Summary of Contents for Airsecure TPK20
- Page 1 Pressure Dew point monitoring device TPK 20 Functional description and operating instructions...
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Page 2: Table Of Contents
List of Contents 1 Scope of supply........................3 2 General dangers and precautions ..................4 2.1 Safety instructions for electrical connection ..............4 2.2 Safety instructions for compressed air systems..............5 3 Important application notes....................6 3.1 Avoiding damage to the measuring probe..............6 3.2 Calibration and measuring accuracy................6 3.3 Intended application.......................6 4 Humidity measurement in compressed air systems............7 5 Features..........................7... - Page 3 15 Appendix.........................31 15.1 Condensate formation in compressed air plants............31 15.2 Pressure dependence of Dew point................31 15.3 Thermodynamic concepts...................33 16 Working of an adsorption compressed air dryer............34 17 Checking the measuring accuracy................35 18 Working principle......................35 18.1 Format of data transfer at the serial interface ............37 19 EG-Conformance details....................38 20 Guarantee........................38 21 Accessory list.........................39...
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Page 4: Scope Of Supply
Scope of supply The Pressure dew point monitoring device is supplied in ready-to-use condition. The scope of supply includes a plug-in power supply unit, a mounting bracket as well as all components for hose connection 6 / 4 mm. Additionally, you may require these items, if necessary: ... -
Page 5: General Dangers And Precautions
General dangers and precautions Please carefully read the following precautions before putting into operation! The symbols used in the operating manual are to make you careful, before hand, regarding safety considerations and dangers. But all these symbols used cannot substitute the text of the associated safety instructions in any way. Therefore, the instructions should also be always read completely! This symbol indicates likely danger for persons, material or environment. -
Page 6: Safety Instructions For Compressed Air Systems
Safety instructions for compressed air systems The energy stored in the compressed gas can lead to unforeseen events causing damage to objects or injury to persons. The risk increases with the operating pressure in the plant. Therefore, all activities are to be executed by only suitably trained personnel. -
Page 7: Important Application Notes
Important application notes Avoiding damage to the measuring probe Instruments are sensitive and must be treated carefully: Avoid impact, shocks and vibration. The sinter filter protects the sensor against mechanical effects and contamination. Do not remove the filter. Use the measuring probe only with sinter filter in intact condition! Before installation, ensure that the measuring point has no condensed water, oil or dirt secretion! If this is the case, then first put the system in order and dry up! -
Page 8: Humidity Measurement In Compressed Air Systems
Humidity measurement in compressed air systems In the industry, there are always high quality requirements for the compressed air. Humidity and condensate are not allowed in the compressed air because these often lead to damages on the machines and loss of quality in production. Therefore, normally compressed air dryers are used to reduce the humidity content in air for correct application and to provide high quality compressed air. -
Page 9: Function
Function If compressed air is not dried before feeding into the compressed air network, considerable amount of condensate gets accumulated in the air line network and causes malfunctioning of valves, pneumatic components and finally leads to loss of production. Hence, the pressure dew point in compressed air system is a decisive parameter for air quality and should be measured in every plant. -
Page 10: Mounting Of The Device
Mounting of the device Safety instructions The product should be installed and used only according to the intended application. Fitment of the regulator and maintenance work should be carried out by only trained personnel. Mounting and servicing operations should be carried out only after switching off the voltage. -
Page 11: Procedure For Installation
Procedure for Installation The installation is done in following steps: Fastening of the device, if required Connection at the compressed air network Adjustment of diverting throttle, if required Connection at the power supply First time operation ... -
Page 12: Connection At The Compressed Air Network
Connection at the compressed air network Direct stationery assembly at the compressed air line In stationery applications, normally the device is directly installed after the dryer/filter, in order to monitor the entire plant. However, the assembly can also take place at any position in the subsequent distribution network, in order to monitor any sub unit or the operating air of a particular machine. -
Page 13: Application Of A Pre-Filter/Water Separator
Application of a pre-filter/water separator According to the condition of the compressed air plant and the distribution network, it is possible that unexpectedly dirt, condensate or oil also gets discharged at the measuring point. In order to avoid damage to the measuring probe in such critical application areas, a water separator with fine filter can also be connected before the device. -
Page 14: Adjustment Of Diverting Throttle
Connection over compressed air hose: This connection variant is ideal, for example, if the device is to be used as a portable unit, for mounting in a machine or on a panel. Mounted with thread 3/8“ below on 6/4 mm hose. -
Page 15: For The Rarest Of The Cases
For the rarest of the cases... If the device does not come into operation, then please check the following points: Is there voltage in mains socket? Is the mains plug correctly inserted Is the socket of voltage supply sufficiently inserted inside? ... -
Page 16: Operation
Operation General hints for description of operating procedure All figures in the display, numerals and configuration shown are examples, which have been used for the explanation and clarification of the transmitted contents. The actual display in your device can vary according to the selected settings or ambient conditions. 10.1 View of device front and the control elements... -
Page 17: Description Of The Displays
10.2 Description of the Displays View of Displays Function The upper display line is for the display of measured values The lower display line is for the display of selected physical units 10.3 Operation of keys The keys of control unit have the following basic functions: Description Function Settings-Key... -
Page 18: Switching On The Device
10.4 Switching on the device In order to guarantee high long term stability of the dew point probes, the sensor element is cyclically heated up. The heating takes place in every 13 h for a period of approx. 5 min. each after which the sensor passively cools down again to ambient conditions. -
Page 19: Changing The Alarm And Hysteresis Value
10.5 Changing the alarm and Hysteresis value The device is used for monitoring of dew points. The user can set a dew point limit value for both early warning alarm and main alarm. In addition, the desired Hysteresis value for each alarm value can also be adjusted. -
Page 20: 10.5.1 Switching On/Off Of Alarm Generator And Indicator Leds
10.5.1 Switching ON/OFF of alarm generator and indicator LEDs As per requirement, the alarm can also be completely turned off. The device is supplied with alarm in switched on condition. Operation of keys View of display By keeping the Enter - key in pressed condition till "Off"... -
Page 21: Changing The Temperature Units
10.6 Changing the temperature units The currently determined pressure dew point temperature is shown in the upper display line. The associated temperature units of pressure dew point temperature is shown in the lower display line; during delivery it is adjusted at °C. If required, the display can be switched over to °F. -
Page 22: Technical Data
Technical data PRESSURE DEW POINT MONITORING DEVICE TPK 20 Measuring range -20 ... +40 °C tpd Sensor element Capacitive Polymer sensor Application temperature -10 ... +50 °C Accuracy ≤ ±1 K (tpd -10.0 ... +40.0 °C) (at 23 °C) ≤ ±2 K (tpd -20.0 ... -10.0 °C) ≤... -
Page 23: Drawing
11.1 Drawing... -
Page 24: Connection Of External Components
Connection of external components The product should be installed and used only according to the intended application. Fitment of the regulator and maintenance work should be carried out by only trained personnel. Mounting and servicing operations should be carried out only after switching off the voltage. -
Page 25: 12.1.1 External Signal Generator
Signal Pin Funktion REL1B Hauptalarm, potenzialfreier Relaisausgang 1, Anschluss B, Öffner 30 V / 1A AC / DC REL1A Hauptalarm, potentialfreier Relaisausgang 1, Anschluss A, Öffner 30 V / 1A AC / DC REL2B Voralarm, potentialfreier Relaisausgang 2, Anschluss B, Öffner 30 V / 1A AC / DC REL2A Voralarm, potentialfreier Relaisausgang 2, Anschluss A,... -
Page 26: 12.1.2 Alarm Output
12.1.2 Alarm output The device has two independent switching points, each of which triggers a relay. The relays can be used either as early warning/main alarm, or as output for the dryer regulation and alarm signal. Both the outputs are configured as Normally Closed at works, that means in normal operation, the contact is closed. -
Page 27: 12.1.4 Rs 232 / 485-Interface
12.1.4 RS 232 / 485-Interface The measured pressure dew point values are cyclically passed out over the serial interface. The documentation on interface protocol is available in the appendix. The signals are given out both as per RS 232 and RS 485 standard. The interface is not potentially isolated. -
Page 28: Special Type Of Applications
Special type of applications 13.1 Stationery mounting location with cooling segment For precise measurements in the lower dew point range (-10... -20 °C tpd), the temperature of the gas to be measured should preferably be at room temperature (20 ... 25 °C). For special applications in the plastic industry, for example, in granule dryers, the temperature of the measured gas is substantially higher. -
Page 29: Maintenance Work
Performing a measurement: The connection takes place over a plug nipple with valve cock. First the air quality should be checked at the measuring point, for which the ball valve to be kept at "Divert" position. With condensate discharge, the measurement should be discontinued and first the plant should be put in order.. -
Page 30: Trouble Shooting Guide
Trouble shooting guide 14.1 The measured value is flow dependent and too high (i.e. too hu- mid) Cause Solution The humidity measuring system Wait for the stabilization time. If the measuring system was kept is still not stabilised, transient unused for a longer time in ambient humidity, specially in deep process. -
Page 31: The Measured Value Is Too Low (I.e. Too Dry)
14.3 The measured value is too low (i.e. too dry) Cause Solution The pressure at the measuring Remove the pressure loss, check the position of valve cock. point is lower than as in the system, hence the pressure dew point at the sensor becomes drier. -
Page 32: Appendix
Appendix 15.1 Condensate formation in compressed air plants If air is compressed, then a part of the environment moisture contained in the intake air precipitates as condensate, since compressed air cannot hold so much water as the air at atmospheric pressure. Higher the pressure rises, lower the water which the compressed air can hold and hence the relative humidity further increases. - Page 33 In order to evaluate the absolute humidity content (e.g. MRW) of air, it is therefore often advantageous to measure the dew point in the compressed gas (at higher pressure). Because of the measuring principle of the capacitive polymer sensors used here, exact measured values can be achieved same as measurement in expanded air.
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Page 34: Thermodynamic Concepts
15.3 Thermodynamic concepts Term Description % rH The relative humidity is the relationship of water vapour partial pressure in the test gas to maximum possible water vapour partial pressure (water vapour-saturation pressure) at the same temperature and total pressure The test temperature, T , is the gas temperature at the measuring Test temperature location. -
Page 35: Working Of An Adsorption Compressed Air Dryer
Working of an adsorption compressed air dryer The additional measurement of achieved dew point value in compressed air enables reduction of operating cost by optimisation of the regeneration and drying intervals, so that the amount of compressed air required for the drying process (regeneration) with respect to the air consumption is minimized. -
Page 36: Checking The Measuring Accuracy
With the application of pressure dew point regulator IDPC 40, it is possible to use the first alarm contact for regulation of dryers. Hence, the air is dried only so much, which is necessary for the process and the operating costs are substantially reduced. The period of regeneration interval, when flushing air is used, is adapted as per the desired dew point value at the air outlet of dryer. - Page 37 Table: Relative humidity [%] as a function of pressure dew point at different ambient temper- atures -20 °C 0 °C 23 °C 40 °C 60 °C 3.871 0.6583 0.144 54.93 E-03 20.36 E-03 12.55 2.134 0.4669 0.1781 66.02 E-03 36.96 6.287 1.375 0.5246...
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Page 38: Format Of Data Transfer At The Serial Interface
18.1 Format of data transfer at the serial interface The interface works with a data rate of 4800 bauds, 8 data-bits, no parity and a Stopbit The transfer of useful data takes place in lines. All characters are ASCII coded. All information is sent continuously without separation characters. -
Page 39: Eg-Conformance Details
EG-Conformance details As per EMV-Guidelines 89/336/EWG hereby declares that the product “Pressure Dew point Monitoring Device TPK 20“ conforms to the essential safety requirements, that are specified in the guidelines of the council of legal rules of the member states regarding electromagnetic compatibility (89/336/EWG). -
Page 40: Accessory List
Dimensions (450 x 360 x 123 mm) TPK20-POR External alarm generator with acoustic and distantly visible optical signal, for... - Page 41 The technical information in this document has been checked with adequate care at our end and is intended to inform about the product and its applications. The descriptions are not to be understood as assurance of the defined characteristics of the product and should be checked by the user for the intended application.
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