Compressed Air Alliance K Series User manual

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User Manual
Dew Point Sensor -
K Series
Model: DEK

Dew Point Sensors –K Series User Manual v1.1
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Table of Contents
Notices...........................................................................................................................................3
Warnings .......................................................................................................................................3
About Dew Point Sensors............................................................................................................5
Specifications –K Series ..............................................................................................................6
Dew Point Sensor Pack................................................................................................................8
Installation Overview ...................................................................................................................9
Installation –Mechanical...........................................................................................................10
Installation –Electrical ...............................................................................................................15
Commuication Settings .............................................................................................................19
Using the Display........................................................................................................................20
Warranty......................................................................................................................................26
Calibration...................................................................................................................................26
Trouble Shooting........................................................................................................................27
Commissioning Report ..............................................................................................................31

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Notices
Please read this manual in full and
carefully observe the notes and
instructions before and during
installation, operation and
maintenance. The manufacturer cannot
be held liable for any damage which
occurs as a result of noncompliance
with this manual.
Do not tamper with device. Should
the device be tampered with in any
manner other than a procedure which
is described and specified in this
manual, the warranty is cancelled and
the manufacturer is exempt from
liability.
The product is designed exclusively
for the described application. Use of
this product in conditions not specified
in this manual or, contrary to the
instructions provided by the
manufacturer, is considered improper
handling of the product and will void
your warranty. The manufacturer will
not be held liable for any damages
resulting from improper use of the
product.
This manual should be read carefully by
relevant personnel and the end user.
This manual should be kept with the
product and be made available as
needed. Once you install or use the
product, you accept that you have
read, understood and complied with
this manual.
Compressed Air Alliance endeavours to
make the content of this manual
correct, but is not responsible for
omissions or errors and the
consequences caused. In case of any
doubts or questions regarding this
manual or the product, please contact
Compressed Air Alliance.
Warnings
Ignoring the warnings can lead to
serious injury and/or cause damage!
When handling, operating or carrying
out maintenance on this product,
personnel must employ safe working
practices and observe all local health &
safety requirements and regulations.
Improper operation or maintenance of
this product could be dangerous and
result in an accident causing damage to
machinery or injury or death.
The manufacturer cannot anticipate
every possible circumstance which may
represent a potential hazard. The
warnings in this manual cover the most
common potential hazards and are
therefore not all-inclusive. If the user
employs an operating procedure, an
item of equipment or a method of
working which is not specifically
recommended by the manufacturer
they must ensure that the product will
not be damaged or made unsafe and
that there is no risk to persons or
property.
NEVER CHANGE ORIGINAL
COMPONENTS WITH ALTERNATIVES.

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Compressed Air
Safety
Any contact with quickly escaping air
or bursting parts of the compressed
air system can lead to serious injuries
or even death.
•Do not exceed the maximum
permitted pressure.
•Only use pressure rated
installation materials and parts.
•Avoid getting hit by escaping air
or bursting parts.
•The system must be pressure-
less during maintenance work.
Electrical Safety
Any contact with energised parts of
the product, may lead to an electrical
shock which can lead to serious
injuries or even death. The user shall
take all measures necessary to
protect against electrical shock.
Consider all regulations for electrical
installations.
The system must be disconnected
from any power supply during
maintenance work.
Any electrical work on the system is
only allowed by authorised qualified
personal.
Storage and transportation
•Make sure that the
transportation temperature of
the sensor is between
-10°C to 60°C (14°F to 140°F).
•Please make sure that the
storage temperature of the
sensor is between -10°C to 50°C
(14°F to 122°F) and the humidity
is <90%, no condensation. Avoid
direct UV and solar radiation
during storage.
Cleaning
If you need to clean the sensor it is
recommended to use a clean, dry
cloth. For stubborn marks, use
distilled water or isopropyl alcohol
only.
Please note: contamination on the
sensor tip will affect calibration and
accuracy of the sensor. Removal of
the contamination may not fix the
issue.
Disposal
Electronic devices are recyclable
material and do not belong in the
household waste. The product,
accessories and its packing material
must be disposed according to local
statutory requirements.

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About Dew Point Sensors
When it comes to monitoring
compressed air and gas systems,
nothing offers a better payback than
a dew point sensor. Once you have
moisture in your system, everything
becomes a problem. If you have ever
had this occur, you'll know the
problem occurred days before you
discovered it and it took even longer
to dry out after the issue was fixed.
Most people don't think of dew point
sensors as providing efficiency, but
wet compressed air or gases will do
irreparable damage to components,
create reliability issues throughout
your entire plant and allow bacteria,
rust and corrosion to build up in your
system. Moisture issues are
extremely difficult to rectify and
component failures will go on for
years.
If you have a system running a
desiccant dryer or with a specified
purity requirement, then you are
already aware that dew point is a
critical component of your system
and therefore should be monitored
continuously.
Indicators on refrigerant dryers
don’t measure dew point
The indicator on your refrigerant
dryer is exactly that, an indicator, it is
not measuring the dew point
entering your plant. It is only
measuring the temperature of the
refrigerant gas. Any number of issues
before and after your dryer can lead
to the dew point deteriorating and
will not be shown on the dryer
indicator.
Compared to your compressed air or
gas system, dew point sensors are
cheap, easy to install and have low
maintenance requirements. They are
the most cost effective sensor
purchase you are ever likely to make.
Benefits of monitoring dew point
•Improve system reliability
•Reduce product contamination
risks
•Reduce system maintenance
•Reduce operating and energy
costs
•Reduce the risk of rust and
corrosion build up
•Improve dryer reliability
•Improve filter life and
performance
•Reduce the risk of bacteria,
fungus and yeast build up
•Alerts you to changes in dryer
performance before moisture
appears in your plant
•Easy to install and low
maintenance
•Suitable for temporary or
permanent installations.

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Specifications –K Series
K Series - Standard
K Series - with Display
Technology
Polymer
Dryer Type
Refrigerant, Desiccant or Membrane dryers up to 4 Mpa
(600psi)
Gases
Air, Argon, Carbon Dioxide, Carbon Monoxide, Helium,
Hydrogen, Nitrogen, Oxygen
Accuracy
Dew Point: ±3°C
Temperature: ±0.5°C
Pressure: ±0.3% FS (at 23°C)
The accuracy of the sensor is affected by on-site conditions.
Contaminants such as oil, high humidity or other impurities can
affect the calibration and accuracy of the sensor.
Minimum gas flow
> 1 L/min
Measurement Ranges
Dew Point
Measurement
-60°C to +60°C
-76°F to 140°F
Gas Relative Humidity
0 to 95% RH
Pressure Measurement
0 to 50 bar or
0 to 16 bar if using the integrated pressure sensor
Gas Temperature
Measurement
-40°C to +100°C
-40°F to +212°F
Outputs
Output
Analogue: 4 to 20mA (3 wire)
Digital: RS485 Modbus / RTU

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K Series - Standard
K Series - with Display
Modbus Output Signals
Pressure Dew Point (PDP), Relative Humidity (RH),
Temperature (°C or °F)
Optional integrated pressure transducer
Analogue Output
Signals
Pressure Dew Point (PDP) only
Relay output
NA
Normally open, 32vDC / 500
mA
Power
Power Supply
10 to 30V / 30 mA + 4-20mA
Current output
16 to 30vDC
Electrical Connection
1 x 5 pin M12, female
2 x 5 pin M12, female
EMC
According to IEC 61326-1
Other Information
Inbuilt Display
NA
1.5” LCD Touch screen
Measurement Chamber
1/2” Quick coupling (Nitto type) with Adjustable Bleed Screw
Ambient Temperature
-30°C to +70°C
-22°F to +158°F
Dimensions
135 mm L x 35 mm W
5.3” L x 1.4” W
148 mm L x 67 mm W
5.8” L x 2.6” W
Casing
Stainless Steel
Anodised Aluminium
IP Rating
IP65
Installation Type
Permanent or temporary installation
Calibration Frequency
Every 2 years provided the sensor is not exposed to relative
humidity above 85%

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Dew Point Sensor Pack
Each dew point sensor comes with:
✓Dew Point sensor –either standard K Series sensor or K Series with Display
✓Measurement Chamber
oStandard option = 1/2” Quick coupling (Nitto type) with Adjustable Silencer
oTalk to you local dealer about other options
✓Connector –either 5 meter cable with connector or connector only (no cable).
5 meter cable with
M12 connector
OR
M12 connector only
(no cable)
Connector
Measurement
Chamber
PLUS
PLUS
Dew Point Sensor
OR
Standard Dew
Point Sensor
Dew Point Sensor
with Display

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Installation Overview
Compressed Air Alliance recommends that our dew point sensors are installed via a
measurement chamber.
Step 1 –Find a suitable section of pipe
•The sensor must be installed vertically, on dry side of system
•Do NOT install the sensor before a dryer or in gases with a relative
humidity above 80%
•Do NOT install the sensor upside down, horizontally, at an angle or in wet
gas
Step 2 –Install connection point in pipe, eg a ball valve, nozzle or nipple
Step 3 –Attach Dew Point Sensor to connection point
Step 4 –Set the gas bleed
Step 5 –Wire the sensor (see ‘Installation –Electrical’)
Step 6 –Check the sensor settings
Step 7 (optional) –Connect the sensor to your SCADA or energy management
system
Step 8 –Fill out the Commissioning Report (last page of this manual)
Tools and Equipment needed for installation
(not included with Dew Point Sensor Pack)
Ball Valve
(optional)
Screw Driver
Wrench /
Spanner
Thread Tape /
Sealant

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Installation –Mechanical
WARNING! Incorrect installation can damage the sensor or cause it to work
incorrectly.
Notes
•Before installing the sensor, make sure it is rated for your system (refer to
the “Specifications” section).
oUse of the product outside specified ranges or operating parameters can
lead to malfunctions and may damage the product or system.
•Do not use this product in explosive areas.
•Always use a spanner / wrench to install the product.
•Only use pressure rated materials and parts when installing and maintaining
the product.
•Do not disassemble the product.
•Please observe local and national regulations before/during installation and
operation.
•The product must be installed properly and calibrated regularly, otherwise it
may lead to inaccurate measurement values.
Measurement Chamber
Dew Point Sensor
Nitto fitting can be
removed, if needed
Bleed Screw
Ball Valve
(optional)

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Step 1 –Find a suitable section of pipe
The sensor must be installed vertically in dry gas (gas humidity should be less
than 80% relative humidity (RH)).
Make sure the sensor location has enough room above the pipe to install the
sensor.
If installing the sensor outdoor, protection from sun and rain is necessary.
Correct Installation
Incorrect Installation
Do NOT install the sensor before a dryer or in gases with a re lative humidity above
80%.
Do NOT install the sensor upside down, horizontally or at an angle, as shown below.
Do NOT let condensate reach the tip of the sensor
Dry Side
Wet Side
Dryer
Compressor
Filter
Filter
Dry Side
Wet Side
Dryer
Compressor
Filter
Filter
Sensor in wet air
Sensor upside down
Sensor horizontal

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Step 2 –Install connection point in pipe
To install the sensor, you need a connection point to the pipe, eg a ball valve or a
nozzle or nipple. The thread must be G 1/2".
Use of a ball valve is optional - You do not need to use a valve to install the sensor.
However, using a valve will make removing the sensor easier (eg when you need to
remove the sensor for calibration).
If installing a ball valve, you can use a hot tap drill and clamp to create a connection
point on pressurized or unpressurised pipes. See the Compressed Air Alliance
website for information on hot tap drills and clamps.
Ball Valve
Welded nipple on pipe
OR

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Step 3 –Attach dew point sensor to connection point
The dew point sensor’s measurement chamber comes with a nitto fitting. This can
be removed and the chamber connected directly to a valve with a male BSP fitting, if
required.
•Screw the sensor into the measurement chamber
•Screw the measurement chamber into the connection point and tighten with a
spanner
(eg valve, nipple or nozzle)
oCompressed Air Alliance recommends that our dew point sensors are
installed via a measurement chamber
oA reducing bush may be needed if connecting the measurement chamber
to a large ball valve or nipple
oFix measurement chamber firmly to prevent loosing or shaking
oUse thread tap or sealant, where required
•Open the valve
Measurement Chamber
Dew Point Sensor
Nitto fitting can be
removed, if needed
Bleed Screw
Ball Valve
(optional)

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Step 4 –Set the Gas Bleed
To ensure a flow of gas past the sensor tip, either allow a small amount of gas to
escape to atmosphere (option 1 below) or connect a zero loss chamber (option 2
below).
Option 1 –Bleed gas to air
On the measurement chamber:
•Close the bleed screw completely.
•Then slowly open the bleed screw to allow a small flow
of gas to escape to the atmosphere.
Option 2 –Zero Loss Chamber
The zero loss chamber will prevent gas escaping to atmosphere and can improvie
system efficiency.
•Remove the bleed screw and fitting from
measurement chamber
•Install a 1/4" to 6mm push fit into
measurement chamber
•Connect a 6 mm tube between the
measurement chamber and a second
connection point downstream of the
sensor.
Tip - use cable ties to secure the 6 mm tube to the pipe.
Bleed
Screw
Bleed Screw replaced
with push fitting
Direction of gas flow
6 mm tube
Zero Loss Chamber set up

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Installation –Electrical
WARNING! Incorrect wiring can damage the sensor or cause it to work
incorrectly.
Notes:
•Do not screw the M12 connector using force, otherwise it may damage the
connection pins.
•Always check the M12 connectors to make sure they are wired correctly.
•Consider all local and national safety requirements and regulations for electrical
installations.
•The system must be disconnected from any power supply during
installation and maintenance work.
•Any electrical work on the system is only allowed by authorised and qualified
personal.
4-20mA Scaling
The sensor has an analog output range of 4 to 20 mA, which is a 3-wire active
analog output. The analog output scaling is:
•4 mA = -60°C (-76°F)
•20 mA = +60°C (140°F)
The analog output can be set to correspond to temperature, dew point, or humidity.

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Wiring - Standard Dew Point Sensor
The standard Dew Point Sensor has one 5 pin, M12
connector on top of the sensor.
If you ordered a cable with the sensor, the cables will be
coloured coded as shown in the table below. Its good
practice to check the cable colours and make sure they
match the chart below.
Connector
Cable Colour
Pin 1
RS845, Data + (A)
Brown
Pin 2
RS845, Data - (B)
White
Pin 3
4-20mA Output
Blue
Pin 4
+12-30 vDC
Black
Pin 5
0 vDC (Ground for Modbus)
Grey
M12 Connector plug

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Wiring - Dew Point Sensor with Display
The Dew Point Sensor with Display has two 5 pin, M12 connectors on the back of
the sensor.
•Port A is used for Modbus and Power
•Port B is used for 4-20mA and Alarm Relay
If you ordered a cable with the sensor, the
cables will be coloured coded as shown in the
table below. Its good practice to check the
cable colours and make sure they match the
chart below.
Port A
(Modbus & Power)
Cable
Colour
Port B
(4-20mA & Alarm Relay)
Pin 1
RS845, Data + (A)
Brown
4-20mA+
Pin 2
RS845, Data - (B)
White
4-20mA-
Pin 3
NA
Blue
Relay A
Pin 4
+16 to 30 vDC
Black
Relay B
Pin 5
0 vDC (Ground for Modbus)
Grey
NA
M12 Connector
Port A
M12 Connector
Port B

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Alarm Relay Output for Dew Point Sensor with Display
The Dew Point Sensor with Display has a relay output which can monitor dew point.
For example, when the dew point reaches a set value, the sensor will issue an alarm.
Alarm relay specifications:
•Maximum: 32 VDC / 500 mA
•Power switch status: Normally open
(N/O)
Relay States
Relay Status
Alarm Status
Dew Point Sensor powered off
Normally open (N/O)
Alarm Off
Dew Point Sensor powered on and
the alarm valve is not reached.
Normally open (N/O)
Alarm Off
Dew Point Sensor powered on and
the alarm valve is reached.
Normally closed (N/C)
Alarm Activated
M12 Connector
Port B
Used Alarm Relay
and 4-20mA
Relay Status:
Normally Open (N/O)
Alarm
Off
Alarm
On
Relay Status:
Normally Closed (N/C)

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Commuication Settings
Default Modbus Settings
All dew point sensors use the following default Modbus settings. Settings can be
changed to suit system requirements using the Service Software (contact
Compressed Air Alliance for more information) or the display (if fitted).
Default Modbus RTU (RS485) Settings
Address
Baud
Rate
Frame /
Parity /
Stop Bit
Response
Time
Response
Delay
Frame Spacing
1
9600
8 / N / 1
1 Sec
0 Milliseconds
7 Characters
Modbus Registers
Holding
Register
Address
Data Type
Byte
Length
Description
Unit
Read /
Write
1
0
FLOAT
4
Temperature
ºC or
ºF
Read
3
2
FLOAT
4
Relative
Humidity
%RH
Read
5
4
FLOAT
4
Pressure Dew
Point
ºCtd or
ºFtd
Read
Optional integrated pressure sensor
21
20
FLOAT
4
Absolute
Pressure
KPa,
Mpa,
Bar, PSI
Read
42
41
FLOAT
4
Gauge
Pressure
KPa,
Mpa,
Bar, PSI
Read

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Dew Point Sensors –K Series User Manual v1.1
Using the Display
Dew Point Sensor with Display
If you purchased the Dew Point Sensor with Display, you can view or edit the
following dew point settings:
✓Gas type
✓Units of measurement
✓Modbus / RS485 settings
✓Analog / 4-20mA settings
✓Alarm (Relay) settings
✓Which measurements are displayed on
the touch-screen
✓Language
✓Screen Timeout
✓Screen Brightness
Standard Dew Point Sensor
The standard dew point sensor does not come with an in-built
display.
If you need to change dew point settings, you will need to use
the Service Software. Contact Compressed Air Alliance for more
information.
Touch-Screen
Display