CKD SHD3025 User manual

ＳＭ−１３０２４−Ａ
ＩＮＳＴＲＵＣＴＩＯＮ ＭＡＮＵＡＬ
SUPERHEATLESSAIRDRYER
SHD3025
SHD3045
SHD3075
SHD3100
SHD3125
SHD3150
SHD3200
SHD3240
●
Please read this instruction manual
carefully before using this product,
particularly the section describing safety
．
●
Retain this instruction manual with the
product for further consultation whenever
necessary
．
DEC-2112thedition
ＣＫＤCorporation

<SM-13024-A>
TableofContents
1. INTRODUCTION
1
2.
SAFETYINSTRUCTION
2
3. CAUTIONS
3-1
Formalities when installed Super Heatless Dryer
3
3-2
Cautions at operation
3
4. INSTALLATION
4-1
Check items before installation
4
4-2
Transportation
4
4-3
Installation place
5
4-4
Air piping
5,6
4-5
Drain piping
6
4-6
Electric wiring
6
5. OPERATION
5-1
Operation
7
5-2
Operation stop
8
5-3
Energy saving unit
8,9
5-4Noloadoperation 9
5-5Alarmoutlet 9,10
5-6Remoteoperation 10
5-7Operationoutput 11
5-8Parametersettingcharge11,12
6. MAINTENANCEANDINSPECTION13
6-1
Replacement of desiccant vessel
14
6-2
Replacement of silencer
14
6-3
Replacement of dew point sensor
15
7. TROUBLESHOOTING
16,17
8. ATTACHEDREFERENCES
8-1
Specifications
18
8-2
Outside drawing
19
8-3
Internal structure drawing
20
8-4
System diagram
21
8-5
Electric circuit diagram
22,23
8-6
List of spare parts
24,25

<SM-13024-A>
1
Thankyouverymuchforpurchasingourheatlessairdryer,SHDseries.
Thismanualexplainsbasicpointsofinstallation,operation,etc.tohaveour                    
dryersperformattheirbest.  Besuretoreadthismanualbeforeusingyourdryer.
Keepthisbooklethandyforquickreference.
Please be advised in advance that there may be some discrepancies between
products and contents of this book due to improvement of specification after
printing.
 1.INTRODUCTION

<SM-13024-A>
2
Safetyinstructions
Thismanualisintendedforpersonnelwhoarefamiliarwithbasicknowledgeaboutelectricity,compressedair,fluid,
piping,andrefrigerant.CKDshallnotbeheldresponsiblefortroublesoraccidentsthatresultfrominstallation,
operationorrepairsmadebypersonnelwhoarenotqualifiedortrainedfortheabovesubjects.
Improperhandlingmaycausethemachinenottobeoperatedatitsmaximumperformancelevelorleadtoaccidents
orpersonalinjury.
AlwaysconfirmthemachinespecificationandoperatethemachineinthecorrectmannerdesignatedbyCKD.
Thismachineisequippedwithvarioussafetyandotherprotectivedevices.
However,improperhandlingofthemachinemaycausepersonalinjuryand/ordamagetothemachine.Readthis
operationmanualcarefullyandfullycomprehenditscontentsbeforeoperation.
Readthecontentsofthefollowingwarninglabels,aswellascautionsstatedintheoperationmanual,andfollowthe
instructionscontentedtherein.
Keepthisoperationmanualnearthemachinewhereallconcernedpersonnelhaveeasyaccesstoit.
Safetyprecautions
Safetyprecautionsareclassifiedintothefollowinggroups,
WARNINGandCAUTION.
WARNING CAUTION
ThisdenoteshazardswhichCOULDresultinseverepersonalinjuryordeath,if
notavoided.
WARNING
ThisdenoteshazardswhichCOULDresultinminorpersonalinjuryand/orproduct
orpropertydamage,ifnotavoided.
CAUTION
Thismachineisdesignedforindustrialuse.Alwayscarefullyhandlethemachineinthecorrect
manner.
WARNING:
ELECTRICAL SHOCK
★
Power supply terminal box, switches, etc. may cause you electrical
shock.
●
Be sure to turn off the power before inspection. Do not operate the
dryer with your wet hands.
★
Be sure to connect earth to prevent electrical shock.
CAUTION
:GROUND CONNECTION
★
You could fall if you climb on the panel.
●
Do not climb on the panel.
CAUTION:
FOOT HOLD

<SM-13024-A>
3
3-1.Formalities when installed Super Heatless Dryer
Super Heatless Dryer is classified

Pressure vessel

subject to

Safety Regulation of Pressure
Vessel

.
Safety Regulation of Pressure Vessel
As models SHD3075- SHD3240 are applied as

Second Class Pressure Vessel

according to

Boiler and Pressure Vessel Safety Regulation

by legislation of Ministry of labor, they are
accompanied by a certificate for withstanding pressure of the Second Class Pressure Vessel.
During use of this machine, keep this certificate in your possession.
3-2.Cautions at operation
1) Do not use the dryer to remove humidity of except compressed air.
*Breakdown, explosion, or fire may result.
2) Install an earth leakage breaker on the power supply.
*Electric shock may result.
3) Need to earth wiring.
*Causes of an electric shock or a fire.
4) Operate the dryer within specification ranges.
*Operation may stop abnormally, or the product’s service life may be shortened.
*When the working pressure range is low, it is not likely to be able to start.
5) Do not turn on the power switch without enclosures.
*Electric shock or heat injury may result.
6) Do not remodel this dryer.
*Break-down or shorter life time of the product may result. If you did, the warranty is
expired. 
7) Remote start terminal (11-13 or 12-13) is alternate non-voltage input.
8) Do not operate local-remote switch during operation.
*It becomes the cause of stop.
9) Do not touch any parts, wires, terminals or piping in side of the dryer.
*Causes of an electric shock or a fire.
10) If emergency stop occurs during operation, remove the cause of abnormal conditions referring to
the trouble shooting.
*If the emergency stop occurs repeatedly, this may cause the dryer to malfunction.
11) Do not use the dryer for pneumatic caisson shield or respiratory medical equipment.
*It could cause an accident includes injury.
12) Do not use the dryer for transportation devices such as automobile, ship etc.
*Vibration could be a cause of break down of the internal components.
３．
CAUTIONS

<SM-13024-A>
4
4-1Checkitemsbeforeinstallation
 Checkthecontentsstatedonthenameplate,such
asmodelNo.andspecifications.
Attacheddocuments
Instructionmanual(thisdocument)･･･1copy
Pressure-proofcertificate 
(ExceptforSHD3025/3045)・・・・1copy
AirFilter ・・・・・・・・・・・・・・・・・・・・・・・2pieces
Tool(See6-1) ・・・・・・・・・・・・・・・・・・1piece
4-2Transportation
1)
 Never lay down this product or apply any vibration or
impact to the product during transportation.  Failure to
dosomaycausedamagetointernalcomponents.
2)
Do not step on this product or place any object on it.
Doingsomaycausepersonalinjury.
3)
Donotliftupthisproductusingthehandleonthetopof
thedesiccantvessel.  Doingsomaycausedamagetothe
mainbody.Transportthisproductproperlyusingthefork
holesinthebase.
４．
INSTALLATION

<SM-13024-A>
5
Filter Valve
Totheend
Fromthecompressor
4-3Installationplace
1)
Installthisproductinaplacewheretheambient
temperatureis0to40 C.
2) Installthisproductonaleveledfloorwhereany
vibrationdoesnotexist.
Whenafloorisnotlevel,distortionmayarisefor
aproductandfaultmayoccur.
3)
Ifthefoundationoftheinstallationplaceisweak,
carryoutthefoundationconstructionwork.
4)
Keep the following space for the maintenance
andinspectionwork.(600mmormore).
5)
Securethisproductfirmlyusinganchor boltssothattheproductisnotlaiddown ifan
earthquakeorasuddenimpactoccurs.
6)
Do not install this product in an outdoor place.  This product does not have any
water-proofstructure.Ifrainwaterissplashedontotheelectricalsystem,earthleakageor
fireaccidentmayoccur.
7)
Donotinstallthisproductinaplacewhereitisnotexposedtothedirectsunlight,particle
dust, or heating element, or any corrosive gas, explosive gas, flammable gas, or
combustiblematerialdoesnotexist.
*Breakdown, explosion, or fire may result.
8)
Compressedairshouldnotflowbackwardsforfilterprotection.
9) Waterdropmaydispersefromtheexhaustsilencerofdryerrarelyundertheinfluenceof
ambienttemperatureetc.Installdrainpanetc.inthatcase.
10) Donotmixwaterdropinairinlet.Performancenotonlygetsworse,butitbecomesthe
causeoffailure.Whenthereisapossibilitythatwaterdropmaymix,installaftercooleror
refrigeratedairdryerintheupstreamofthisequipment.
4-4Airpiping
1)
Alwaysstartthepipingworkaftercheckingtheairinletandoutlet.
2) AttachtheairfilterM-seriessuppliedwiththeproducttotheairinlet. Inaddition,when
thequalityofairflowinginisbad,attachanoptionalfilterbeforetheMseriesconcerned.
3) AttachtheairfilterP-seriessuppliedwiththeproducttotheairoutlet.Inaddition,whena
visitor'squalityofdemandairishigh,attachanoptionalfilterafterthePseriesconcerned.
4) Sincemoisturemaycondensewithinpiping,thedistancebetweenairfilterMseriesand
theentranceofmainpartissetto1morlessasastandard.
5)
MakethedistancebetweentheairfilterM-seriesandtheinletofthemainbodyasshort
aspossiblesincewatercontentsmaybecondensedinsidethepiping.
6)
If the flow inside the piping cannot be shut down
whenstartingthemaintenanceandinspectionwork
ofthemainbody,installabypasscircuithavingthe
stopvalve.
7)
Carefullydesignthepipingroutesothattheweight
ofthepipingisnotappliedtothemainbody.

<SM-13024-A>
6
8)
Alwaysusethepipingwithstandingtheworkingpressureandtemperature.  Carryoutthe
pipingworksothatnoairleaksfromtheconnectionpart.
9) For piping materials, use galvanized or stainless pipes. Before connecting the piping,
alwaysperformtheflushingsothatnodustenterstheaircircuit.
4-5Drainpiping
1)
Use a tube with an inside diameter ofφ6 or more for the drain piping of the air filter. 
Openthedischargeendtotheatmosphere.
2)
Ifthedrainpipingrisesoristoolong,thebackpressureisapplied,causingthedrainnotto
bedischarged.  Alwayscarryoutthedownwardpipingsothatthedrainflowsnaturally.
3)
Thedrainisnormallydischargedbytheairpressure.  Alwayssecurethedraindischarge
tubefirmlysothatitdoesnotdeflectwhenthedrainisdischarged.
4)
Ifoilismixedwiththedrain,anappropriatewastewatertreatmentisrequired.Forwaste
watertreatment,consultwithyournearestindustrialwastedisposalcompany.
4-6Electricwiring
1)
Alwaysoperatetheproductataproperpowervoltage.
Operatetheproductatavoltagerangeofratedvoltage ±10%orless.
2)
Mount a circuit breaker for overload protection and earth leakage shut down (rated
current:5A,sensitivitycurrent:30mA)onthemainpowersupply.
3)
Connectionofpowercable
Make ahole in the rubber bushing at the upper portionof the side panel of the main
body,throughwhichtheelectriccablesandwiresarepassed.
Connect the earth leakage circuit breaker to the terminal block L1 and L2 inside the
mainbody.
4)
Connectionofgroundingcable
ConnectthegroundingcabletotheterminalblockPEinsidethemainbody.
Neverconnectthegroundingcabletoanycitywaterpipe,gaspipe,andlightningrod.
5)Insulationresistanceandwithstandvoltagetest
Don't performinsulationresistanceandwithstandvoltagetest.Carrieddewpointmeter
andtemperatureandhumiditysensoraredamaged.
When you carry out unavoidably, carry out after removing dew point meter and
temperatureandhumiditysensor.
Terminalbox

<SM-13024-A>
7
5-1Operation
1)
Make sure again that the air piping, drain piping, and electric
wiringhavebeenconnectedproperly.
2)
Closetheoutletandinletvalves,andthebypassvalve.
3)
 TurnONthemainpowersupply.  Anumericvalueisshownon
DEWPOINT.  Thisvalueshowsthedewpointatthattime.
4)
Slowly open the inlet valve to sufficiently pressurize the main
body.  Twopressuregaugesshowthesamepressurelevel.
5) Since inlet valve may have closed when pressure is not improved,
even if it introduces air, even when it is troublesome, open manual
valve in front panel. If it works normally, be sure to close manual
valve.(Domeasuressameastheaboveintherebeingthethingthat
the inlet valve of both vessels closes it at the time of
re-pressurization when you skipped pressure in the dryer without
stopping it by STOP button or when you did START in less than
0.4MPa.)
6)
Aftercheckingthatthepressurelevelis0.4MPaormore,press
theSTARTbutton.
7)
Check that the left and right desiccant vessels are switched
alternatelyatintervalsof2min.
8)
Iftheproducthasnotbeenusedforanextendedperiodoftime,
the desiccant may get damp
.
Close the outlet valve and carry
out the regenerationpurge forseveralhours while referring to
DEWPOINT.
9)
Whenthedewpointbecomesclosetotherequiredlevel,slowly
opentheoutletvalvetoflowthecompressedair.
10)Duringoperation,when thepowersupplyreturniscarriedout
aftertheformerpowersupplywasshutoffbypowerfailureetc.,
operation is resumed. But the phenomenon that informed 5）
clausesmayoccurwhenpressureinthedryerislessthaninlet
pressurerange.
11)Ifyouuseitunderbytheselectedpressure,sinceyoumaybe
unable to demonstrate aperformance, please use it abovethe
surelyselectedpressure.
12)Becarefulthatthedewpointwillnotbestabilizedifusingflow
rateischangedsharply.
13) At thetimeoftestrunstartingafterthismachineinstallation, pass
about10-20%offlowrate,andoperatethefollowingtime.
５
．
OPERATION
Manual
valve
(2portvalve)

<SM-13024-A>
8
Pressuredewpoint(℃)
（NOTE）
 -20 -30 -40 -60
(reference)
Atmosphericdewpoint
(℃) -40 -48 -57 -74
Time（h） 6 12 24 72
NOTE：Pressuredewpointis0.7MPa.
14) Sinceithassetupbeforehand,donottouchtheneedlevalve(referto6-3clause)attachedtothe
dewpointsensorlowerpart.
5-2Operationstop
1)
Closetheinletandoutletvalves.
2)
PresstheSTOPbutton.DEWPOINTisstilldisplayedevenatthistime.
3)
TurnOFFthemainpowersupply.
4) Sincedryerpassesairalsoduringastop,besuretocloseinletandoutletvalve.
5-3Energysavingunit
Thisproductisequippedwithanenergysavingunitasastandardaccessory.  Thefollowing
showstheoutlineoftheenergysavingunit.
1)
TurnONorOFFtheenergysavingunitusingthe ECOMODEbutton.  Whentheenergy
savingunitispoweredON,theindicationlampislit.Additionally,thelampislittoshowthe
dewpointvalue,whichissetatthistime.
2)
To change the set dew point, keep the ECO MODE button pressed for 2 sec. with the
energysavingunitturnedOFF([ECO]lampisoff.).Since ECOMODEblinksinthatcase
anditdisplaysthatachangeispossible,pleasebesuretocheckblinking.Whenpressing
theSTOPbuttoninthisstate,thenumericvaluecanbechanged.Whenadesirednumeric
valueisshown,presstheECOMODEbuttontosetthisvalue.(Blinkingchangestolighting.)
3) ThedewpointsetfortheG-type(standardtype)isdifferentfromthatsetfortheM-type
(high-gradetype).
Pressuredewpoint
 -10℃ -20℃ -40℃ -60℃
G-type
 ○ ○ ○ 
Ｍ -type   ○ ○ ○
4) Thedewpoint,atwhichtheoperationisactuallychangedtotheenergysavingoperation,is
set at a level slightly lower than the set dew point level. Therefore, the energy saving
operationisnotstartedatthesetdewpoint.
 -10℃setting -20℃setting -40℃setting -60℃setting
Dewpointchangedto
energysaving 
Lessthan-14℃ Lessthan-24℃ Lessthan-44℃ Lessthan-64℃
Dewpointwhich
energysavinggoesout
Over-12℃ Over-22℃ Over-42℃ Over-62℃
5) If the flow consumption is small,the dewpoint does not become worse with the energy
saving operation started.  At this time, the operation is forcibly returned to the normal
operationafter1hourhaselapsed.