Related Manuals for Parker Zander KA-MT 1
Summary of Contents for Parker Zander KA-MT 1
- Page 1 Adsorption dryer KA-MT 1-8/D3 ( Generation - 3) Operating manual 30/07/2020 rev02 EN Cod: 398H272185...
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Page 3: Table Of Contents
Daily maintenance tasks ......................36 Monthly maintenance tasks ....................37 Maintenance work to be completed every 12 months ............41 Maintenance work to be completed every 24 months ............44 Maintenance work to be completed every 48 months ............44 KA-MT 1-8/D3... - Page 4 Identify and eliminate faults Summary of faults ........................49 Annex with technical documentation Technical data ......................... 53 Replacement and wear part list ....................54 Logic control diagram ......................58 Flow diagram .......................... 60 Installation on fl oor ......................... 61 KA-MT 1-8/D3...
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Page 5: Machine Passport
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 ) KA-MT 1-8/D3... -
Page 6: General Information
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. KA-MT 1-8/D3... -
Page 7: For Your Own Safety
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. KA-MT 1-8/D3... -
Page 8: Safety Notes On Specifi C Operating Phases
◊ When fi 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! KA-MT 1-8/D3... - Page 9 Suspected misuse The dryer must not be misused as a climbing aid! Pipes, valves, and similar fi ttings have not been designed for such loads. They could fracture, tear off, or become damaged in another way. KA-MT 1-8/D3...
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Page 10: Signs And Hazard Areas On The Dryer
Type plate of dryer Type plate of downstream fi lter Type plate of upstream fi lter Front view Please note the above plates and instructions attached to the dryer. Ensure that they are not removed and are always readable. KA-MT 1-8/D3... - Page 11 When working at the oil indicator, always wear protective goggles. Skid risk When emptying and fi lling the vessels with drying agent, there is a risk of skidding caused by spilt drying agent. KA-MT 1-8/D3...
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Page 12: Transportation, Installation And Storage
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. KA-MT 1-8/D3... -
Page 13: Transporting And Installing The Dryer
The dryer should only be transported in an upright position. Note the weight of the dryer! Depending on its size, the dryer may weigh up to approx. 110 kg. Take this into account with regard to the following work steps! KA-MT 1-8/D3... - Page 14 Retighten the screws securing the stand profi le and the muffl er. Use suitable attachment material of suffi cient carrying force to anchor the dryer to the wall. KA-MT 1-8/D3...
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Page 15: Storing The Dryer
If you wish to take the dryer back into service after an extended period of sto- rage, please proceed as described for its fi rst commissioning and start-up (see page 26). Store drying agents Do not store drying agents in the open air. Protect drying agents against humidity. KA-MT 1-8/D3... -
Page 16: Technical Product Description
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-humidifi ed (adsorption), in the other vessel the humid drying KA-MT 1-8/D3... - Page 17 The humidity stored in the drying agent is taken up by the air fl ow and expelled into atmosphere via the muffl er. Regeneration in in the right drying agent chamber KA-MT 1-8/D3...
- Page 18 When the drying agent in the adsorbing chamber has taken up a suffi 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. KA-MT 1-8/D3...
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Page 19: Available Options
This replacement optimizes the regeneration air consumption and therefore restores the energy effi ciency of the dryer. To receive more information on this conversion, please contact the manufacturer. KA-MT 1-8/D3... -
Page 20: Installation
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. KA-MT 1-8/D3... -
Page 21: Connect Piping
If you fi 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. KA-MT 1-8/D3... -
Page 22: Installing The Electrical Connection
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. KA-MT 1-8/D3... - Page 23 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. KA-MT 1-8/D3...
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Page 24: Start-Up
- of which: expansion time ~ 0,2 min ~ 0,2 min - of which: dehumidifi cation time ~ 4 min ~ 4 min - of which: pressure build-up ~ 1 min ~ 1 min Standby ~ 55 min, max. KA-MT 1-8/D3... -
Page 25: Overview Of Operating And Control Elements
Switchbox with ON/OFF switch 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 KA-MT 1-8/D3... - Page 26 With the optional dewpoint-sensing control, the following error messages might be dis- played: Display Cause ◊ Upper measuring range limit exceeded ◊ Dewpoint sensor defective. sens ◊ Dewpoint sensor not powered ◊ Cable defective or disconnected -999 ◊ Sensor defective KA-MT 1-8/D3...
- Page 27 (1) at the indicator should be closed during normal operation. For detailed instructions on the measuring procedure for residual oil, please refer to the respective section in the maintenance instructions, page 33. Oil indicator KA-MT 1-8/D3...
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Page 28: Start Up Dryer
This causes the drying agent in each chamber to be regenerated repeatedly and thus to be prepared optimally for the take-up of humidity. KA-MT 1-8/D3... - Page 29 (see also chapter , page 30). Then proceed as follows: Remedy fault: Look up possible cause of the fault, and how to remedy the same, in the table on page Remedy fault. Repeat the start-up procedure. KA-MT 1-8/D3...
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Page 30: Changing Cycle Mode (Optional)
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 fl ow diagram. Set the ON/OFF switch to position The programme continues the cycle. KA-MT 1-8/D3... -
Page 31: Monitoring Dryer Operation
Display Cause ◊ Upper measuring range limit exceeded ◊ Dewpoint sensor defective sens ◊ Dewpoint sensor not powered ◊ Cable defective -999 ◊ Sensor defective For instructions on how to eliminate faults, see chapter Identify and eliminate faults KA-MT 1-8/D3... -
Page 32: Shutdown And Restart Dryer
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. KA-MT 1-8/D3... -
Page 33: If Work Is To Be Carried Out On The Electrical System
Ensure that the manual drain on the downstream fi lter is closed. Pressurise and switch on the dryer as described in the section Open compressed air supply and switch on dryer on page 26. The dryer is now in operation again and operates fully automatically. KA-MT 1-8/D3... - Page 34 Reassemble the fi lter and commission the dryer (see the operating manual of the fi lter for the reassembly). Switch on the dryer and pressurise as described in section Open compressed air supply and switch on dryer, page 22. Check that the vessel and the downstream fi lter are leak tight. KA-MT 1-8/D3...
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Page 35: Maintenance And Repair Of The Dryer
◊ 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. KA-MT 1-8/D3... -
Page 36: Regular Maintenance Intervals
Carry out visual checks and function checks. • Oil indicator Measure the residual oil content and the resid- • ual capacity of the purifying agent. Muffl er KA-MT 1-2 : • • Clean muffl er, replace if necessary. KA-MT 3-8 : • •... -
Page 37: Instructions For Use Of The Dongle
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. KA-MT 1-8/D3... -
Page 38: Monthly Maintenance Tasks
Subsequently, close the needle valve. Write down end time of measurement. At the indicator tube, mark the highest segment with a colour change, using a suitable pen. Write down the number of scale segments that have changed colour since the start of the measurement. KA-MT 1-8/D3... - Page 39 0.037 0.045 0.055 0.065 0.070 0.002 0.007 0.012 0.018 0.02 0.025 0.032 0.035 1000 0.001 0.003 0.005 0.007 0.008 0.012 0.014 0.018 Table for the determination of the residual oil content in [ppm] at 7 bar operating pressure KA-MT 1-8/D3...
- Page 40 If the established maximum admissible number of segments with colour change is reached, the purifying agent must be replaced (see also page 45 ). If all scale segments in the indicator tube show a colour change, the indicator tube is spent and must be replaced as described below. KA-MT 1-8/D3...
- Page 41 Screw indicator tube into the reducer, applying a non-locking thread seal. Check the union nut (3) and the reducer (4) to ensure that they are properly tightened. To check tube: Open the needle valve (1) for a short time and check screw connections for tightness. KA-MT 1-8/D3...
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Page 42: Maintenance Work To Be Completed Every 12 Months
Therefore, muffl ers must be checked at least once a year and cleaned (KA-MT 1-2 ) or renewed (KA-MT 3-8 ) if they are contaminated. Warning against sudden air ejection! During expansion the pressure is released suddenly through the muffl er: ◊... - Page 43 If no other maintenance work is to be carried out: Restart the dryer (see page 31 ). Place the protective caps (4, 5) onto the old dew point sensor and dispose of it in accor- dance with the applicable regulations. KA-MT 1-8/D3...
- Page 44 Dispose of the used purifying agent in accordance with all applicable regulations. Refi ll the chamber with new purifying agent. Use a funnel, if necessary. Ensure that the agent is fi lled into the chamber with a high bulk density. Mount perforated plates onto the top plate. KA-MT 1-8/D3...
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Page 45: Maintenance Work To Be Completed Every 24 Months
Use a dyamometric key to tighten the screws, and take care to observe the following torques: — 25 Nm in the case of KA-MT 1-4 — 50 Nm in the case of KA-MT 6-8 Tighten the screws crosswise in accord- ance with the sequence shown on the right. - Page 46 Risk of falls! The dryer must not be misused as a climbing aid! The components have not been designed for such loads and could fracture. Only use approved climbing aids when disassembling the check valve plate. KA-MT 1-8/D3...
- Page 47 If the dryer is not used within specifi cations, the drying agent can be conta- minated with pollutants. Always take this into account for the environmentally safe disposal of the drying agent. The waste code numbers of the drying agent can be obtained from the manufacturer. KA-MT 1-8/D3...
- Page 48 Use a dyamometric key to tighten the screws, and take care to observe the following torques: — 25 Nm in the case of KA-MT 1-4 — 50 Nm in the case of KA-MT 6-8 Tighten the screws crosswise in accordance with the sequence shown on the right.
- Page 49 Use a dyamometric key to tighten the screws, and take care to observe the following torques: — 25 Nm in the case of KA-MT 1-4 — 50 Nm in the case of KA-MT 6-8 Tighten the screws crosswise in accordance with the sequence shown on the right.
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Page 50: Identify And Eliminate Faults
• pressurised. Eliminate any faults in the compressed air system. Excessive compressed Leakage Check condensate trap at • • air consumption the upstream fi lter; clean, if necessary. KA-MT 1-8/D3... - Page 51 Check spring and solenoid; • • (audible humming sound or replace, if necessary. Check valve fl apping). diaphragm; replace, if necessary. Dryer is excessively Solenoid valve Y1/Y2 can- Check solenoid and • • bled not be closed diaphragm; replace, if necessary. KA-MT 1-8/D3...
- Page 52 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). KA-MT 1-8/D3...
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Page 53: Annex With Technical Documentation
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 KA-MT 1-8/D3... -
Page 54: Technical Data
Volumetric Nominal Upstream fi lter Downstream Nominal Nominal fl ow¹ in pipe size fi lter Pressure temperature m3/h in bar °C KA-MT 1 AAP010AGFI AOP010AGMI KA-MT 2 AAP010AGFI AOP010AGMI KA-MT 3 AAP010AGFI AOP010AGMI KA-MT 4 AAP010AGFI AOP010AGMI KA-MT 6 AAP015AGFI... -
Page 55: Replacement And Wear Part List
Oil indicator tube P02/ZR KA-MT 8 necessary Dessicant and activated carbon packages Order-ID. KA-MT 1 KA-MT 2 KA-MT 3 KA-MT 4 KA-MT 6 KA-MT 7 KA-MT 8 12 months – activated carbon DESPAC3AK DESPAC10AK 48 months – drying agent DESPAC1MS... - Page 56 0.059 0.075 0.090 0.095 0.125 0.005 0.012 0.020 0.030 0.036 0.048 0.055 0.059 1000 0.002 0.005 0.010 0.012 0.015 0.020 0.025 0.030 Table for the determination of the residual oil content in [ppm] at 4 bar operating pressure KA-MT 1-8/D3...
- Page 57 0.050 0.060 0.076 0.085 0.097 0.005 0.008 0.012 0.020 0.030 0.037 0.042 0.050 1000 0.002 0.005 0.006 0.008 0.010 0.012 0.015 0.020 Table for the determination of the residual oil content in [ppm] at 5 bar operating pressure KA-MT 1-8/D3...
- Page 58 0.036 0.050 0.060 0.070 0.075 0.002 0.008 0.012 0.018 0.025 0.033 0.034 0.035 1000 0.001 0.002 0.005 0.008 0.010 0.012 0.015 0.018 Table for the determination of the residual oil content in [ppm] at 5 bar operating pressure KA-MT 1-8/D3...
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Page 59: Logic Control Diagram
EN | User Manual Annex with technical documentation Logic control diagram Adsorption in B1 and regeneration in B2 KA-MT 1-8/D3... - Page 60 EN | User Manual Annex with technical documentation Regeneration in B1 and adsorption in B2 KA-MT 1-8/D3...
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Page 61: Flow Diagram
Demister, right 130.154 Seal 10.109 Left perforated plate 130.155 Perforated plate 10.110 Conical pressure spring Oil indicator 10.111 Right perforated plate Regeneration gas orifi ce plate Optional devices: Control unit Start-up device Control system Dewpoint-sensing unit Upstream fi lter KA-MT 1-8/D3... -
Page 62: Installation On Fl Oor
EN | User Manual Annex with technical documentation Installation on fl oor Installation on fl oor IN - OUT - 1/4" BSP BSP-P/ Dimensions [mm] Weight [kg] Type KA-MT 1 1/4" 15,0 KA-MT 2 1/4" 20,0 KA-MT 3 1/4" 28,0 KA-MT 4 1/4"... - Page 64 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.
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