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Adsorption dryer
K-MT 35-95/D3
( Generation 3 )
Operating manual
Revision 00—2018 /EN
Cod: 398H272182
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EN | User Manual
Index
Machine passport 3
General information 4
Manufacturer’s details .............................................................................................................. 4
Details on the dryer ................................................................................................................... 4
About these operating instructions ........................................................................................... 5
For your own safety 6
General safety notes ................................................................................................................. 6
Intended use of the dryer .......................................................................................................... 7
Signs, instruction plates and danger zones at the dryer ........................................................... 8
Transportation, installation and storage 10
Information on transportation packaging ................................................................................ 10
What to do in the case of transport damage occurring? ........................................................ 10
Transporting and installing the dryer ....................................................................................... 11
Storing the dryer ..................................................................................................................... 13
Technical product description 14
Summary Drawing Standard Dryer* ........................................................................................ 14
Function description ............................................................................................................... 15
Available options ..................................................................................................................... 17
Installation 19
Preconditions for installation .................................................................................................. 19
Connect piping ....................................................................................................................... 20
Installing the electrical connection .......................................................................................... 21
Start-up 23
Requirements for initial start-up ............................................................................................. 23
Setting times of the operating phases .................................................................................... 24
Overview of operating and control elements .......................................................................... 24
Start up dryer .......................................................................................................................... 27
Changing cycle mode (optional) ............................................................................................. 29
Monitoring dryer operation 30
With dewpoint-sensing control (optional) ............................................................................... 30
Shutdown and restart dryer 31
Emergency shutdown ............................................................................................................31
Depressurising and shutting down the dryer .......................................................................... 31
If work is to be carried out on the electrical system ............................................................... 32
Restart .................................................................................................................................... 32
Maintenance and repair of the dryer 33
Notes on maintenance ............................................................................................................ 33
Regular maintenance intervals ................................................................................................ 34
Instructions for use of the dongle ........................................................................................... 35
Daily maintenance tasks ......................................................................................................... 36
Maintenance work to be completed every 12 months ............................................................ 36
Notes on further maintenance work ........................................................................................ 39
Identify and eliminate faults 40
Summary of faults ................................................................................................................... 40
Annex with technical documentation 44
K-MT 35-95/D3 1
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Technical data ......................................................................................................................... 45
Replacement and wear part list .............................................................................................. 46
Tightening torque values ......................................................................................................... 48
Logic control diagram ............................................................................................................. 49
Flow diagram .......................................................................................................................... 51
Dimensional drawing .............................................................................................................. 52
2 K-MT 35-95/D3
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EN | User Manual Machine passport
Machine passport
It is the responsibility of the owner,
◊ to enter for the rst time any appliance data not stated above,
◊ to keep these appliance data up to date.
The above-stated appliance data provide for a clear identi cation of the dryer and its components, and signi cantly 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 )
K-MT 35-95/D3 3
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EN | User Manual General information
General information
Manufacturer’s details
Name and address
Parker Hannifi n Manufacturing S.r.l.
Sede Legale: Via Privata Archimede, 1- 2009 Corsico (MI) Italy
Sede Operativa: Gas Separation and Filtration Division EMEA - Strada Zona Industriale, 4
35020 S.Angelo di Piove (PD) Italy
tel +39 049 971 2111- fax +39 049 9701911
Web-site: www. parker.com/hzd
e-mail: technical.support.hiross@parker.com
Details on the dryer
Standard equipment
Standard dryer*, consisting of
◊ 2 vessels, lled with desiccant
◊ 1 upstream lter
◊ 1 downstream lter
◊ Piping and muf er
◊ Control system
Associated documents
◊ Operating instructions (present)
◊ Technical documentation (see annex)
◊ Circuit diagrams (see separate document)
◊ Operating manual for installed lters (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
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EN | User Manual General information
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 tri-
angles.
◊ Lists are marked by a small box
Note:
These notes provide you with hints and information on the safe and effi cient
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.
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 specialist personnel, e.g. tters 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.
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EN | User Manual For your own safety
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-quali ed personnel,
◊ not used within its intended design speci cations,
◊ 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 fl ows suddenly out of
the sound absorber.
◊ This causes a sudden loud cracking noise.
◊ Due to particles carried in the air fl ow, 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, fi rst 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 qualifi cation
Only authorized and quali ed specialist personnel may be tasked with the work on the dryer
described in these operating instructions.
Conversions and modifi cations
Without prior approval by the manufacturer, no conversions and modi cations must be made
to the dryer! Any non-approved modi cations may restrict the operational safety of the dryer
and cause damage to property or personal injury.
Handling drying agents
The drying agents used do not pose any risk to health. However, when lling and emptying
the hollow section vessels with drying agents, increased dust generation may occur. Please
comply with the following instructions:
◊ When lling drying agents, 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!
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EN | User Manual For your own safety
Disassembly and disposal
◊ Dispose all parts of the dryer, the drying agent, and all other operating materials in an envi-
ronmentally safe way and in accordance with all current statutory regulations.
Intended use of the dryer
The dryer is exclusively intended for drying compressed air. Depending on de ned 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 ttings have not
been designed for such loads. They could fracture, tear off, or become damaged in another
way.
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Signs, instruction plates and danger zones at the dryer
Signs and instructions
Type plate of
the down-
Type plate of
the dryer
Vessel plate
stream lter
Type plate of
the upstream
lter
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.
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EN | User Manual For your own safety
Hazard areas on the dryer
Hazard caused by electrical voltage
Hazard caused by overpressure
Hazard caused by sudden air ejection during
expansion
Symbol Hazard area
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 ows suddenly out of the sound absorber:
◊ This causes a sudden loud cracking noise.
◊ Due to particles carried in the air ow, 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 lling the vessels with drying agent, there is a risk of skidding
caused by spilt drying agent.
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EN | User Manual Transportation, installation and storage
Transportation, installation and storage
Danger due to incorrect transportation!
The dryer must be transported by authorized and qualifi ed 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 suf cient 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 13.
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 lm material
and in a wooden box.
If the packaging is undamaged
The undamaged packaging should be removed only at the nal installation site, as it
offers protection against any weather in uences.
What to do in the case of transport 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.
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Transporting and installing the dryer
Requirements for the installation site
The conditions at the installation site have a large in uence 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, rm and vibration-proof. It must have the necessary car-
rying capacity for the weight of the dryer. The weight of the dryer is speci ed in the technical
data section of the annex.
◊ The dryer should be installed with suf cient
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 gure).
If in doubt, the installation site must be inspected by specialists. If you have any queries in this
regard, please contact the manufacturer (see
pag. 4
Necessary spacing at the top and sides
Transportation using lifting or forklift trucksr
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.
= min. 1 m
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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 gure I).
Raise the dryer (see gure II) and remove the transportation pallet.
Place the dryer at its installation site.
I: Transport lugs on pressure vessel
Anchoring the dryer
Use suitable attachment material to anchor the dryer to the oor.
In the case of vibrating oors: place the dryer on suitable vibration dampers.
II: Installing by crane
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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 31.
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 lm 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 fi rst commissioning and start-up (see
page 27).
Store drying agents
Do not store drying agents in the open air.
Protect drying agents against humidity.
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Technical product description
Summary Drawing Standard Dryer*
Dewpoint sensor
Vessel pressure gauge
Compressed air inlet
Upstream lter
On/Off-Switch
Power supply connector
Compressed air outlet
Downstream lter
Control cabinet
Discharge point
Check valve block
Differential pressure gauge
Muf er
Transport lugs
Vessel
Solenoid valve block
*Planned dryers may differ in their con guration (in this case, refer to the enclosed dimensional drawing)
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Function description
The dryer dries the compressed air supplied by the compressor and makes it available for
industrial use.
Upstream lters clean the compressed air and remove dust, dirt, oil, and water droplets, before the compressed air reaches the dryer. Thus, an upstream lter is also used for extending
the service life of the drying agent.
Downstream lters clean the compressed air from drying agent abrasions, before it is fed into
the compressed air system.
The two chambers of the hollow section vessel contain an extremely porous drying agent by
means of which humidity is removed from the compressed air and stored just as in a sponge.
The stored humidity is then removed again from the drying agent and re-introduced into the
ambient environment.
To this end, the two chambers alternate between different operating modes. Whilst in one
vessel, compressed air is de-humidi ed (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 lter. From here, the
compressed air ows upwards through the
absorption chamber, which is pressurised. In
so doing, the drying agent dehumidi es the air.
The dry compressed air is supplied to the pipe
network via the downstream lter.
Here, adsorption is shown in the left
vessel.
Regeneration (running in parallel to the adsorption)
At the same time the other chamber is prepared for a renewed take-up of humidity. This
process is called regeneration.
The regeneration is subdivided into three phases: expansion, dehumidi cation, and pressure build-up.
With the dewpoint-sensing control option, the regeneration phase is followed by a standby
phase.
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Expansion phase
During the expansion phase the pressure in the
right chamber is released via the muf er down
to ambient pressure within just a few seconds.
The out ow of the compressed air becomes
noticeable due to a sudden powerful ow noise
at the muf er.
Dehumidifi cation phase
Prior to being released into the pipe network,
dried compressed air is bled by means of an
ori ce plate. This separate regeneration air ow
is fed through the depressurised chamber. The
humidity stored in the drying agent is taken up
by the air ow and expelled into atmosphere via
the muf er.
Here, regeneration is shown in the right
vessel.
Pressure build-up phase
After dehumidi cation 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 chamber has taken up a suf cient 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.
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Available options
The following options are available for the dryer:
◊ Start-up device
◊ Signalling contacts of the control system
◊ Regeneration gas recirculation
◊ Dewpoint-sensing control
◊ Fine lter muf er
◊ 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 lled 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 system
The control system is equipped with a digital input for the synchronised operation with a
compressor. This feature allows for synchronised and thus ef cient 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 suf ciently 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.
Dewpoint-sensing control
With a dewpoint-sensing control system, you can operate the dryer in xed or variable
cycles. In the xed cycle, switchover is effected after a xed 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 fi lter muffl er
A ne lter muf er is used to reduce the noise emission of the dryer to lower levels than the
standard muf er can provide. If installed, the ne lter muf er replaces the original installed
muf er.
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Nozzle kit
In the case that the operating pressure deviates from the standard design pressure (7bare)
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 modi ed bore. This replacement
optimizes the regeneration air consumption and therefore restores the energy ef ciency of
the dryer. To receive more information on this conversion, please contact the manufacturer.
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Installation
Only authorized and qualifi ed 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 installation
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 20).
◊ All pipes, couplings, and connections must have the correct diameter and match the oper-
ating pressure.
Hazard caused by exceeding the limit values!
A safety device must be provided in order to protect against the maximum
permissible operating pressure from 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.
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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 gure shows an installation example.
Compressed air system Item. Component
1 Entry, humid air
Compressed air inlet
2
valve, owner end
3 Upstream lter
4 Dryer
5 Downstream lter
Compressed air outlet
6
valve, owner end
7 Outlet, dry air
8 Bypass line (option)
Valve in bypass line
9
(option)
10 Bypass lter (option)
Valve, outlet bypass lter
Example of an installation with bypass line
The connection lines for the upstream lter (3) are to be installed at a slight incline in the
direction of the upstream lter.
One shutdown valve each (2, 6) is to be installed at the compressed air inlet and outlet
ends of the dryer.
If you t 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.
11
(option)
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Installing the electrical connection
Warning against electrical voltage
Only qualifi ed 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.
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.
Connect electrical cable to device
adapter
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Connecting the external signalling lines
For compressor synchronisation
The controller is tted 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 gure 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).
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, 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.
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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 4.
◊ 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 initial start-up
For the rst start-up 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 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.
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EN | User Manual Start-up
Setting times of the operating phases
In its standard version the dryer is delivered with a time-dependent control system. The
phase sequence occurs in a xed cycle.
With the 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, max
Regeneration, total 5 min 5 min
- of which: expansion time ~ 0,2 min ~ 0,2 min
- of which: dehumidi cation time ~ 4 min ~ 4 min
- of which: pressure build-up ~ 1 min ~ 1 min
Standby -- ~ 55 min, max.
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 gure):
◊ 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 xed 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
24 K-MT 35-95/D3
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EN | User Manual Start-up
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
Regeneration 1
Adsorption 1
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 49.
Vessel B2
Regeneration 2
Adsorption 2
K-MT 35-95/D3 25
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EN | User Manual Start-up
Display Explanation
2 215 Default display: The gure to the left indicates the current processing step; the
gure 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 ashing.
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
o
-999
LED Economy cycle (4)
This LED is only relevant in units that are equipped with the optional dewpoint-sensing
control. The diode lights up when the dryer is switched on and in the standby phase and no
regeneration air is required.
Vessel pressure gauge
On both vessels, pressure gauges are tted 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 dehumidi cation 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.
◊ The dam pressure should not exceed 0.3 bar, otherwise read the instructions on page 36.
◊ During the pressure build-up phase the indication on the pressure gauge should again rise
to operating overpressure level.
◊ Dewpoint sensor not powered
◊ Cable defective or disconnected
◊ Sensor defective
26 K-MT 35-95/D3
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EN | User Manual Start-up
Start up dryer
Warning against sudden air ejection!
During expansion the pressure is released suddenly through the muffl er:
◊ A loud cracking noise occurs which can injure your hearing.
◊ Particles carried in the air fl ow 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, fi rst depressurise the plant.
◊ The more powerful the dryer is, the more noise may be generated during operation. There-
fore, 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 of ce or person.
◊ In the event of an emergency or if a safety-relevant disruption occurs (e.g. escaping com-
pressed air, defective component), the dryer must be shut down immediately as described
in the section on page 31). 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
Ensure that the compressed air system upstream of the dryer is pressurised. If necessary,
pressurise (switch on compressor).
20).
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 rst 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.
K-MT 35-95/D3 27
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EN | User Manual Start-up
Operating the dryer for the fi rst time (or after a change of drying agent) separately
Depending on the transportation and storage conditions, the drying agent in the chambers
can already be loaded with humidity from the environment. At each rst 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 chamber 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 fi rst start-up with compressed air consumption:
◊ for at least 4 hours at a pressure dew point of –25 to –40 °C or
◊ for approx. 5 to 7 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:
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
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.
17) was installed into the compressed air system directly
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
lled up completely; only then should the valve be opened fully.
The dryer has then be taken into operation within the compressed air system.
In the event of a fault
In the event of an emergency or if a safety-relevant disruption occurs (e.g. escaping compressed air, defective component), immediately close the compressed air supply line and set
the ON/OFF switch of the dryer to 0 in order to disconnect it from the power supply. Afterwards depressurise the dryer (see also chapter , page
Then proceed as follows:
Remedy fault:
Look up possible cause of the fault, and how to remedy the same, in the table on page
40.
Remedy fault.
Repeat the start-up procedure.
31).
28 K-MT 35-95/D3
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EN | User Manual Start-up
Changing cycle mode (optional)
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 vessels is just below operating pressure so that a fast
pressure build-up is prevented when the vessels are switched.
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 ow diagram.
Set the ON/OFF switch to position II.
The programme continues the cycle.
K-MT 35-95/D3 29
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EN | User Manual Monitoring dryer operation
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 muffl er:
◊ A loud cracking noise occurs which can injure your hearing.
◊ Particles carried in the air fl ow 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 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 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 ashing. 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
o
-999
For instructions on how to eliminate faults, see chapter Identify and eliminate faults
◊ Dewpoint sensor not powered
◊ Cable defective
◊ Sensor defective
30 K-MT 35-95/D3
Page 33
EN | User Manual Shutdown and restart dryer
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 chamber 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 chamber. 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 build-up
phase or is in standby mode (before switchover).
Note:
If the unit is equipped with a compressor synchronisation system, fi rst 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 cycle
from the point at which it has been stopped.
Emergency shutdown
To emergency shut-down the dryer heed to the following instructions:
Close shut off valves upstream and downstream of the dryer (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 air system
Close the compressed air outlet valve installed by the owner.
K-MT 35-95/D3 31
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EN | User Manual Shutdown and restart dryer
If available, open bypass line.
Depressurise dryer
Depressurise dryer, e.g. by opening the manual drain at the downstream lter.
If work is to be carried out on the 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 voltage-free!
Make the electrical supply cable to the dryer voltage-free.
Secure the electrical supply cable to the dryer against switch-on.
Restart
Depending on the ttings 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 ow direction. With the optional start-up de-
vice , the set minimum pressure must however be reached prior to restart.
◊ A return ow 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 gradu-
ally, according to the read measuring current.
If compressed air system and dryer have remained at operating pressure
Ensure that the compressed air inlet valve (provided by the operator) is open.
Set ON/OFF switch to I. The programme continues the cycle from the point at which it
was interrupted.
Slowly open compressed air outlet valve!
Avoid a sudden drop in 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
lled 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.
Ensure that the manual drain on the downstream lter is closed.
Pressurise and switch on the dryer as described in the section Open compressed air
supply and switch on dryer on page 27.
The dryer is now in operation again and operates fully automatically.
32 K-MT 35-95/D3
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EN | User Manual Maintenance and repair of the dryer
Maintenance and repair of the dryer
In order to allow maintenance work on the dryer to be carried out ef ciently 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.
Danger!
Before commencing any maintenance tasks always shut down the dryer as
described on page
Warning!
Maintenance tasks may be carried out only by authorized and qualifi ed 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 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 manipulations on a hollow pro le vessel or modify the same in any
way!
◊ Following maintenance work, always check all ange and bolt connections for leakage and
secure seating.
◊ Never use pipes and ttings 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 techni-
cal requirements stipulated by the manufacturer. This is always the case, if you use original
replacement parts only.
31 !
K-MT 35-95/D3 33
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EN | User Manual Maintenance and repair of the dryer
Regular maintenance intervals
Note:
If a chamber has been depressurised, e.g. after completion of the ex-pansion
phase, and the pressure remains above 0 bar, the chamber is pressurised by
what is known as ram pressure. This might be due to
◊ blockage at the muffl er(s)
◊ contamination of the perforated plates
◊ 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 individual
tasks are described in the following pages.
Component Maintenance task to be carried out Maintenance
interval
Complete dryer Carry out visual checks and function checks.
Vessel pressure gauge Check dam pressure. For a dam pressure
exceeding 0.3 bar:
– Check muf er.
– Check dust sieve.
– Check drying agent.
Muf er Replace muf er after 1 year of operation and
after renewing the dessicant.
Fine lter muf er
(option)
Dew point sensor
(with optional dew
point sensing-control)
Pilot valves Renew
Main valves V1/V2 Renew
Expansion valves
V3/V4
Replace element of ne lter muf er after 1
year of operation and after renewing the drying
agents.
Renew.
Renew
daily
12 months
24 months
•
•
••
•
•
•
•
•
48 months
See page
36
36
36
37
37
39
39
39
Check valves V5/V6 Renew
Solenoids Renew
Drying agent Renew
Upstream and downstream lter
Please see the enclosed operating instructions for the attached lters.
Maintenance work has to be carried out as speci ed in this document.
•
•
39
39
39
•
34 K-MT 35-95/D3
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EN | User Manual Maintenance and repair of the dryer
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.
Danger!
Before commencing any maintenance tasks always shut down the dryer as
described on page
Warning against electrical voltage!
Only qualifi ed specialist personnel may carry out work on the electrical system!
31 !
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, ashing 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 ashing
The service counter is then reset to 0.
If the following appears in the display
for a short time FAIL
then ashing
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.
OFF
OFF
K-MT 35-95/D3 35
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EN | User Manual Maintenance and repair of the dryer
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 31).
Dam pressure can be caused by:
- a blocked muf er,
- 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 be completed every 12 months
Renew muffl ers
The dryer is equipped with a muf er. If the muf er becomes blocked, a dam pressure is generated which in extreme cases may cause the muf er to burst.
Hazard caused by blocked muffl er!
Blocked muffl ers can cause a dangerous overpressure to build up which may
cause the muffl ers to burst. Flying fragments may cause personal injury and
damage to property.
Therefore, the muffl ers must be replaced every 12 months and after each
change of desiccant.
Warning against sudden air ejection!
During expansion the pressure is released suddenly through the muffl er:
◊ A loud cracking noise occurs which can injure your hearing.
◊ Particles carried in the air fl ow 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!
36 K-MT 35-95/D3
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EN | User Manual Maintenance and repair of the dryer
Depressurise the dryer and shut it down
(see page 31 ).
Unscrew muf er as shown in the opposite
gure.
Replace muf er and secure it.
Restart dryer (see page 32).
Undo muf er
Replace the element in the fi ne fi lter muffl er
Depressurise the dryer and shut it down
(see page 31 ).
Undo knurled screw on the lid cap and
remove cap.
Unscrew old lter element. Arrows on the
element bottom mark the direction of rotation.
Insert new lter element and screw on
tightly.
Renew muf er element
Re-engage lid cap at the top section of the housing and x in position by means of the
knurled screw.
Restart dryer (see page 32 ).
Renew dewpoint sensor
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.
K-MT 35-95/D3 37
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EN | User Manual Maintenance and repair of the dryer
In order to limit the impact on the dryer operation to a minimum, we recommend that you
contact the manufacturer well in advance and order a new dewpoint sensor. After receipt of
the new pressure dewpoint sensor, replace the sensor as follows:
Hold the box of the dewpoint sensor ready.
Release pressure from dryer and shut down the unit (see page 31 )
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 32 ).
Place the protective caps (4, 5) onto the old dew point sensor and dispose of it in accor-
dance with the applicable regulations.
38 K-MT 35-95/D3
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EN | User Manual Maintenance and repair of the dryer
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 of ce.
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 ttings
such as e.g. sieve bottoms and dust sieves, including gaskets. If necessary, these ttings
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 signi cantly from the degree of contamination in the
compressed air (or the quality of the compressed air upstream lters). Oil, dust, and dirt particles cover the drying agent surface and reduce its effective surface, in part quite irreversibly.
K-MT 35-95/D3 39
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EN | User Manual Identify and eliminate faults
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.
Used abbreviation Component
PI Pressure gauge
PDI Differential pressure gauge
V1–V2 (Y2–Y1) 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
Excessive dam pressure during regeneration
Vessel pressure is too
low
No pressure build-up The compressed air system
Muf er or lter element of
the muf er is contaminated.
Expansion valve V3/V4 does
not open correctly.
Dust sieves are contaminated.
Excessive differential pressure on the upstream lter.
upstream of the dryer is not
pressurised.
Check muf ers or lter
elements for contamination,
clean if nec., and poss.
renew.
Check expansion valve for
contamination, if nec. clean/
renew.
Clean or renew dust sieves.
Check differential pressure
on the upstream lter, if.
nec. renew lter element.
Check whether the
compressed air system
upstream of the dryer is
pressurised. Remove any
faults.
Specialised
personnel
Service
technician
••
••
••
•
•
Solenoid valve Y1/Y2 does
not open correctly.
Check supply voltage, cable, contacts and solenoid;
replace, if necessary.
••
40 K-MT 35-95/D3
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EN | User Manual Identify and eliminate faults
Fault Possible cause Remedy
Specialised
personnel
Excessive compressed
air consumption
Leakage Check condensate trap at
the upstream lter; clean, if
necessary.
••
Service
technician
Dryer does not switch
over
No expansion Solenoid valve Y3/Y4 can-
Solenoid valve Y1/Y2 does
not open correctly.
Solenoid valve Y1/Y2 cannot be opened properly
(audible humming sound or
valve apping).
Control board defective. Check fuse in supply line
Power supply interrupted,
cable broken.
Compressor might be off. Check compressor synchro-
Error in control programme. Restart programme.
not be opened.
Solenoid valve Y3/Y4 cannot be opened properly
(audible humming sound or
valve apping).
Check supply voltage, cable, contacts and solenoid;
replace, if necessary.
Check supply voltage.
Check pilot valves; replace,
if necessary.
and in the switchbox; replace, if necessary.
Reconnect the unit to the
power supply.
nisation circuit.
Check supply voltage, cable, contacts and solenoid;
replace, if necessary.
Check supply voltage.
Check spring and solenoid;
replace, if necessary. Check
solenoid valve for contamination; clean or replace, if
necessary.
••
••
••
••
•
•
••
••
Dryer is continuously
bled
Dryer is excessively
bled
Pressure dew point is
not reached
Solenoid valve Y3/Y4
cannot be closed properly
(audible humming sound or
valve apping).
Main valve V1/V2 does not
open.
Solenoid valve Y1/Y2 cannot be closed
Operating pressure is too
low.
Compressed air volume ow
is too high.
Check supply voltage.
Check spring and solenoid;
replace, if necessary. Check
diaphragm; replace, if
necessary.
Check main valve, replace
if nec.
Check solenoid and
diaphragm; replace, if
necessary.
Increase operating pressure.
Reduce compressed air
volume ow
••
••
••
•
•
K-MT 35-95/D3 41
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EN | User Manual Identify and eliminate faults
Fault Possible cause Remedy
Specialised
personnel
Pressure dew point is
not reached
Compressed air inlet temperature is too high.
Reduce compressed air inlet
temperature or pre-connect
a compressed air cooler.
••
Service
technician
Control board is defective. Check control board, if nec.
renew.
Differential pressure on the
upstream lter is too high.
Condensate trap on the upstream lter does not work.
Drying agent is contaminated or too old.
Regeneration gas too low. Check function of expansion
sensor is defective Replace sensor
Check differential pressure
on the upstream lter, if nec.
renew lter element.
Check function of the condensate trap, if nec. clean
or renew.
Check upstream lter for
contamination, if nec. renew
element.
Check drying agent for
contamination, if nec. renew
drying agent.
valve V3/V4 and muf er, if
nec. renew muf er or lter
element.
•
•
••
•
••
••
••
42 K-MT 35-95/D3
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EN | User Manual Identify and eliminate faults
With dewpoint-sensing control (optional)
Fault code Description of
fault
+20 Upper measuring
range limit exceeded
999 Dewpoint sensor
defective
sens
o
–999
SEr Display for service
Sensor not powered,
or cable or sensor
defective
interval. Regular
maintenance tasks
must be carried out.
Possible cause Remedy
Drying capacity
exceeded.
Error in programme. Restart programme.
Sensor defective or
irreversibly contaminated.
Sensor, sensor cable
or sensor adapter
defective.
The display appears
after every 8000
operating hours.
See instructions for
commissioning. If the
drying agent is wet,
replace it.
Replace sensor.
Visual inspection; check
power supply (24 V
to terminals 4 and 6).
Replace defective component(s).
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 dongle see the
enclosed information
sheet (in the service kit).
Specialised
personnel
Service
technician
•
••
••
••
K-MT 35-95/D3 43
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EN | User Manual Annex with technical documentation
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
44 K-MT 35-95/D3
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EN | User Manual Annex with technical documentation
Technical data
Operating Range
Site Selection frost-free indoor installation in a
non-hazardous environment
Ambient temperature 1,5 to 50 °C (24,7 to 122 °F)
Compressed air inlet temperature 25 to 50 °C (68 to 122 °F)
Max. operating overpressure 16 bar
e
Min. operating pressure 5 bare
Medium Compressed air and gaseous nitrogen
Fluid group 2
Electrical connection
Mains voltage, standard 230 V, 50-60 Hz
Alternative voltage 115 V, 50-60 Hz and 24 V DC
Protection class IP65
Please note type plate and attached electrical circuit diagram!
Performance details
Type Volumetric
fl ow¹ in
m3/h
Nominal2
pipe size
Upstream fi lter Downstream
fi lter
Nominal
Pressure
in bar
e
Nominal
temperat.
K-MT 35 350 1.1/2 AAP030GGFI AOP030GGMI 16 50
K-MT 45 420 1.1/2 AAP035GGFX AOP035GGMX 16 50
K-MT 60 620 2 AAP040HGFX AOP040HGMX 16 50
°C
K-MT 75 750 2 AAP040HGFX AOP040HGMX 16 50
K-MT 95 940 2.1/2 AAP045IGFX AOP045IGMX 16 50
1
. m/h, relating to 1 bara and 20°C at the compressor suction capacity. Subsequently com-
pressed to 7 bare and 35°C inlet ..temperature to the dryer at 100% relative humidity – for
pressure dewpoints of -25°C and -40°C.
2
In accordance with DIN ISO 228 (BSP-P); alternatively ANSI B 1.20.1 (NPT-F).
Noise emission
Noise level : +3 dB (A)1 65 – 95 dB(A)
1
.. relative to free eld measurement, 1 m surr. eld
Dimensions
Please heed to the dimensional drawings and the according table containing dimensions
and weight on page 52.
Drying agent
Chamber 1 100 % molecular sieve
Chamber 2 100 % molecular sieve
K-MT 35-95/D3 45
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EN | User Manual Annex with technical documentation
Replacement and wear part 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
K-MT 35 115V, 230V SKK35/D3/12
K-MT 45 115V, 230V SKK45/D3/12
K-MT 60 to
K-MT 75
K-MT 95 115V, 230V SKK95/D3/12
Service-kits 24 and 48 months
For model Mains
K-MT 35
K-MT 45
K-MT 60 to
K-MT 75
115V, 230V SKK60-K75/D3/12
voltage
115V SKK35/D3/24/115
230V SKK35/D3/24
115V SKK45/D3/24/115
230V SKK45/D3/24
115V SKK60-K75/D3/24/115
230 V SKK60-K75/D3/24
Order-ID. Scope of delivery
Order-ID. Scope of delivery
Reset-module, muf er, lter
elements, pilot-valves
Reset-module, muf er, lter
elements, inlet- expansionand check valves, solenoid
K-MT 95
115V SKK95/D3/24/115
230V SKK95/D3/24
46 K-MT 35-95/D3
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EN | User Manual Annex with technical documentation
Additional spare parts
Order no. Maintenance
interval
ZHM100/450 12 months 1 Dewpoint sensor
LS5/ZR 12 months 1 Element ne lter muf er
RK-MANO.063SR0219-1 12 months 1 Vessel pressure gauge
Desiccant packs (complete dryer)
Typ Order-ID. Content
K-MT 35 K-MT35DESMIX
K-MT 45 K-MT60DESMIX
K-MT 60 K-MT60DESMIX
K-MT 75 K-MT75DESMIX
Quantity Scope of delivery
Both chambers have to be lled
completely with adequate desiccant packets acc. to the
maintenance instructions
K-MT 95 K-MT95DESMIX
K-MT 35-95/D3 47
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EN | User Manual Annex with technical documentation
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)
48 K-MT 35-95/D3
Page 51
EN | User Manual Annex with technical documentation
Logic control diagram
Adsorption in B1 and regeneration in B2
K-MT 35-95/D3 49
Page 52
EN | User Manual Annex with technical documentation
Regeneration in B1 and adsorption in B2
50 K-MT 35-95/D3
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EN | User Manual Annex with technical documentation
Flow diagram
Item Designation
1 Upstream lter
2 Dust sieve
3 Solenoid valve block V1–V4
4 Muf er
5 Control system
6 Regeneration gas ori ce plate
7 Check valve block V5–V6
8 Downstream lter
* Options:
9 Dewpoint-sensing unit
K-MT 35-95/D3 51
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EN | User Manual Annex with technical documentation
Dimensional drawing
K-MT 35 & K-MT 95
Type connection
K-MT 35
K-MT 45
K-MT 60
K-MT 75
K-MT 95
Dimensions [mm]
AA1B CC1C2D E
G 1½ 870 570 1420 490 400 60 1070 1070 120
G 1½ 860 820 1820 605 400 80 1320 1320 249
G 2 910 860 1870 635 500 80 1320 1320 277
G 2 1020 950 2000 640 500 80 1515 1515 408
G 2½ 1050 1000 2020 670 500 80 1515 1515 510
Weight
[kg]
52 K-MT 35-95/D3
Page 55
Page 56
A division of Parker Hannifin Corporation
Parker Hannifin Manufacturing S.r.l.
Sede Legale: Via Privata Archimede, 1- 2009 Corsico (MI) Italy
Sede Operativa: Gas Separation and Filtration Division EMEA - Strada Zona
Industriale, 4
35020 S.Angelo di Piove (PD) Italy
tel +39 049 971 2111- fax +39 049 9701911
Web-site: www. parker.com/hzd
e-mail: technical.support.hiross@parker.com
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