have not been designed for such loads. They could fracture, tear off, or
become damaged in another way.

14 K-MT10-95_EN_02

Transportation, installation and storage

Danger due to incorrect transportation!
The dryer must be transported by authorized and qualified specialist

personnel only. During transportation all applicable national regulations
for accident prevention must be complied with. Otherwise there is a risk
of personal injury.

Always adhere to the stickers and notes on the packaging of the dryer!

 Only use suitable and technically perfect lifting gear with a sufficient carrying

capacity.
During transportation the dryer must be carefully secured against falling over.
The manufacturer will not be liable for any damage caused by incorrect storage

or incorrect transportation. Please note therefore the following instructions as well
as the storage instructions on page 17.

Information on transportation packaging

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 packaging is undamaged

► The undamaged packaging should be removed only at the final installation

site, as it offers protection against any weather influences.

What to do in the case of transp o rt damage occurring?

► Check whether only the packaging or the dryer itself were damaged.
► Inform the haulier immediately in writing of any damages.
► Contact the manufacturer urgently in order to report the damage.

Warning!

A damaged dryer must not be taken into operation! Damaged components
may lead to functional faults and possibly cause further damage.

K-MT10-95_EN_02 15

T ransporting and installing the dryer

Requirements for the installation site

The conditions at the installation site have a large influence on the functional
capability of the dryer and the service life of the drying agent. In order to ensure a
mode of operation, which is as continuous as possible, and low maintenance, the
installation site must meet the following requirements:

 The installation site must be located within a building. Protect the dryer against

moisture.

 The ambient temperature must not drop below +1,5 °C (34,7 °F).
 Heed the dryer’s noise emission when selecting the installation location.
 The installation area must be level, firm and vibration-proof. 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
drying agent without any hindrances
(see figure).

Necessary spacing at the top and sides

= min. 1 m

If in doubt, the installation site must be inspected by specialists. If you have any
queries in this regard, please contact the manuf acturer (for details see page 8).

Transportation using lifting or forklift trucks

Warning against damage to property!

The dryer is delivered standing on its side on a transportation pallet. Top

and sides have not been designed for mechanical loads. Therefore do not

place any load onto the top face. Do not stack.

Therefore, always transport the dryer on a lifting or forklift truck.

The dryer should only be transported in an upright position.

► Secure the dryer on the lifting or forklift truck against sliding movements.
► Transport the dryer to its installation site.

16 K-MT10-95_EN_02

Installing the dryer

Caution!
Always use the lifting lugs at the top of the tank to lift

the dryer. Use a lifting

beam with a suitable spacing for this purpose. This will ensure the tanks
cannot come in contact with 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 the floor.
► In the case of vibrating floors: place the dryer on suitable vibration dampers.

K-MT10-95_EN_02 17

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 storage room must be dry.
The storage room must be free from dust or the dryer must be covered by a

protective sheet.
The storage room must have an ambient temperature of at least +1 °C (33,8 °F).

In order to store the dryer proceed as follows:

► Take dryer out of operation as described on page 37.
► Ensure that the compressed air inlet valve installed 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 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 extended period

of storage, please proceed as described for its first commissioning
and start-up (see page 32).

Store drying agents

► Do not store drying agents in the open air.
► Protect drying agents against humidity.

18 K-MT10-95_EN_02

Technical product description

Summary Drawing Stan d ar d D r yer∗

Dewpoint sensor

Vessel pressure gauge

Compressed air inlet

Compressed air outlet

Upstream filter

Downstream filter

On/Off-Switch

Power supply connector

Control cabinet

Discharge point

Muffler

Check valve block

Transport lugs

Differential pressure gauge

Vessel

Solenoid valve block

∗

Planned dryers may differ in their configuration (in this case, refer to the enclosed dimensional drawing)

K-MT10-95_EN_02 19

Function description

The dryer 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 into the compressed air system.

The two vessels 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 vessels alternate between different operating modes. Whilst
in one vessel, compressed air is de-humidified (adsorption), in the other vessel
the humid drying agent is prepared for another charge (regeneration). These two
states, which run in parallel during compressed air preparation, are described
below.

Adsorption

Via a compressor, humid compressed air is

supplied to the upstream filter. Fr om here, t he
compressed air flows upwards through the
absorption vessel, which is pressurised. In so
doing, the drying agent dehumidifies the air. The
dry compressed air is supplied to the pipe
network via the downstream filter.

Here, adsorption is shown in the

left vessel.

Regeneration (running in parallel to the adsorption)

At the s ame time t he other vessel is prepared for a renewed 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.

20 K-MT10-95_EN_02

Expansion phase

During the expansion phase the pressure in the
right vessel 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 sudden powerful flow noise at

the muffler.

Dehumidification phase

Prior to being released into the pipe network,
dried compressed air is bled by means of an
orifice plate. This separate regeneration air flow
is fed through the depressurised vessel. The
humidity stored in the drying agent is taken up by
the air flow and expelled into atmosphere via the
muffler.

Here, regeneration is shown in the

right vessel.

Pressure build-up phase

After dehumidification the pressure in the
regenerated hollow section vessel is built up to
operating pressure, so that the switchover from
regeneration to adsorption can take place at
operating pressure level.

Pressure build-up

Standby phase (only with the dewpoint-sensing 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 vessel has taken up a sufficient level of
humidity, then the switchover between the vessels will be effected between the
vessels. Following switchover, the above-described process is repeated, with the
adsorption and regeneration now taking place in the respective different vessel.

K-MT10-95_EN_02 21

Available options

The following options are available for the dryer:
Start-up device
Signalling contacts of control system
Regeneration gas recirculation
Dewpoint-sensing control
Fine filter muffler
Nozzle kit

Start-up device

A start-up device basically consists of a pressure holding device, which is located
at the rear of the dryer. The pressure holding device ensures that pressure can
build up in the dryer and adsorption take place.

It is always required when an empty compressed air reservoir or an empty
compressed air system must be filled downstream of the dryer (e.g. following
weekend shutdowns and when the pressure in the compressed air system can
frequently drop below the stated operating pressure).

Signalling contacts of the control syst em

The control system is equipped with a digital input for the synchronised operation
with a compressor. This feature allows for synchronised and thus efficient dryer
operation with discontinuous compressor operation.

Compressor synchronisation helps reduce energy costs, as the dryer can be
operated independently of the compressor.

The compressor synchronisation controller is a higher-level 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
contact as standard. It is used for the transmission of operating signals and for
the output of dewpoint alarms.

Regeneration gas recirculation

When the compressor is switched off, the regeneration gas recirculation serves to
continue regeneration provided a sufficiently large compressed air volume is
present downstream of the dryer. The regeneration process must be continued
and ended so that the drying agent does not become unusable prematurely.

Regeneration gas recirculation depends on the properties of the installed
compressed air network and should be discussed with the manufacturer
beforehand.

22 K-MT10-95_EN_02

Dewpoint-sensing control

With a dewpoint-sensing control system, you can operate the dryer in fixed or
variable cycles. In the fixed cycle, switchover is effected after a fixed time period
(usually after 5 minutes). In the variable 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 amounts to 60 minutes maximum.

Fine filter muffler

A fine filter muffler is used to reduce the noise emission of the dryer to lower
levels than the standard muffler can provide. If installed, the fine filter muffler
replaces the original installed muffler.

Nozzle kit

In the case that the operating pressure deviates from the standard design
pressure (7bar

e

) it is possible that the amount of necessary regeneration 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 manufacturer.

K-MT10-95_EN_02 23

Installation

Only authorized and qualified specialist personnel may carry out work on
pipes and electrical systems.

As soon as the dryer has been set up at its installation location, you can install
the compressed air infeed and outlet lines make the electrical connections.

Preconditions for install atio n

For a correct installation the following preconditions must be met on the part of
the owner.

Connections and lines for the infeed and outfeed of compressed air must be
provided.

A compressed air inlet valve as well as a compressed air outlet valve must be
installed by the owner, so that the dryer can be installed and maintained in a
depressurised condition (see also the installation example on page 24).

All pipes, couplings, and connections must have the correct diameter and match the
operating 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 installed so that the dryer is reliably protected

from exceeding the maximum permitted operating pressure even when
the temperature of the compressed gas increases.

The data required to meet these preconditions are contained in the technical
documentation attached in the annex.

Warning!

If the above preconditions are not complied with, a safe operation of the
dryer cannot be assured. Also, the functionality of the dryer may be
detrimentally affected.

24 K-MT10-95_EN_02

Connect piping

In order to ensure that the dryer operates optimally, the dryer must be assembled
into the compressed air system free of all stresses.

► Ensure before connection that all infeed and outfeed compressed air lines

and valves are clean and undamaged.

► Check the bolt connections and retighten if necessary, as they could have

worked loose during transportation.

► Remove plugs on the pressure inlet and outlet.

All piping must be free from any stress and tension whatever!
Pipes subject to stress may burst due to the load placed on them during

operation. This may cause damage to property and personal injury.

► Use steel pipes to 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

Outlet, dry air

8

Bypass line (option)

9

Valve in bypass line

(option)

1
0

Bypass filter (option)

1

1

Valve, outlet bypass
filter (option)

Example of an installation with bypass line

► The connection lines for the upstream filter (3) are to be installed at a slight

incline in the direction of the upstream filter.

► One shutdown valve each (2, 6) is to be installed at the compressed air inlet

and outlet ends of the dryer.

► If you fit a bypass line (8) with additional shutdown valve:

Fit the line such that, when carrying out maintenance work on the dryer, the
line system can continue to be supplied with compressed air.

K-MT10-95_EN_02 25

Installing the elect r ical connection

Warning against electrical voltage
Only qualified specialist personnel may carry out work on the electrical

system!

Installing the supply cable

The components of the dryer have been connected to the control cabinet at the
factory. You only need to connect the control cabinet to the electrical supply
cable.

The switchbox is provided with a connector where electrical power must be
connected.

► Ensure that the cross-section of the electrical supply cable corresponds to

the power rating of the dryer and the electrical voltage provided 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
longer than 35 mm max.

► Now make the cable connection as

follows:

— Earth

to terminal PE

— L1 to terminal 1
— N to terminal 2

Terminal 3 is not used.

Connect electrical cable to device

adapter

► Fit terminal block into the connector and use bolt to remount the connector

with seal on the switchbox.

► In all phases the dryer must be protected against short circuits by means of

fuses.

► In order to relief cable strain, re-tighten the PG union.

26 K-MT10-95_EN_02

Connecting the external signalling lines

For compressor synchronisation

The controller is fitted as standard with a digital input which makes the dryer
regeneration dependent on operation of the compressor (switch S1 on the
controller’s circuit board, see also figure below).

If switch S1 is in the ON position, operation of the compressor and dryer
regeneration run synchronously: When 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 the control board (see circuit diagram).

Note:
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,
connecting the respective line to a potential-free operation signalling contact.
With this option, the following statuses and events can for example be
transmitted to a remote control room:

Dryer on (contact made)
Power supply disconnected (no contact)
Dewpoint alarm (only with dewpoint-sensing control option, no contact)
To install the external lines, proceed as follows:
► Connect the lines of the fault signalling system to relay K5 (see circuit

diagram).

Check bolt connections

Before the initial start-up:
► Check all unions and bolt connections as well as the terminals in the control

cabinet for secure seating; re-tighten if necessary.

K-MT10-95_EN_02 27

Start-up

Warning!

The dryer must be taken into operation by trained personnel only!
Untrained personnel does not have the required knowledge. Such
personnel might cause serious faults.

Note:
You can order the initial commissioning and start-up from the

manufacturer and have your personnel trained by the manufacturer.
For telephone number, see page 8.

Carry out all prescribed tests and checks.
Before start-up, ensure that no tools or other foreign parts have been left lying in a

part of the dryer where they might pose a hazard to the dryer being started up.

Requirements for i n itial start-up

For the first start-up the following preconditions must have been met:
The pipe system is free from

— scales
— thread abrasions
— welding beads and
— other contaminations.

All shutdown valves

— 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 connections on the dryer have been retightened,
no pipes chafe against body edges,
all mountings are perfectly secure,
the needle valve of the oil indicator is closed,
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.

28 K-MT10-95_EN_02

Setting times of th e o p er ati n g p h ases

In its standard version the dryer is delivered with a time-dependent control
system. The phase sequence occurs in a fixed cycle.

With t he optional dewpoint-sensing control, the dryer can also be operated at
variable cycles (depending on the dewpoint).

The following table provides information on the duration of the individual phases.

Phase duration

Fixed cycle

Variable cycle

Adsorption 5 min 60 min, maximum
Regeneration, total 5 min 5 min

− of which: expansion time

~ 0.2 min

~ 0.2 min

− of which: dehumidification time

~ 4 min ~ 4 min

− of which: pressure build-up

~ 1 min ~ 1 min

Standby — ~ 55 min, maximum

Overview of operating and control elemen ts

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 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-controlled).

Position II is only relevant for
operation with the optional

compressor synchronisation and/or
dewpoint-sensing control.

Switchbox with ON/OFF switch

K-MT10-95_EN_02 29

Display panel

The display panel at the
switchbox is equipped
with LEDs (light emitting
diodes) and a digital
display, indicating the
operating status of the
dryer:

Display panel at the switchbox

LED Power (1)

LED is on when dryer is switched on.

Flow diagram (2)

The current operating 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 details regarding the sequence of the individual processing
steps and their duration, please refer to the logic control diagram, page 56.

30 K-MT10-95_EN_02

Display Explanation

2

215

Default display: The figure to the left indicates the current
processing step; the figure to the right shows the remaining
time in 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 default data. The
range of display is -100 °C (-148 °F) to +20 °C (68 °F).
If the measured dewpoint exceeds the preset alarm limit (5 °C
(41 °F) above the switchover value), the displayed dewpoint
value is flashing.

With the optional dewpoint-sensing control, the following error messages might
be displayed:

Display Cause

+20



Upper 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 dewpoint­sensing control. The diode lights up when the dryer is switched on and in the

standby phase and no regeneration air is required.

Vessel pressure gauge

On both vessels, pressure gauges are fitted which show the operating
overpressure. The operating overpressure indicates the operating phase of the
relevant vessel:

 During adsorption the pressure gauge should indicate the nominal operating

overpressure.

 During regeneration the indication of the pressure gauge on the regenerating

vessel

— should decrease in the expansion phase from operating overpressure to 0

bar overpressure,

— indicate an overpressure of 0 bar in the dehumidification phase.

With an increasing duration of operation, a higher overpressure can be indicated
during regeneration. This overpressure during regeneration is also designated as
dam pressure.

K-MT10-95_EN_02 31

 The dam pressure should not exceed 0.3 bar, otherwise read the instructions

on page 42.

 During the pressure build-up phase the indication on the pressure gauge

should again rise to operating overpressure level.

Emergency shutdown

To emergency shut-down the dryer heed to the following instructions:

► Close shut off valves upstream and downstream of the dryer (if applicable)
► Disconnect the electrical power supply (i.e. by switching the ON/Off switch to

0).

 The dryer is now off-line.

► If applicable, depressurise the dryer now.
Before re-commissioning the dryer ensure that the emergency situation has been

solved and that the dryer is not damaged.
Never commission a damaged dryer!

Start up dryer

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!

Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,

for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries.

Before carrying out any work on the dryer, first depressurise the plant.

 The more 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 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.

32 K-MT10-95_EN_02

 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 37). The unit may only be
restarted after all defects have been eliminated.

Open compressed air supply and switch on dryer

For start-up, please proceed in the sequence shown here.
► Ensure that the compressed air inlet and outlet valves installed by the owner

are closed (see installation example on page 24).

► 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. 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 this end, set the ON/OFF switch to I.
If the dryer is taken into operation for the first time, or after a change of drying

agent, the following intermediate step is meaningful. In the case of a restart
situation, the following 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 the drying agent in each vessel to
be regenerated repeatedly and thus to be prepared optimally for the take-up of
humidity.

Note:
Depending on the pressure dew point to be achieved, we recommend

to operate the dryer at first start-up without compressed air
consumption:

 for at least 4 hours at a pressure dew point of –25 to –40 °C or

 for approx. 3 to 5 days at a pressure dew point of –70 °C.

If you wish to take the dryer into operation in accordance with our
recommendation, proceed as follows:

► Ensure that the compressed air outlet valve installed by the owner is closed.
► Keep the compressed air outlet valve closed for the time period

recommended above.
Then the dryer can be taken into service in the compressed air system as

described in the following section:

K-MT10-95_EN_02 33

Operate dryer immediately in the compressed air system

► Ensure that the compressed air system downstream of the dryer is

pressurised or that a start-up device (option, see page 21) 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 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 compressed air outlet valve installed by the owner. Observe

the vessel pressure gauge of the pressurised vessel. 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 dryer has filled up completely; only then should
the valve be opened fully.

Then the dryer has to 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 37).

Then proceed as follows:

Remedy fault

► Look up possible cause of the fault, and how to remedy the same, in the

table on page 46.

► Remedy fault.
► Repeat the start-up procedure.

Changing cycle mode

When can I change cycle mode?

If the dryer has been successfully commissioned and is equipped with one of the
following options:

compressor synchronisation or
dewpoint-sensing control
it can be set to economy cycle mode.

When should I change cycle mode?

Cycle changes should be made during the pressure build-up phase and prior to
switchover; during this phase, the pressure in both chambers is just below
operating pressure so that a fast pressure build-up is prevented when the
chambers are switched.

34 K-MT10-95_EN_02

During this period, only the adsorption LED is on in the diagram, and the digital
display shows step 4 or step 9 for the duration of 1 minute (see logic control
diagram; not displayed with dewpoint sensing).

Which cycle modes can I choose?

If the dryer is connected to a compressor synchronisation system and is
equipped with the dewpoint-sensing control option, these two optional devices
can only started together. The compressor synchronisation has thereby
precedence over the dewpoint-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 switchover, which is made as soon as the compressor is switched on.

Note:
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.

With dewpoint-sensing control

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 absorbing
chamber is saturated, the chambers are switched.

The dewpoint at which a switchover is made is preset at the factory.

How do I change cycle mode?

► Wait until the dryer has reached the pressure build-up phase (phase prior to

switchover).

One LED for Adsorption B1/B2 is on in the flow diagram.

► Set the ON/OFF switch to position II.

The programme continues the cycle.

K-MT10-95_EN_02 35

Monitoring dryer operation

The dryer operates fully automatically. However, you should carry out the regular
checks described in the Chapter Maintenance and repair of the dryer.

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 dryer!

With dewpoint-sensing control (optional)

Display of dewpoint

If the dryer is equipped with a dewpoint-sensing control system, the digital display
at the front of the switchbox 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 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

If the measured dewpoint exceeds the preset alarm limit (5 °C (41 °F) above the
switchover value), the displayed dewpoint value is flashing. In addition, an error
message can be issued through the potential-free busbar.

Error codes and their causes:

Display Cause

+20



Upper measuring range limit exceeded

999

 Dewpoint sensor defective

sens



Dewpoint sensor not powered

 Cable defective
 Sensor defective

or

–999

For instructions on how to eliminate faults, see chapter Identify and eliminate
faults

36 K-MT10-95_EN_02

Shutdown and restart dryer

In the following cases, the dryer must be fully shut down and depressurised:

 In the event of an emergency or malfunction
 For maintenance work
 For dismantling

Risk of injury from escaping compressed air!
Never remove any parts of the dryer, or manipulate the same in any way,

as long as the unit is pressurised! Suddenly escaping compressed air
might cause serious injuries.

Prior to any work, release all pressure from the unit.

Caution!
Risk of damage to the dryer, if it is switched off during the expansion or

drying phase.
During these phases, the pressure in the regenerating vessel is released

to ambient pressure: If the main valve is opened, as the dryer is switched
off, there is a sudden pressure build-up in the vessel. This might result in

 damage to the drying agent, and
 excessive abrasion, with negative impact on the regeneration

capacity.

Before switching off the dryer, wait until it has reached the pressure build­up phase or is in standby mode (before switchover).

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 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.

K-MT10-95_EN_02 37

Emergency shutdo wn

To emergency shut-down the dryer heed to the following instructions:

► Close shut off valves upstream and downstream of the dryer (if applicable)
► Disconnect the electrical power supply (i.e. by switching the On/Off switch to

0).

 The dryer is now off-line.

► If applicable, depressurise the dryer now.
Before re-commissioning of the dryer ensure that the emergency situation has

been solved and that the dryer is not damaged.
Never commission a damaged dryer!

Depressurising and shutting down the dryer

Close compressed air feed line

► Close the compressed air inlet valve (provided by the operator).

Disconnect voltage supply

► Switch off the dryer by setting the ON/OFF switch to position 0.

Disconnect dryer from compressed ai r system

► Close the compressed air outlet valve installed by the owner.
► If available, open bypass line.

Depressurise dryer

► Depressurise dryer, e.g. by opening the manual drain at the downstream

filter.

If work is to be carried o u t o n th e electrical system

► Depressurise and shut down the dryer, following the instructions in the above

chapter.

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 supply cable and all external power lines must be made voltage­free!

► Make the electrical supply cable to the dryer voltage-free.

► Secure the electrical supply cable to the dryer against switch-on.

38 K-MT10-95_EN_02

Restart

Depending on the fittings installed by the operator and the actual pressure
conditions, the unit might have to be restarted at operating pressure. The
following general rules apply:

When switched off, the dryer is open in main flow direction. With the optional start-
up device , the set minimum pressure must however be reached prior to restart.

A return flow is only possible in connection with the optional regeneration gas return
(and provided that the pressure outlet valve is open).

If the dryer is equipped with a dewpoint-sensing control system, it is depressurised
gradually, 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 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 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 dryer has filled up

completely; only then should the valve be opened fully.
► If available, block off bypass line.
The dryer is now in operation again and operates fully automatically.

If compressed air system and dryer have not remained at operating pressure

► If disconnected, reconnect the voltage supply of the dryer.
► Pressurise and switch on the dryer as described in the section Open

compressed air supply and switch on dryer on page 32.
The dryer is now in operation again and operates fully automatically.

K-MT10-95_EN_02 39

Maintenance and repair of the d ryer

In order to allow maintenance work on the dryer to be carried out efficiently and
without danger for maintenance personnel, you should comply with the following
instructions.

Notes on maintenance

Danger!
There is a very considerable risk of personal injury, when carrying out

work on the activated and pressurised dryer.
Before commencing any maintenance tasks always shut down the dryer

as described on page 37, !

Warning!
Maintenance tasks may be carried out only by authorized and qualified

specialist personnel, and only with the plant in a switched off and
depressurised condition.

Note:
In order to ensure perfect maintenance and reliable operation we

recommend that you conclude a maintenance contract.
When exchange or replacement parts are ordered, always state the

dryer type and the build no. 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

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 any manipulations on a hollow profile vessel or modify the

same in any way!

 Following maintenance work, always check all flange and bolt connections for

leakage and secure seating.

 Never use pipes and fittings as steps or holding points! The components

might fracture, or the distortions which occur may cause internal 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 at or on the dryer.
 Only use replacement parts that are suitable for the relevant function and

meet the technical requirements stipulated by the manufacturer. This is
always the case, if you use original replacement parts only.

40 K-MT10-95_EN_02

Regular maintenan ce intervals

Note:
If a vessel has been depressurised, e.g. after completion of the

expansion phase, and the pressure remains above 0 bar, the vessel is
pressurised by what is known as ram pressure. This might be due to

 block age at the muffler(s),
 contamination of the dust sieves,
 spent drying agent.

To prevent such malfunctions, regularly service the dryer as
described below.

The table provides an overview of the maintenance work to be carried out. The
following pages describe some of these tasks. Maintenance work requiring the
dryer to be largely disassembled is not described. We recommend to have this
work to be performed by authorised specialists.

Component

Maintenance task to be carried

Maintenance interval

daily 12 months 24 months 48 months see page

Complete dryer

Carry out visual and function checks.



42

Vessel pressure gauge

Check dam pressure.

For a dam pressure

exceeding 0.3 bar

:

–

Check muffler.

–

Check dust sieve.

– Check drying agent.

 42

Muffler

Replace muffler after 1 year of operation

and

after renewing the dessicant.

  42

Fine filter muffler

Replace element of fine filter muffler after 1

year of operation

and after renewing the

drying

agents

.

 

42

Dew point sensor (with
optional dew point
sensing-control)

Renew

 44

Pilot valves

Renew.



45

Main valves V1/V2

Renew.

 45

Expansion valves V3/V4

Renew.



45

Check valves V5/V6

Renew.

 45

Solenoids

Renew.

 45

Drying agent

Renew.



45

Upstream and
downstream filter

Please see the enclosed operating instructions for the attached filters. Maintenance work

has to be carried out as specified in this document.

K-MT10-95_EN_02 41

When carrying out any maintenance work, comply with the following safety
instructions:

Danger!
There is a very considerable risk of personal injury, when carrying out

work on the activated and pressurised dryer.
Before commencing any maintenance tasks always shut down the dryer

as described on page 37, !

Warning against electrical voltage!
Only qualified specialist personnel may carry out work on the electrical

system!

Instructions for use of the dongle

If the message SEr. is displayed on the display of the Multitronic controller, 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 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 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 remove the dongle.
► Dispose of the unusable dongle and use a new one.

42 K-MT10-95_EN_02

Daily maintenance tasks

Carry out visual and function check on the complete dryer

► Check dryer for external damage or unusual noise generation.
► Duly eliminate any defects found.

If message SEr. is displayed, a routine service must be completed:
► Contact the service department of the manufacturer.

Clean dryer

► Remove any loose dust by means of a dry cloth, and, if required, also by

means of a moist and well wrung cloth.
► 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 dam pressure is greater than 0.3 bar:
► Depressurise the dryer and shut it down (see page 37).
Dam pressure can be caused by:
a blocked muffler,
a blocked dust sieve or
drying agent which is too old.
The respective necessary maintenance measures are described in the following

sections.

Maintenance work to b e co mpleted every 12 month s

Renew muffler

The dryer is equipped with a muffler. If the muffler becomes blocked, a dam
pressure is generated which in extreme cases may cause the muffler to burst.

Hazard caused by blocked muffler!
Blocked mufflers can cause a dangerous overpressure to build up which

may cause the mufflers to burst. Flying fragments may cause personal
injury and damage to property.

Therefore, the mufflers must be replaced every 12 months and after each
change of desiccant.

K-MT10-95_EN_02 43

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!

► Depressurise the dryer and shut it down (see page 37).

► Unscrew muffler as shown in the

opposite figure.

► Replace muffler and secure it.

Undo muffler

► Restart dryer (see page 38).

Replace the element in the fine filter muffler

► Depressurise the dryer and shut it down (see page 37).
► Undo knurled screw on the lid cap

and remove cap.

► Unscrew old filter element. Arrows

on the element bottom mark the
direction of rotation.

Renew muffler

► Insert new filter element and screw on tightly.

► Re-engage lid cap at the top section of the housing and fix in position by

means of the knurled screw.

► Restart dryer (see page 38).

44 K-MT10-95_EN_02

Renew dewpoint se ns or

To ensure precision dew point

measurement, it is recommended
to replace the dew point sensor
every year.

This period depends
however 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 operation to a minimum, we recommend
that you contact the manufacturer well in advance (for contact details, see page

8) 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 37)

Installing / dismantling pressure dewpo int sen sor

► 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 new dewpoint sensor (2) from the box, remove the protective caps

(4, 5) and screw it into the sensor chamber (3).

► Place seal onto sealing face; connect adapter (1) and secure it by tightening

the screw.

► If no other maintenance work is to be carried out: Restart the dryer (see

page 38).

K-MT10-95_EN_02 45

Notes on further maintenance work

Every 12 months

Replacing pilot valves

The pilot valves are part of every service kit and must be replaced every 12
months.

Every 24 months

Replacing inlet valves (V1/V2) and check valves (V5/V6)

The inlet valves (main valves) and the check valves are part of the 24-month
service kits. Replace them every 2 years as a precautionary measure.

Expansion valves (V3/V4)

In addition to the inlet valves and the check valves, the expansion valves have to
be replaced 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 vessels, the drying agent must be removed.
When inspecting the pressure vessels, it is recommended to check the condition

of all fittings such as e.g. sieve bottoms and dust sieves, including gaskets. If
necessary, these fittings must be cleaned or renewed.

In the event of comprehensive maintenance or repair tasks, contact the
manufacturer.

Renew drying agent

The service life of the drying agent is usually approx. 3 to 5 years. However, in
favourable installation conditions, the change of drying agent may be carried out
at a substantially later date. The change interval depends very significantly from
the degree of contamination in the compressed air (or the quality of the
compressed air upstream filters). Oil, dust, and dirt particles cover the drying
agent surface and reduce its effective surface, in part quite irreversibly.

46 K-MT10-95_EN_02

Identify and eliminate faults

The following table provides information on what designatory abbreviations are to
be used for the various components. These designations are also found in the
technical documentation.

Abbreviation Component

PI Pressure gauge

PDI

Differential pressure gauge

V1–V2 (Y1–Y2)

Main valves (solenoid valves)

V3–V4 (Y3–Y4)

Expansion valves (solenoid valves)

V5–V6

Check valves

Summary of faults

There are different fault types. In the case of most electrically caused faults (e.g.
short 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 of possible faults

Fault Possible cause Remedy

Spec. personnel Service engineer

Excessive dam

pressure during
regeneration

Muffler or filter element of the muffler is

contaminated.

Check mufflers or filter elements for

contamination, clean if nec., and poss.
renew.

 

Expansion valve V3/V4 does not open

correctly.

Check expansion valve for contamination, if

nec. clean/renew.

 

Dust sieves are contaminated.

Clean or renew dust sieves.

 

Vessel pressure

is too low

Excessive differential pressure on the

upstream filter.

Check differential pressure on the upstream

filter, if. nec. renew filter element.



No pressure build
up

The compressed air system upstream of
the dryer is not pressurised.

Check whether the compressed air system
upstream of the dryer is pressurised.
Remove any faults.



Solenoid valve Y1/Y2 does not open

correctly.

Check supply voltage, cable, conta cts and

solenoid; replace, if necessary.

 

Excessive

compressed air
consumption

Leakage.

Check condensate trap at the upstream

filter; clean, if necessary.

 

K-MT10-95_EN_02 47

Fault

Possible cause

Remedy

Spec. personnel Service engineer

Dryer does not

switch over

Solenoid valve Y1/Y2 does not open

correctly.

Check supply voltage, cable, contacts and

solenoid; replace, if necessary.

 

Solenoid valve Y1/Y2 cannot be opened

properly
(audible humming sound or valve
flapping).

Check supply voltage.

Check pilot valves; replace, if necessary.

 

Control board defective.

Check fuse in supply line and in the

switchbox; replace, if necessary.

 

Power supply interrupted, cable broken.

Reconnect the unit to the power supply.



Compressor might be off.

Check compressor synchronisation circuit.

Error in control programme.

Restart programme.



No expansion

Solenoid valve Y3/Y4 cannot be opened.

Check supply voltage, cable, contacts and

solenoid; replace, if necessary.

 

Solenoid valve Y3/Y4 cannot be opened

properly
(audible humming sound or valve
flapping).

Check supply voltage.

Check pilot valves; replace, if necessary.

Check valve bodies for contamination; clean

or replace, if necessary.

 

Dryer is

continuously bled

Solenoid valve Y3/Y4 cannot be closed

properly (audible humming sound or
valve flapping).

Check supply voltage.

Check solenoid and diaphragm; replace, if
necessary.

 

Main valve V1/V2 does not open.

Check main valve, replace if nec.

 

Dryer is

excessively bled

Solenoid valve Y1/Y2 cannot be closed.

Check solenoid and diaphragm; repla ce, if

necessary.

 

Pressure dew

point is not
reached

Operating pressure is too low.

Increase operating pressure.



Compressed air volume flow is too high.

Reduce compressed air volume flow



Compressed air inlet temperature is too

high.

Reduce compressed air inlet temperature or

pre-connect a compressed air cooler.

 

Control board is defective.

Check control board, if nec. renew.



Differential pressure on the upstream

filter is too high.

Check differential pressure on the upstream

filter, if nec. renew filter element.



Condensate trap on the upstream filter

does not work.

Check function of the condensate trap, if

nec. clean or renew.

 

Drying agent is contaminated or too old.

Check upstream filter for cont a mina tion , if

nec. renew element.



Check drying agent for contamination, if

nec. renew drying agent.

 

Regeneration gas too low.

Check function of expansion valve V3/V4

and muffler, if nec. renew muffler or filter
element.

 

sensor is defective Replace sensor  

48 K-MT10-95_EN_02

With dewpoint-sensing control (optional)

Fault code

Description of fault

Possible cause

Remedy

Specialised

personnel

Service technician

+20

Upper measuring range

limit exceeded

Drying capacity
exceeded.

See instructions for commissioning.
If the drying agent is wet, replace it.



Error in programme.

Restart programme.



999

Dewpoint sensor

defective

Sensor defective or

irreversibly

contaminated.

Replace sensor.

 

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 appropriate
service kit.

The package includes a
dongle with which you can reset the
operating hours counter after
maintenance has been carried out.
For instructions on how to use the
do

ngle see the enclosed information

sheet (in the service kit).

 

K-MT10-95_EN_02 49

Index

A

Abbreviation

Components ........................................................ 45

Address, manufacturer .............................................. 7

Adsorption, explanation ........................................... 18

air ejection

hazard.................................................................. 11

Air ejection, sudden ................................................... 9

B

Bolt connections ...................................................... 23

Build no. ............................................................ 38, 52

Bypass line .............................................................. 23

C

Changing cycle mode

explanation .......................................................... 32

Check valves

maintenance interval ........................................... 39

Components ............................................................ 45

Compressed air ................................................. 12, 18

Compressor synchronisation

option ................................................................... 20

compressor synchronisation c ontrol ler .................... 20

Compressor synchronisation line

installation ............................................................ 25

Condensate trap

maintenance interval ........................................... 39

Connection lines ...................................................... 23

Connector

electrical .............................................................. 24

Control

dewpoint-sensing ................................................. 21

Control cabinet ........................................................ 17

Control system

signalling contacts ............................................... 20

Conversions............................................................... 9

Cycle

fixed ..................................................................... 21

variable ................................................................ 21

Cycle mode change

explanation .......................................................... 32

D

Danger notes

Danger! .................................................................. 8

Danger warning, maintenance ........................... 38, 40

Date of manufacture .................................................. 4

Dehumidification

explanation .......................................................... 19

Dew point sensor

maintenance interval............................................ 39

Dewpoint-sensing control ........................................ 21

Digital display

explanation .......................................................... 28

Documentation, technical ........................................ 50

Dongle

use ....................................................................... 40

Dryer

maintenance interval............................................ 39

drying agent

service life ............................................................ 44

Drying agent

charging ............................................................... 21

storage ................................................................. 16

drying agents

handling ............................................................... 10

dust generation ........................................................ 10

dust mask ................................................................ 10

E

Ear protection .......................................................... 30

electrical voltage, hazard ......................................... 11

Example for installation............................................ 23

Expansion, explanation ........................................... 19

F

Fabrication no. ........................................................... 4

Fixed cycle ............................................................... 21

H

hazard areas ............................................................ 11

I

Installation area ....................................................... 14

Installation example ................................................. 23

Installation site, requirements .................................. 14

L

LEDs

explanation .......................................................... 28

lifting gear ................................................................ 13

Limits, permissible ................................................... 30

M

Machine damage, prevention .................................... 9

50 K-MT10-95_EN_02

Machine passport ...................................................... 4

main voltage .............................................................51

Maintenance

dam pressure .......................................................41

drying agent .........................................................44

Muffler ..................................................................41

sensor ..................................................................43

Maintenance contract ...............................................38

Maintenance, danger warnings ..........................38, 40

Misuse ......................................................................12

Misuse, suspected ...................................................12

Modifications on the dryer ......................................... 9

Muffler

maintenance interval ............................................39

N

Noise level ..............................................................51

Notes

safe, efficient handling ........................................... 8

O

On/Off switch

explanation ...........................................................27

On/Off-Swit ...............................................................17

Operating instructions ............................................... 7

safe place .............................................................. 8

safety notes ........................................................... 9

target group ........................................................... 8

Operating overpressure

minimum, maximum ...........................................51

Operating pressure ..................................................31

permissible ............................................................ 4

safety device ........................................................22

Operating signalling contact

installation ............................................................25

Operation signalling

contact ..................................................................20

Original replacement parts .......................................38

overpressure, hazard ...............................................11

P

Packaging ................................................................13

Personnel qualification .........................................9, 40

Pressure build-up

explanation ...........................................................19

sudden .................................................................31

Pressure Conditions .................................................37

Pressure vessel ........................................................38

Programme

sequence, steps .................................................. 55

Protection class ....................................................... 51

R

Regeneration, explanation ...................................... 18

Regulations for accident prevention ........................ 13

Replacement parts .................................................. 38

S

Safety notes .............................................................. 9

general .................................................................. 9

Warning! ................................................................ 8

Safety valves ..................................................... 22, 26

Shutdown valves ..................................................... 23

Shutting down ......................................................... 36

Signalling lines

external ............................................................... 25

skid risk ................................................................... 11

Specialist personnel ............................................ 8, 22

Standard equipment .................................................. 7

Start-up device ........................................................ 20

Start-up, requirements ............................................. 26

Storage room

requirements ....................................................... 16

Supply cable, electrical ............................................ 24

Supply lines ............................................................. 22

symbols, explanation ............................................... 11

T

Target group .............................................................. 8

Transport damage ................................................... 13

transport lugs .......................................................... 15

Type plate ............................................................... 10

U

Use, intended .......................................................... 12

Use, safe ................................................................... 8

V

Variable cycle .......................................................... 21

Vessel pressure gauge

maintenance interval ........................................... 39

vibration dampers .................................................... 15

Visual inspection ..................................................... 41

Voltage

electrical .............................................................. 24

K-MT10-95_EN_02 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

52 K-MT10-95_EN_02

Technical data

Operating Range

Site Selection

frost-free indoor installation in a non-hazardous enviroment

Ambient temperature

1,5 to 50 °C (34,7 to 122 °F)

Compressed air inlet temperure

25 to 50 °C (68 to 122 °F)

max. operating overpressure

16 bare

operating overpressure, minimal

5 bare

Medium

Compressed air and gaseous nitrogen

Fluid group

2

Electrical connection

Main voltage, standard

230 V, 50-60 Hz

Alternative voltage

115 V, 50-60 Hz and 24 V DC

Protection class

IP65

Please heed to the type plate and enclosed wiring diagram!

Performance data

Model

Volumetric

flow

in m3/h

Nominal

pipe

Upstream

filter

Downstream

filter

Nominal

Pressure

in bar(e)

Nominal

temperature

in °C

K-MT 10

105

1

GL9XLD

GL9ZLDH

16

50

K-MT 15

145

1

GL9XLD

GL9ZLDH

16

50

K-MT 20

200

1

GL9XLD

GL9ZLDH

16

50

K-MT 25

255

1 1/2

GL11XLD

GL11ZLDH

16

50

K-MT 35

350

1 1/2

GL11XLD

GL11ZLDH

16

50

K-MT 45

420

1 1/2

GL12XLD

GL12ZLDH

16

50

K-MT 60

620

2

GL13XLD

GL13ZLDH

16

50

K-MT 75

750

2

GL13XLD

GL13ZLDH

16

50

K-MT 95

940

2 1/2

GL14XLD

GL14ZLDH

16

50

1

m³/h relating to 1 bara and 20 °C at the compressor suction capacity., subsequently compressed to 7 bare and 35 °C inlet

temperature to the dryer at 100 % relative humidity for pressure drewpoints of von -25 und -40 °C.

2

in accordance with DIN ISO 228 (BSP-P).

Noise emission

Noise level: +3 dB (A)1

65 – 95 dB(A)

relative to free field measurement, 1 m surr. field

Drying agent

Vessel 1

100 % molecular sieve

Vessel 2

100 % molecular sieve

Dimensions

Please heed to the dimensional drawings and the according table containing dimensions and weight on page 59.

K-MT10-95_EN_02 53

Replacement and wear p ar ts list

Note:
When exchange or replacement parts are ordered, 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

K-MT 10 to K-MT 20

115V, 230V

SKK10-K20/D2/12

Reset-module, muffler,

filter elements, pilot-valves

K-MT 25

115V, 230V

SKK25/D2/12

Reset-module, muffler,
filter elements, pilot-valves

K-MT 35

115V, 230V

SKK35/D2/12

Reset-module, muffler,

filter elements, pilot-valves

K-MT 45

115V, 230V

SKK45/D2/12

Reset-module, muffler,

filter elements, pilot-valves

K-MT 60 to K-MT 75

115V, 230V

SKK60-K75/D2/12

Reset-module, muffler,
filter elements, pilot-valves

K-MT 95

115V, 230V

SKK95/D2/12

Reset-module, muffler,

filter elements, pilot-valves

54 K-MT10-95_EN_02

Service kits 24 and 36 months

For model

Mains
voltage

Order-ID. Scope of delivery

K-MT 10 to K-MT 20
115V

SKK10-K20/D2/24/115

Reset-module, muffler, filter

elements, inlet- expansion­and check valves, solenoid

230V

SKK10-K20/D2/24

K-MT 25
115V

SKK25/D2/24/115

Reset-module, muffler, filter

elements, inlet- expansion-

and check valves, solenoid

230V

SKK25/D2/24

K-MT 35
115V

SKK35/D2/24/115

Reset-module, muffler, filter

elements, inlet- expansion-

and check valves, solenoid

230V

SKK35/D2/24

K-MT 45
115V

SKK45/D2/24/115

Reset-module, muffler, filter

elements, inlet- expansion­and check valves, solenoid

230V

SKK45/D2/24

K-MT 60 to K-MT 75
115V

SKK60-K75/D2/24/115

Reset-module, muffler, filter

elements, inlet- expansion­and check valves, solenoid

230V

SKK60-K75/D2/24

K-MT 95
115V

SKK95/D2/24/115

Reset-module, muffler, filter

elements, inlet- expansion­and check valves, solenoid

230V

SKK95/D2/24

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

When necessary

1 Vessel pressure gauge

Desiccant packs

Typ Order-ID. Content

K-MT 10

K-MT10DESMIX

Both chambers have to be

filled completely with

adequate desiccant packets

acc. to the

maintenance instructions.

K-MT 15

K-MT15DESMIX

K-MT 20

K-MT20DESMIX

K-MT 25

K-MT25DESMIX

K-MT 35

K-MT35DESMIX

K-MT 45

K-MT60DESMIX

K-MT 60

K-MT 75

K-MT75DESMIX

K-MT 95

K-MT95DESMIX

K-MT10-95_EN_02 55

Flow diagram

Pos.

Designation

1

Upstream filter

2

Dust sieve

3

Solenoid valve block V1–V4

4

Muffler

5

Control system

6

Regeneration gas orifice plate

7

Check valve block V5–V6

8

Downstream filter

* Options:

9

Dewpoint-sensing unit

56 K-MT10-95_EN_02

Logic control diagram

Adsorption in B1 and regeneration in B2

K-MT10-95_EN_02 57

Regeneration in B1 and adsorption in B2

58 K-MT10-95_EN_02

Dimensional drawing

K-MT 10 & K-MT 15

K-MT10-95_EN_02 59

K-MT 20 – K-MT 95

Type

Connection

Dimensions [mm]

weight

[kg]

A A1 B C C1 C2 D E

K-MT 10

G 1

870

570

1420

490

400

60

1070

1070

120

K-MT 15

G 1

870

570

1750

490

400

60

1320

1320

142

K-MT 20

G 1

670

630

1530

490

400

60

1160

1160

143

K-MT 25

G 1½

670

630

1760

530

400

60

1320

1320

173

K-MT 35

G 1½

830

790

1810

585

400

60

1320

1320

210

K-MT 45

G 1½

860

820

1820

605

400

80

1320

1320

249

K-MT 60

G 2

910

860

1870

635

500

80

1320

1320

277

K-MT 75

G 2

1020

950

2000

640

500

80

1515

1515

408

K-MT 95

G 2½

1050

1000

2020

670

500

80

1515

1515

510

60 K-MT10-95_EN_02