KAESER KBD Series Instruction Manual
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KAESER KBD Series Instruction Manual

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3158146
Rev. R
12/17
INSTRUCTION MANUAL
KBD SERIES
RATED
MODELS
FLOW
KBD500
500 SCFM
KBD600
600 SCFM
KBD750
750 SCFM
KBD900
900 SCFM
KBD1050
1050 SCFM
KBD1300
1300 SCFM
KBD1500
1500 SCFM
KBD1800
1800 SCFM
KBD2200
2200 SCFM
KBD2600
2600 SCFM
KBD3200
3200 SCFM
KBD3600
3600 SCFM
KBD4300
4300 SCFM
MODEL
REFERENCE
500
600
750
900
1050
1300
1500
1800
2200
2600
3200
3600
4300
SERVICE DEPARTMENT : (724) 745-3038
BLOWER PURGE
DESICCANT
COMPRESSED
AIR DRYERS

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  • Page 1 3158146 Rev. R 12/17 INSTRUCTION MANUAL KBD SERIES RATED MODEL MODELS FLOW REFERENCE KBD500 500 SCFM KBD600 600 SCFM KBD750 750 SCFM KBD900 900 SCFM KBD1050 1050 SCFM 1050 KBD1300 1300 SCFM 1300 KBD1500 1500 SCFM 1500 KBD1800 1800 SCFM...

  • Page 2: Table Of Contents

    Contents 1.0 General Safety Information ......1 2.0 Receiving, Storing, and Moving ..... 1 3.0 Description ............ 2 4.0 Installation ............. 2 5.0 Instrumentation ..........7 6.0 Operation ............11 7.0 Maintenance ..........28 8.0 Troubleshooting ..........30 DRAWINGS Electrical Schematic – 460VAC, 3 phase ....33 Electrical Schematic –...

  • Page 3: General Safety Information

    WARNING—Hazard or unsafe practice which could 1.0 General Safety Information result in severe injury or death. CAUTION—Hazard or unsafe practice which could result This equipment is designed and built with safety as a in minor injury or in product or property damage. prime consideration;...

  • Page 4: Description

    To ensure downstream air purity (prevent desiccant dust 3.0 Description from traveling downstream) adequate filtration down- stream of the dryer is required. A High Temperature 3.1 Function Afterfilter, typically rated at 450°F (232°C) operating Blower purge type regenerative dryers are an economi- temperature and capable of removing all desiccant fines cal and reliable way to dry compressed air to dew points 1 micron and larger should be installed at the dryer outlet.
  • Page 5 Compressor Aftercooler Separator Receiver Prefilters Desiccant Dryer Afterfilter Receiver Figure 1 Typical System Configuration 4.5 Electrical Connections CAUTION: The blower and motor have been completely checked and operated prior to shipment from the fac- WARNING — These procedures require entering tory.
  • Page 6 Dimensions and Connections – Dryer Only Figure 2 (continued on next page) (For construction purposes, contact factory to request certified drawings when mounted filters are included with order)
  • Page 7 Dimensions and Connections Figure 2 (continued from previous page)
  • Page 8 shut downs and long delays between delivery and 4. Utilizing an appropriate sized funnel, fill each desic- start-up. Connect one lead of a megger to an un- cant tower as follows: painted surface of the control panel or dryer frame. a.

  • Page 9: Instrumentation

    5.5 Energy Management System 5.0 Instrumentation The optional Energy Management System (EMS) au- tomatically adjusts dryer operation to compensate for The following instrumentation helps in monitoring dryer changes in operating conditions. Air samples are con- operation and performance. Instruments which are avail- tinuously taken from the on-stream tower and passed able as options are so noted.
  • Page 10 AND MOTOR REAR VIEW REPRESS VALVE ASME RELIEF VALVE OUTLET CHECK VALVE PURGE PRESSURE GAUGE DESICCANT RIGHT TOWER FILL PORT PRESSURE GAUGE KAESER CONTROL ENCLOSURE LEFT TOWER HIGH TENSION PRESSURE GAUGE ENCLOSURE (LOCATED BEHIND PANEL DOOR) MOISTURE INDICATOR TOWER INSULATION...
  • Page 11 AND MOTOR REAR VIEW ASME RELIEF VALVE OUTLET CHECK VALVE PURGE PRESSURE GAUGE DESICCANT RIGHT TOWER FILL PORT PRESSURE GAUGE CONTROL KAESER ENCLOSURE LEFT TOWER PRESSURE GAUGE HIGH TENSION ENCLOSURE (LOCATED BEHIND PANEL DOOR) MOISTURE INDICATOR TOWER INSULATION PRESSURE REGULATOR (OPTIONAL) &...
  • Page 12 THROTTLING VALVE PURGE BLOWER AND MOTOR REAR VIEW DESICCANT PURGE FILL PORT PRESSURE GAUGE RIGHT TOWER PRESSURE GAUGE LEFT TOWER KAESER PRESSURE GAUGE CONTROL ENCLOSURE HIGH TENSION ENCLOSURE MOISTURE INDICATOR (LOCATED BEHIND PANEL DOOR) PRESSURE REGULATOR & PILOT AIR FILTER...

  • Page 13: Operation

    through the right tower, and exits through the Right 6.0 Operation Purge Valve V4. The Blower intake air is filtered to keep dust and dirt from entering the dryer. The 6.1 Controls Blower M and Heater H1 are de-energized when A solid-state controller controls valve and heater opera- the temperature at the bottom of the right tower, tion, monitors all critical operating conditions, and indi-...
  • Page 14 SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEW POINT MONITOR OPTION PR&G SET AT 100 PSIG SET @ 370°F LEFT RIGHT RTD 3 CHAMBER CHAMBER SET @ 650°F SET @ SET @ 45 PSIG 45 PSIG SET @ SET @ 5 PSIG 5 PSIG...
  • Page 15 from entering the dryer. The Blower M and Heater 6.3.1 Energy Management Control (optional) H1 are de-energized when the temperature at the Operation of the Energy Management Control cycle is bottom of the left tower, as sensed by the Left Tower identical to the fixed cycle except the cycle is extended Temperature Sensor RTD1, reaches the Heat Ter- until the desiccant bed in the on-line tower has been fully...
  • Page 16 6.4 Control Board Jumpers 7. JP7 – Download Language Text Jumper JP7 is factory installed in the OFF position In the upper left hand corner of the control board there to disable Language Text download. The jumper is are eight two-pin jumpers labeled JP1 through JP8. Only installed in the ON position to allow for language text six of the eight jumper pairs are utilized.
  • Page 17 Filter Service / Left Tower Pressure Maintenance LED Switch LED: On=Tower Pressurized Filter Service / Maintenance LED Left Tower Drying LED Right Tower Pressure Left Purge Valve LED Switch LED: On=valve open On=Tower pressurized Off=valve closed Left Inlet Valve LED Right Tower Drying LED On=valve open Off=valve closed...
  • Page 18 Screen 7: Set Point for Dew Point Demand Control b. SEVERE Service Intervals are: (This feature is only active when JP3 is “on”) i. 2000 hours for filters ii. 4000 hours for desiccant DPNT CNTL SETPT iii. 4000 hours for valves ±XX°C ±XXX°F 2.
  • Page 19 2. When finished, press to acknowledge the selec- 5. When finished, press to acknowledge the selec- tion and scroll to the pressure set point screen. tion and move to next screen. Exit Program Mode when there are no more active screens to display. 3.
  • Page 20 6.5.6 Alarm & Service Mode d. On alarm condition, the blower and heater are de-energize, the cycle sequence is stopped, a 1. Alarm & Service Mode is active when the controller local alarm is displayed and the common alarm is in Display Mode. It is not active in Program Mode, relay is de-energized.
  • Page 21 ALARM MESSAGES LEFT TOWER ALARMS RIGHT TOWER ALARMS OTHER ALARMS ALARM LEFT TOWER ALARM RIGHT TWR ALARM HEATER DRYING DRYING OVER-TEMPERATURE LOW PRESSURE LOW PRESSURE ALARM LEFT TOWER ALARM RIGHT TWR ALARM HEATER REGENERATING REGENERATING LOW TEMPERATURE HIGH PRESSURE HIGH PRESSURE ALARM LEFT TOWER ALARM RIGHT TWR ALARM ENRGY MGNT...
  • Page 22 9. Heater Low Temperature 13. Dew Point Sensor a. RTD3 is used to detect Heater Low Temperature. a. High Dewpoint Alarm i. The user enters an alarm value through the b. Alarm if the heater temperature is less than 250°F Program Mode.
  • Page 23 Service Due Messages 6.5.7 Display Mode 1. Display Mode is active when the user exits Program 14. There are two service levels (normal and severe) as Mode or Setup Mode and no alarms are active (un- described in Program Mode. Each service level has less MANUAL CYCLE was selected in Setup Mode).
  • Page 24 DRYER STATUS SCREENS LEFT TOWER DRYING RIGHT TOWER DRYING LT DRYING LT DEPRESSURIZE RT DEPRESSURIZE RT DRYING LT DRYING LT HEATING RT HEATING RT DRYING LT DRYING LT COOLING RT COOLING RT DRYING LT DRYING LT REPRESSURIZE RT REPRESSURIZE RT DRYING LT DRYING LT HOLDING RT HOLDING...
  • Page 25 6.5.8 Test Mode 5. To exit Test Mode: 1. Test Mode is active when the user exits Program a. Press and hold for 3 seconds to exit Test Mode after selecting operation in MANUAL CYCLE. Mode. The display switches to Screen 2 of Setup Mode.
  • Page 26 TEST MODE SCREENS Screen 1: Step 1 Screen 7: Step 7 TEST1: LT DRYING TEST7: RT DRYING XX°C XXX°F XX°C XXX°F Screen 2: Step 2 Screen 8: Step 8 TEST2: DEPR RT TEST8: DEPR LT XX°C XXX°F XX°C XXX°F NOTE: Sequence step will not advance to HEAT until NOTE: Sequence step will not advance to HEAT until tower has fully depressurized.
  • Page 27 6.6 Start-up 6.7.5 Process Valves Determine if air control valves are operating and 6.6.1 Controller Settings sequencing correctly. Set or verify settings on Controller. Detailed operational points are presented in section 6.5. 6.7.5.1 Valves – Models 500 and 600 Inlet switching valves are normally open, pneumatically WARNING - Enclosure may have live electric parts.
  • Page 28 6.10 Operating Parameters The tower pressure gauge of the off-line tower should read below 2 psig (0.14 kgf/ cm ) while that tower is Control valves are designed so that upon loss of power purging. If excessive air is exhausting during the purge the air dryer is capable of drying air until the desiccant cycle, the inlet-switching valve or outlet check valve on exposed to the airflow is saturated.
  • Page 29 Example: ASCII representation of the humidity sensor If jumper 8, 5, and 1 are installed, a value of 128+16+1 relative humidity (%) = 145 is returned To decode, the algorithm: xxxx ASCII representation of the dew point reading (°F) · If (number >= 128) è jumper 8 = on ·...

  • Page 30: Maintenance

    e. Utilizing an appropriate sized funnel, fill each 7.0 Maintenance desiccant tower as follows: 1) Install the required quantity of tabular support WARNING - This equipment is a pressure-containing (model 4300 only) or activated alumina in device. Depressurize before servicing. layer 1 of each tower.
  • Page 31 2. Procedure for element replacement a. Isolate dryer from air supply b. Depressurize dryer by running dryer and allowing system pressure to purge to atmosphere. Loss of pilot pressure will eventually prevent purge/ repressurization valves from opening. Remaining pressure can be vented to atmosphere through the manual drain on the pilot air filter.

  • Page 32: Troubleshooting

    8.0 Troubleshooting WARNING - A POTENTIAL ELECTRICAL SHOCK HAZ- ARD EXISTS. Some of the troubleshooting checks may require gaining access to the dryer’s electrical enclosure(s) while the power supply is energized and should be performed by a qualified electrical technician. WARNING - Before performing any electrical or me- chanical repairs or maintenance, or removing or dis- assembling any component, be sure to de-energize...
  • Page 33 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION High Pressure Alarm 1. Faulty regenerating tower pressure 1. Check pressure switch operation using tower pressure Left Tower or Right Tower Re- switch gauge for comparison. Replace switch if defective. generating 2. Regenerating tower Depressurization 2.
  • Page 34 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION Outlet Dew Point Alarm 1. Inlet air flow higher than the sizing 1. Reduce inlet flow to sizing condition. Left Tower or Right Tower condition. 2. Liquids entering the dryer inlet. 2. Check the inlet air line for liquids. Inspect prefilter and drain valve.

  • Page 35: Electrical Schematic - 460Vac, 3 Phase

    Electrical Schematic – 460VAC, 3 phase (Contact factory to request certified drawings) DETAIL A (2-WIRE DEWPOINT TRANSMITTER) +12VDC EXTERNALLY LOCATED DEWPOINT TRANSMITTER + 4-20MA OUT CUSTOMER PROVIDED MOTOR 460VAC, 3 PHASE FUSE AS PER TABLE 249 OHM 1/8W BLACK 1HTR LOW TENSION 0.5 AMP ENCLOSURE...

  • Page 36: Electrical Schematic - 575Vac, 3 Phase

    Electrical Schematic – 575VAC, 3 phase (Contact factory to request certified drawings) DETAIL A CUSTOMER PROVIDED MOTOR (2-WIRE DEWPOINT TRANSMITTER) 575VAC, 3 PHASE +12VDC FUSE AS PER TABLE EXTERNALLY LOCATED DEWPOINT TRANSMITTER + 4-20MA OUT 1HTR 249 OHM 1/8W 2HC1 USED ON MODELS 2HTR 3200, 3600 &...

  • Page 37: Electrical Data - Fusing & Wire Sizing

    Electrical Data – Fusing & Wire Sizing Electrical Service: 460VAC, 3 phase Electrical Service: 575VAC, 3 phase F.L.A. SUGGESTED F.L.A. SUGGESTED MODEL COMPONENT RATING MODEL COMPONENT RATING @460VAC FUSING @575VAC FUSING HEATER 10 KW 12.6 20 AMPS HEATER 10 KW 10.0 15 AMPS MOTOR...

  • Page 38: P&Id Schematic - Models 500 Through 600

    P&ID Schematic Models 500 through 600 (Contact factory to request certified drawings) SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEW POINT MONITOR OPTION SET AT 100 PSIG SET @ 370°F LEFT RIGHT RTD 3 CHAMBER CHAMBER SET @ 650°F SET @ SET @ 45 PSIG...
  • Page 39 LEGEND INLET VALVE (V1 LEFT, V2 RIGHT) PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT) PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT) DEPRESS VALVE (V9 LEFT, V10 RIGHT) PURGE HEATER WITH INSULATION HEATER TEMPERATURE THERMOCOUPLE HEATER OVERTEMPERATURE RTD CHAMBER RTD (LEFT &...

  • Page 40: P&Id Schematic - Models 750 Through 4300

    P&ID Schematic Models 750 through 4300 (Contact factory to request certified drawings) SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEW POINT MONITOR OPTION SET AT 100 PSIG (225°F) SET @ 370°F LEFT RIGHT RTD 3 CHAMBER CHAMBER SET @ 650°F SET @ SET @ 45 PSIG...
  • Page 41 LEGEND INLET VALVE (V1 LEFT, V2 RIGHT) SOL 'C' FLOW CONTROL VALVE SOL 'D' PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT) PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) (NO SPRING) OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT) DEPRESS SOLENOID VALVE (V9 LEFT, V10 RIGHT) PURGE HEATER WITH INSULATION HEATER TEMPERATURE THERMOCOUPLE HEATER OVERTEMPERATURE RTD...

  • Page 42: Replacement Parts Models 500 Through 600

    Replacement Parts – Models 500 through 600 REAR VIEW LEFT CHAMBER RIGHT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Kaeser Compressors Phone: (540) 898-5500 FAX: (540) 898-5520 Web: www.kaeser.com...
  • Page 43 MODEL MAINTENANCE KITS new September 2016 Year 2 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit USKBDMK204 KBDMK2-06 All the contents of the 2 Year Kit, Pressure Switches, Year 3 Maintenance Kit USKBDMK304 KBDMK3-06 Valve Repair Kits, Blower Hose Year 4 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit USKBDMK404 KBDMK4-06...

  • Page 44: Models 750 Through 1800

    Replacement Parts – Models 750 through 1800 MODEL 750 1 1A REAR VIEW LEFT CHAMBER RIGHT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Kaeser Compressors Phone: (540) 898-5500 FAX: (540) 898-5520 Web: www.kaeser.com...
  • Page 45 MODEL 1050 1300 1500 1800 MAINTENANCE KITS Year 2 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit KBDMK2-08 KBDMK2-10 KBDMK2-12 KBDMK2-14 KBDMK2-16 KBDMK2-18 All the contents of the 2 Year Kit, Pressure Switches, Year 3 Maintenance Kit KBDMK3-08 KBDMK3-10 KBDMK3-12 KBDMK3-14 KBDMK3-16 KBDMK3-18...

  • Page 46: Models 2200 Through 2600

    Replacement Parts – Models 2200 through 2600 1 1A REAR VIEW RIGHT CHAMBER LEFT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Kaeser Compressors Phone: (540) 898-5500 FAX: (540) 898-5520 Web: www.kaeser.com...
  • Page 47 MODEL 2200 2600 MAINTENANCE KITS Year 2 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit KBDMK2-20 KBDMK2-22 All the contents of the 2 Year Kit, Pressure Switches, Year 3 Maintenance Kit KBDMK3-20 KBDMK3-22 Valve Repair Kits, Blower Hose Year 4 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit KBDMK4-20 KBDMK4-22...

  • Page 48: Models 3200 Through 4300

    Replacement Parts – Models 3200 through 4300 42 43 1 1A REAR VIEW RIGHT CHAMBER LEFT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Kaeser Compressors Phone: (540) 898-5500 FAX: (540) 898-5520 Web: www.kaeser.com...
  • Page 49 MODEL 3200 3600 4300 MAINTENANCE KITS Year 2 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit KBDMK2-24 KBDMK2-26 KBDMK2-28 All the contents of the 2 Year Kit, Pressure Switches, Year 3 Maintenance Kit KBDMK3-24 KBDMK3-26 KBDMK3-28 Valve Repair Kits, Blower Hose Year 4 Maintenance Kit Elements*, Muffler, Drain, Desiccant Evaluation Kit KBDMK4-24...

  • Page 52: Warranty

    WARRANTY The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with the procedures and recommendations outlined in the manufacturer’s instruction manuals, to be free from defects in material or workmanship for a period of one (1) year from the date of shipment from the manufacturer or the manufacturer’s authorized distributor, or eighteen (18) months from the date of shipment from the factory, whichever occurs first, provided such defect is discovered and brought to the manufacturer’s attention the aforesaid warranty period.

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