KAESER KAD Series Instruction Manual
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KAESER KAD Series Instruction Manual

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3162261
Rev. E
04/10
INSTRUCTION MANUAL
KAD SERIES
RATED
MODELS
FLOW
KAD 40
40 SCFM
KAD 60
60 SCFM
KAD 90
90 SCFM
KAD 115
115 SCFM
KAD 165
165 SCFM
KAD 260
260 SCFM
KAD 370
370 SCFM
KAD 450
450 SCFM
KAD 590
590 SCFM
KAD 750
750 SCFM
KAD 930
930 SCFM
KAD 1130
1130 SCFM
KAD 1350
1350 SCFM
KAD 1550
1550 SCFM
KAD 2100
2100 SCFM
KAD 3000
3000 SCFM
KAD 4100
4100 SCFM
KAD 5400
5400 SCFM
Contents
1.
General Safety InformatIon ................................ 2
2.
receIvInG, movInG, UnpackInG .............................. 2
3.
DeScrIptIon ................................................................. 3
4.
InStallatIon ................................................................. 8
5.
controllerS - General .......................................... 16
6.
controller - tImer BaSeD ..................................... 18
7.
controller - level 1 ............................................... 21
8.
controller - level 2 ............................................... 32
9.
operatIon ..................................................................... 49
10. maIntenance ............................................................... 55
11. troUBleShootInG ..................................................... 56
12. noteS ............................................................................. 57
Warranty ............................................................................. 60
MODEL
REFERENCE
40
60
90
115
165
260
370
450
590
750
930
1130
1350
1550
2100
3000
4100
5400
SERVICE DEPARTMENT : (724) 745-3038
PRESSURE-SWING
DESICCANT TYPE
COMPRESSED
AIR DRYERS

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  • Page 1: Table Of Contents

    3162261 Rev. E 04/10 INSTRUCTION MANUAL KAD SERIES RATED MODEL MODELS FLOW REFERENCE KAD 40 40 SCFM KAD 60 60 SCFM KAD 90 90 SCFM KAD 115 115 SCFM KAD 165 165 SCFM KAD 260 260 SCFM KAD 370 370 SCFM...

  • Page 2: General Safety Information

    gENERAl SAfETy INfoRMATIoN RECEIVINg, MoVINg, UNPACKINg pressurized Devices receiving: • this equipment is a pressure-containing device. • this shipment has been thoroughly checked, packed and • Do not exceed maximum operating pressure as shown on the inspected before leaving our plant. equipment serial number tag.

  • Page 3: Description

    DESCRIPTIoN Dryer function automatic purge Saving System • Dual tower regenerative desiccant dryers are an economical featured with the level 2 controller, the automatic purge Saving and reliable way to dry compressed air to dew points below the System is designed to save energy (purge air) when pressure-swing freezing point of water (dew points as low as -100°f (-73.3°c) dryers are operated at reduced loads.
  • Page 4 Description of operation – Dryer 3.3.1 models 40 to 3000 w/ Shuttle valve (Refer to Fig. 3-1a.) Compressed air flows through inlet shuttle valve (3) OUTLET to tower (4A) where the air is dried. After the air is dried it flows through outlet shuttle valve (5) and then to the dryer outlet.
  • Page 5 3.3.2 models 4100 to 5400 w/ check valves (Refer to Fig. 3-2a.) Compressed air flows through inlet switching OUTLET valve (3a) (normally open) to tower (4a) where the air is dried. after the air is dried it flows through outlet check valve (5A) and then to the dryer outlet.
  • Page 6 3.3.3 models 40 to 450 (high pressure option) OUTLET (Refer to Fig. 3-3a.) Compressed air flows through inlet switching valve (3a) (normally open) to tower (4a) where the air is dried. after the air is dried it flows through shuttle valve (5) and then to the dryer outlet.
  • Page 7 automatic purge Saving System (refer to figure 3-4a for models 40 through 3000 and figure 3-4b for models 4100 through 5400.) Assume tower A is on-line drying while tower B has just gone off-line OUTLET to be regenerated. at the beginning of tower B’s regeneration cycle a thermistor temperature measurement is made at position B1.

  • Page 8: Installation

    4.1.4 heatless pressure-Swing Desiccant air Dryer INSTAllATIoN 4.1.5 Afterfilter(s) – to ensure downstream air purity (prevent desiccant dust from location in the compressed air system traveling downstream) adequate filtration downstream of the dryer note: the air compressor should be adequately sized to handle is required.
  • Page 9 minimum operating pressures: NOTE: When quarter-turn valves (e.g. ball or butterfly valves) are used for isolation of pressure components, care should be taken to 4.5.1 for 150 psig (10.3 barg) mop models - open or close valves slowly. • 60 psig (4.1 barg) is the minimum operating pressure for dryers operated on ISo classes 1, 2, 3, and 4.
  • Page 10 (MAX) CENTERLINE OF CUSTOMER INLET/OUTLET CONNECTIONS (MAX) 7/8” X 1 1/4” SLOT (TYP 4 PLCS) [22mm] [32mm] TOP VIEW OUTLET SHUTTLE LIFTING LUG VALVE ASSY AIR OUTLET PILOT AIR FILTER DESICCANT FILL PORT PURGE PRESSURE GAUGE LEFT CHAMBER & REGULATOR PRESSURE GAUGE PURGE ADJUSTING VALVE WARNING: Disconnect the main power...
  • Page 11 DIMENSIONS IN INCHES MODEL 27.5/8 27.5/8 27.5/8 38.3/8 38.3/8 41.3/8 49.3/8 49.3/8 13.13/16 13.13/16 13.13/16 19.13/16 19.13/16 20.11/16 24.11/16 24.11/16 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 29.1/2 29.1/2 29.1/2 35.1/2 35.1/2 35.1/2 35.1/2 35.1/2 14.3/4 14.3/4 14.3/4 17.3/4 17.3/4 17.3/4 17.3/4...
  • Page 12 CENTERLINE OF CUSTOMER INLET/OUTLET CONNECTIONS (MAX) 7/8” X 1-1/4” SLOT (TYP 4 PLACES) AIR INLET [22mm] [32mm] BOTTOM RIGHT SIDE VIEW (Models 1550, 2100 and 3000) (MAX) RIGHT CHAMBER REMOVED FOR CLARITY TOP VIEW AIR OUTLET DESICCANT FILL PORT PURGE PRESSURE ADJUSTMENT VALVE MOISTURE INDICATOR LIFTING LUG...
  • Page 13 DIMENSIONS IN INCHES MODEL 1130 1350 1550 2100 3000 46.3/4 47.9/16 52.11/16 56.7/16 57.5/16 63.1/8 69.13/16 73.3/8 23.3/8 23.13/16 26.5/16 28.1/4 28.11/16 31.9/16 34.7/8 36.11/16 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 45.1/2 45.1/2 53.1/2 53.1/2 53.1/2 53.1/2 53.1/2 59.1/2 22.3/4 22.3/4...
  • Page 14 CENTERLINE OF CUSTOMER INLET/OUTLET CONNECTIONS FLOW FLOW ASME PRESSURE RELIEF VALVE (MAX) FLOW FLOW 7/8” X 1-1/4” SLOT (TYP 4 PLACES) [22mm] [32mm] (MAX) TOP VIEW AIR OUTLET FLOW FLOW FLOW DESICCANT FILL PORT LIFTING LUG PURGE PRESSURE MOISTURE INDICATOR ADJUSTMENT VALVE PURGE PRESSURE GAUGE LEFT CHAMBER...
  • Page 15 DIMENSIONS IN INCHES MODEL 4100 5400 82.7/8 93.3/8 41.7/16 46.11/16 1.1/4 1.1/4 59.1/2 63.1/2 29.3/4 31.3/4 33.3/16 35.7/8 13.13/16 19.7/16 115.13/16 116.3/16 36.3/16 38.7/8 6 FLANGE 6 FLANGE WT/LBS 9900 12000 DIMENSIONS IN MILLIMETERS MODEL 4100 5400 2106 2372 1053 1186 1511 1613...

  • Page 16: Controllers - General

    inlet flow is less than the adjusted rated capacity of the dryer, average CoNTRollERS – gENERAl purge air requirements are reduced. this reduction can translate to energy savings at the air compressor. overview The Level 1 Controller offers 8 selectable fixed-cycle Energy (purge) the solid-state dryer controller is located in a polycarbonate, nema Saver modes (0% to 70% in 10% increments) to reduce purge time class 4/4X, Ip66 rated electrical enclosure mounted to a center panel...
  • Page 17 table 5-1 (continued from previous page) notes: the timer controller will accept ac (alternating current) input power. the level 1 and level 2 controllers will accept either ac (alternating current) or Dc (Direct current) input power. (level 1 & level 2 controllers) the auxiliary power terminals are in parallel with the input power terminals (i.e., there are two common terminals for each input power connection point, l, n, and pe.

  • Page 18: Controller - Timer Based

    connections – timer Based controller CoNTRollER – TIMER BASED See figure 6-2, point-to-point Diagram for the location and function of the various cable and cord connectors that are provided on the bottom This section provides connection, adjustment and operational of the timer Based enclosure. information for the timer Based –...
  • Page 19 Power ON Light Left Tower Right Tower DRYING Light DRYING Light WARNING: Disconnect the main power supply before removing this cover. figure 6-1 front panel overlay –timer Based controller (note: figure is representative of models kaDe 40 through 3000.) — 19 —...
  • Page 20 BASE BLACK/GREY +VE BLACK FUSE 5 x 20mm VOLTAGE 1 Amp Slow Blow LABEL Live Neutral Black Sleeve Earth White Sleeve SUPPLY 100 - 240v 50/60 Hz INPUT GREEN/YELLOW TERMINALS 100 - 240V 50/60 Hz BLUE EARTH POSITIVE NEGATIVE (CONTROL TIMER BOARD) FUSE 5 x 20mm 1 Amp Slow Blow LEFT TOWER...

  • Page 21: Controller - Level 1

    • the common alarm is designed to activate on: a) either a dryer CoNTRollER – lEVEl 1 fault condition or a service reminder, or b) a dryer fault condition only. this is user selectable. This section provides connection, adjustment and operational •...
  • Page 22 tower that is actively purging when the power on/off button is 7.3.3.3 valve Service actuated will be subjected to a rapid repressurization that can When the service interval for valves has expired, the following leDs lead to fluidization and subsequent abrasion of the desiccant bed. will blink: Ideally, dryers should only be powered off during those portions of •...
  • Page 23 front panel overlay – level 1 controller Filter service / maintenance LED Left tower pressure switch LED: Filter service / On=switch closed maintenance LED Off=switch open Right tower pressure Left tower drying LED switch LED: On=switch closed Off=switch open Left purge valve LED On=valve open Off=valve closed Right tower drying LED...
  • Page 24 7.4.1 front panel leDs 7.4.2.3 percent energy / purge Savings Selector Switch • power on - green • If dryer is operated at less than maximum flow capacity a • alarm – red reduction in purge air usage may be possible. eight settings (0% •...
  • Page 25 Dryer MOP 60 - 150 psig (4.1 - 10.3 barg) 120 - 250 psig (8.3 - 17.2 barg) ISO Class -73°C -40°C -20°C +3°C -73°C -40°C -20°C +3°C Dew Point -100°F -40°F -4°F +38°F -100°F -40°F -4°F +38°F Cycle Time (minutes) Energy (Purge) Time from start of cycle Time from start of cycle...
  • Page 26 Time (refer to Table 7-3) Process valve name (Process valve state w/ de-energized Left Tower Drying Right Tower Drying pilot solenoid valve) Right Tower Regenerating Left Tower Regenerating Half Cycle Half Cycle Pilot Energized Left purge valve (normally closed) (open) Left inlet valve (normally open) Pilot Energized (closed) (See NOTE 1)
  • Page 27 AC TO DC CUSTOMER POWER SUPPLY AC POWER TB5-20 SERVICE REMINDER 3 (PRE FILTERS) CONNECTIONS GRN/YEL 85-264 VAC TB5-21 LEFT INLET VALVE OPEN (SEE NOTE 6) 47-63 HZ NEUTRAL TB5-22 LEFT TOWER REGENERATING SEE NOTE 1 TB5-23 LEFT PURGE VALVE OPEN TB5-24 LEFT TOWER DRYING TB5-25...
  • Page 28 JUMPERS JUMPER (SEE NOTE 3) JUMPER NO. & JUMPER JUMPER FUNCTION J1 - MAXIMUM OPERATING PRESSURE 150 PSIG 250 PSIG JUMPER PINS ACTIVATED BY DRYER J2 - COMMON ALARM DEFAULT FAULT ALARM ONLY J3 - SERVICE INTERVAL NORMAL SEVERE J4 - POWER RECOVERY MODE AUTO JUMPER JUMPER...
  • Page 29 ENCLOSURE DOOR EXTERIOR LEGEND COMMON ALARM RELAY ISO CLAS/MANAUL CYCLE SELECTOR SWITCH RIGHT TWR. DRYING (GREEN) SERVICE REMINDER 3 - PREFILTERS (AMBER) POWER ON LED (GREEN) POWER ON/OFF SWITCH LEFT TOWER REGEN. (AMBER) MAIN SERVICE REMINDER (AMBER) ALARM RESET/MANUAL CYCLE INCREMENT SWITCH LEFT PURGE VALVE OPEN (GREEN) COMMON ALARM (RED) ENERGY SAVINGS % SELECTOR SWITCH...
  • Page 30 11.5-28 VDC 85-264 VAC 47-63 HZ figure 7-4 panel layouts - level 1 controller (continued from previous page) — 30 —...
  • Page 31 caBle DIameter ranGe encloSUre # of connector hole DIa. locatIon fUnctIon mIn. DIa. maX. DIa. conDUctorS SIZe SIZe preSSUre SWItch - rIGht toWer 0.181 0.312 pG-9 0.599 15.2 preSSUre SWItch - left toWer 0.181 0.312 pG-9 0.599 15.2 factory SolenoID - left pUrGe valve 0.181 0.312 pG-9...

  • Page 32: Controller - Level 2

    • the common alarm is designed to activate on: a) either a dryer CoNTRollER – lEVEl 2 fault condition or a service reminder, or b) a dryer fault condition only. this is user selectable. This section provides connection, adjustment and operational •...
  • Page 33 the drying cycle when both desiccant towers are at full operating front panel overlay – level 2 controller pressure. Use of the remote start/stop connections as described refer to figure 8-1, front panel overlay – level 2 controller for in Section 8.2.3 would be preferable in most cases. information regarding the location and function of the leDs, switches, •...
  • Page 34 Left tower pressure Filter service / switch LED: maintenance LED On=switch closed Off=switch open Filter service / maintenance LED Left tower drying LED Right tower pressure Left purge valve LED switch LED: On=valve open On=switch closed Off=valve closed Off=switch open Right tower drying LED Right purge valve LED On=valve open...
  • Page 35 front panel operation • note: time continues to accumulate as long as power is supplied to the controller, whether the controller is switched 1. There are five operating modes for the Level 2 Desiccant on or off. Dryer controller. • When finished Press to save the selection and move to a.
  • Page 36 • one of two things will happen upon exiting Setup mode. 8.9.1.1 pressure Switch alarms there are three alarms for each tower that are triggered by the tower 1. the controller will switch to Display mode if DemanD pressure switches. These alarms can occur in either the fixed or cycle or fIXeD cycle was selected.
  • Page 37 the following text display is shown for each alarm. the second line of 8.9.1.11 alarm mode Screen 8 - right tower Drying – low the alarm screens contains up to three messages, which are scrolled pressure (open pressure Switch circuit) through, displaying each one for 3 seconds after the alarm condition ALARM clears.
  • Page 38 8.9.1.20 alarm mode Screen 17 – alarm 8.9.2.3 Service mode Screen 3 – Service valves ALARM SERVICE DRYER LEFT TOWER VALVES DRYING ensure that valves are cycling properly. check for switching failure OUTLET DEW POINT alarms and adjust purge pressure. Check for leaks. 8.9.1.21 alarm mode Screen 18 –...
  • Page 39 • caUtIon: Do not advance to step 5 until the right tower • press to advance from one screen (program step) to the has fully pressurized. next. Be sure to read and understand all cautions listed with the • press to advance to screen 5.
  • Page 40 program Step left tower status drying drying drying drying regen. regen. regen. regen. right tower status regen. regen. regen. regen. drying drying drying drying left tower closed at start, open at start, closed closed closed closed closed closed pressure switch open at end closed at end right tower...
  • Page 41 Dryer MoP 60 - 150 psig (4.1 - 10.3 barg) 120 - 250 psig (8.3 - 17.2 barg) ISo Class Dew Point -73°C -40°C -20°C +3°C -73°C -40°C -20°C +3°C -100°f -40°f -4°f +38°f -100°f -40°f -4°f +38°f Cycle Time (minutes) Time from start of cycle Time from start of cycle Time...
  • Page 42 time (refer to table 8-3) process valve name (process valve state left tower Drying right tower Drying w/ de-energized right tower regenerating left tower regenerating pilot solenoid valve) half cycle half cycle left purge valve pilot energized (normally closed) (open) left inlet valve (normally open) pilot energized (closed) (See note 1)
  • Page 43 figure 8-2 electrical Schematic – level 2 controller — 43 —...
  • Page 44 ENCLOSURE DOOR J2 (RPB) ENCLOSURE DOOR INTERIOR REMOTE PUSHBUTTON SWITCH CONNECTIONS SELECT ALARM_RESET ENTER POWER ON / OFF figure 8-3 point-to-point Diagram – level 2 controller (continued on next page) — 44 —...
  • Page 45 ENCLOSURE INTERIOR POWER SUPPLY BLACK CUSTOMER AC POWER WHITE CONNECTIONS 85-264 VAC GRN/YEL 47-63 HZ CUSTOMER BLACK DC POWER CONNECTIONS 11.5-28 VDC 20 21 22 23 24 25 26 27 28 29 40 41 JUMPER JUMPER PINS ALARM CONTACTS RIGHT_BTM_THERM TEST DRAIN 2 JUMPER BASE RIGHT_TOP_THERM...
  • Page 46 VACUUM FLOURESCENT TEXT DISPLAY ENCLOSURE DOOR EXTERIOR LEGEND SERVICE REMINDER 3 - PRE FILTERS (AMBER) 15L COMMON ALARM (RED) RS232 SERIAL I/O CONNECTOR LEFT TOWER REGENERATING (AMBER) 16L PRESSURE SWITCH 2 (RIGHT TOWER) CLOSED (GREEN) PICPROG. CONNECTOR LEFT PURGE VALVE OPEN (GREEN) XILINX PROGRAM CONNECTOR 1PB SELECT SWITCH 2PB POWER ON/OFF SWITCH...
  • Page 47 2 3 4 5 6 7 8 DISPPCB ENCLOSURE DOOR INTERIOR CNTRLPCB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 CONTACTS ENCLOSURE INTERIOR figure 8-4...
  • Page 48 caBle DIameter ranGe encloSUre # of connector hole DIa. locatIon fUnctIon mIn. DIa. maX. DIa. conDUctorS SIZe SIZe hUmIDIty-DeW poInt SenSor DraIn 1 (poWer & teSt) DraIn 1 (alarm) 0.230 0.395 10.0 pG-11 0.733 18.6 DraIn 2 (poWer & teSt) factory DraIn 2 (alarm) connectIonS...

  • Page 49: Operation

    9.1.4.1 purge rate pressure – models 40 to 3000 oPERATIoN • refer to table 9-4 for the proper purge rate pressure setting corresponding to the conditions listed in Section 9.1.4. Start-up note: for units with the level 2 controller and the automatic purge Saving System in the demand cycle mode use the ISo 9.1.1 controller Settings (level 1 or level 2 controller) class 2 (10 min.) purge pressure settings only.
  • Page 50 • The purge pressure adjustment valve should never be fully closed. 9.2.4.1 alarms – level 1 controller Proper purge flow is required to regenerate and re-pressurize the Alarm light will flash if either tower fails to pressurize or de-pressurize offline tower. Should the tower fail to re-pressurize, a switching to the required levels at the proper time.
  • Page 51 • models 40 through 3000 are equipped with a single safety relief • De-pressurize the dryer by allowing the controller to run through valve that has been sized at a minimum to provide overpressure tower change cycles until pressure gauges on both towers read protection due to a fire for both desiccant towers.
  • Page 52 from freezing. If installing heat tracing, observe electrical class code eXample requirements for type of duty specified. Purge mufflers and their relief • Find the maximum inlet flow, maximum purge flow, and minimum mechanisms must be kept clear from snow and ice buildup that could outlet flow for a 60 SCFM unit with a MOP of 150 psig operated prevent proper discharge of compressed air.
  • Page 53 moDel 1130 1350 1550 2100 3000 4100 5400 Scfm 1130 1350 1550 2100 3000 4100 5400 1002 1274 1580 1920 2294 2633 3568 5097 6966 9175 table 9-1 maximum Inlet flow at rated conditions psig Inlet preSSUre barg 10.3 11.0 11.7 12.4 13.1...
  • Page 54 Dryer mop 150 psig (10.3 barg) Inlet preSSUre (psig) Inlet preSSUre (barg) 10.3 0.147 0.149 0.151 0.153 0.155 0.151 0.148 0.145 0.143 0.141 0.134 0.136 0.137 0.139 0.141 0.138 0.135 0.133 0.131 0.129 ISo claSS 1 0.120 0.122 0.124 0.125 0.127 0.124 0.122...

  • Page 55: Maintenance

    10.3 valves 10. MAINTENANCE • process and pilot valves should be checked frequently for leaks and proper operation. WarnInG - the heatless desiccant dryer is a pressure-containing • Purge pressure adjustment valve should be checked frequently device. De-pressurize before servicing. (See Section 3.3) for proper adjustment.

  • Page 56: Troubleshooting

    11. TRoUBlEShooTINg SyMPToM PoSSIBlE CAUSE(S) CoRRECTIVE ACTIoN 11.1 Indicator lights not no power to unit. check voltage at terminal board. illuminated off/on switch turned off. turn on. Blown fuse. replace fuse. off/on switch or board malfunction. replace board. 11.2 moisture indica- Design conditions exceeded.

  • Page 57: Notes

    12. NoTES Information from the dryer serial number tag can be recorded in the following table. this information may be necessary when communicating with Service representatives. allowable values from actual values at Serial number tag fields Serial number tag Installation model number: Serial number: Service code:...
  • Page 58 — NoTES — — 58 —...
  • Page 59 — NoTES — — 59 —...

  • Page 60: 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 months from the date of shipment from the factory, whichever occurs first, provided such defect is discovered and brought to the manufacturer’s attention within the aforesaid warranty period.

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