Jorc KAPTIV-CS-HP-S Installation and operating instructions

1
Installation & Maintenance Instructions
KAPTIV-CS-HP-S
Electronically operated level sensed drain
GENERAL OPERATION
The KAPTIV-CS-HP-S (Compact Solution High Pressure Stainless Steel) removes all types of
condensate from compressed air systems up to 100 m
3
/min. without the loss of compressed air.
The KAPTIV-CS-HP-S is a high pressure, stainless steel zero air loss drain with a pressure rating
from 0 to 50 bar.
The compact robust industrial housing, the 2/2 way direct acting valve, the alarm (NC and NO)
and the integrated mesh strainer make the KAPTIV-CS-HP-S a reliable draining solution.
The alarm function can be connected to any alarm device.
11/12

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SAFETY INSTRUCTIONS
SAFETY AND PROPER USAGE
To ensure safe and enduring performance of this product, you must comply strictly with the instructions
enclosed herein. Non-compliance with instructions or improper handling of the product will void your
warranty! This product is designed to drain condensate from compressed air systems. Usage of this product
in conditions not specified in this manual or in contrary to the instructions hereby provided is considered
IMPROPER. The manufacturer will not be held liable for any damages resulting from improper use of the
product.
SAFETY & WARNING INSTRUCTIONS
ATTENTION
- Observe valid and generally accepted safety rules when planning, installing and using this product.
- Take proper measures to prevent unintentional operation of the product or damage to it.
- Do not attempt to disassemble this product or lines in the system while they are under pressure.
- Always depressurise the compressed air system before working on the system.
It is important that personnel use safe working practices and observe all regulations and legal
requirements for safety when operating this product. When handling, operating or carrying out
maintenance on this product, personnel must employ safe engineering practices and observe all local
health & safety requirements & regulations. International users refer to regulations that prevail
within the country of installation. Most accidents, which occur during the operation and
maintenance of machinery, are the result of failure to observe basic safety rules or precautions. An
accident can often be avoided by recognising a situation that is potentially dangerous. Improper
operation or maintenance of this product could be dangerous and result in an accident causing
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 he
must ensure that the product will not be damaged or made unsafe and that there is no risk to
persons or property.

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EXPLODED VIEW - IDENTIFY ALL COMPONENTS DIAGRAM
Connector screw (2x)
Screw gasket (2x)
Connector (2x)
Connector gasket (2x)
Electronics
compartment
(with attached Earth
cable)
Earth cable screw
Electronics
compartment gasket
Valve shaft
Valve plunger with
attached spring
Housing bottom part
Outlet nipple
Sensor module
screw (4x)
Sensor plate
Sensor module
Sensor module
O-ring small
Sensor module
O-ring large
Sensor module
O-ring middle (2x)
Housing bolt (4x)
Housing bolt
Washer (4x)
Housing top part
Housing gasket
WALL MOUNTING BRACKET
Plug (2x)
Screw (2x)
Bracket
Mounting screws (4x)
Inlet Plug
(2x)
Strainer

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INSTALLATION INSTRUCTIONS
IMPORTANT NOTICE
Before installing this product, make sure it
complies with your request and that it suits
your application!
•Do not install in direct sunlight
•Clean strainer periodically
1. Unpack the unit and visually inspect for any
transport damage incurred after leaving our
factory.
2. Depressurise the system before installation or maintenance is carried out!
3. We strongly recommend to use the wall
mounting bracket to avoid damaging the unit
by strong vibrations. Fix the mounting bracket
against a wall or structure before installing the
KAPTIV-CS-HP-S. Use the supplied screws
and plugs.
5a. Top inlet connection.
If you choose to use the top inlet, please locate
a suitable condensate draining point on your
compressed air system and connect your
KAPTIV-CS-HP-S as illustrated.
-We strongly recommend to use flexible tubing to
avoid damaging the unit by strong vibrations
caused by the compressor.
-The use of a ball valve is advisable.
4. Use the four mounting screws to secure the
KAPTIV-CS-HP-S to the mounting bracket.
6a. Side inlet connection.
If you choose to use the side inlet, locate a
suitable condensate draining point on your
compressed air system and connect your
KAPTIV-CS-HP-S as illustrated below.
- We strongly recommend to use flexible tubing to
avoid damaging the unit by strong vibrations
caused by the compressor.
-The use of a ball valve is advisable.
-The use of a venting line may be required.

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INSTALLATION INSTRUCTIONS
5b. Top inlet connection.
Connect the outlet to an oil/water separator.
-We advise to use the outlet nipple delivered with the
KAPTIV-CS-HP-S. If it is necessary to use an
alternative nipple, make sure it has the correct
thread (1/4”BSP), do not over tighten!
7. Power cable connection
Remove the protection cab from the connector
and connect your power cable as shown.
5. Power cable connection
Remove the protection cap from the connector
and connect your power cable as shown.
9. Press and hold down the TEST button to
check the valve function.
10. Your KAPTIV-CS-HP-S is ready for
operation!
L
Power
Connection
-We advise to use the outlet nipple delivered with
the KAPTIV-CS-HP-S. If it is necessary to use an
alternative nipple, make sure it has the correct
thread (1/4”BSP), do not over tighten!
N
8. Slowly open the ball valve to restore
normal system pressure.
6b. Side inlet connection.
Connect the outlet to an oil/water separator.

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ALARM INSTALLATION INSTRUCTIONS
The KAPTIV-CS-HP-S is equipped with an alarm feature.
The alarm feature can be connected to an external alarm device with its own power supply.
1. Remove the protection cap from the alarm
connector and connect your alarm cables
to the connector as shown below. Caution is
required as you may be working with hazardous
voltages.
2. Connect the cable to your alarm device,
any device of your choice can be applied.
i.e. a (flashing) light or alarm panel.
3. Connect your alarm device to a power
supply. The alarm switch type is a “contact
output switch”. An external power supply is
required as the alarm connection point on the
KAPTIV-CS-HP-S works like a relay switch
only.
4. Connect the power supply to the
KAPTIV-CS-HP-S alarm connector to close
the circle.
Power supply
ALARM DEVICE
POWER SUPPLY
Optional
Alarm
Connection
Alarm
device
Power supply
Alarm
device
Alarm
device
Power supply
Alarm
device
Alarm
device
Power supply

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CLEANING INSTRUCTIONS
These instructions are for cleaning the KAPTIV-CS-HP-S. If your KAPTIV-CS-HP-S requires
maintenance, i.e. replacement of wearing components, please refer to our dedicated maintenance
instructions (supplied with the service kit).
Depressurise the system before installation or maintenance is carried out!
1. Close the condensate supply, i.e. close
the ball valve which is installed in front of
the KAPTIV-CS-HP-S.
2.Press the TEST button to empty the
unit of any residual condensate and to
depressurise the KAPTIV-CS-HP-S.
3. Switch off the electrical supply by
unscrewing the connector screw and
removing the power connector.
Make sure the display is off to check if the power
supply is successfully disconnected.
4. Open the housing by unscrewing the
four housing bolts using a 5 mm allen key and
remove the top part from the reservoir.
WARNING: please make sure the electronics
compartment does not get wet, this will damage the unit!
WARNING: The electronics compartment is
connected to the bottom part with a cable! Do
not damage this cable!
5. Slide de electronics up and unscrew the
valve from the bottom part of the housing
using a 23 mm wrench.
6. Clean the valve parts. Also clean the other
parts of the KAPTIV-CS-HP-S unit.

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CLEANING INSTRUCTIONS
7. Reassemble the valve inner parts and
screw the valve back in to the bottom part
of the housing using a 23 mm wrench (Max.
torque 10Nm).
WARNING: The electronics compartment is
connected to the bottom part with a cable! Do not
damage this cable!
8. Close the housing by replacing the electronics
compartment and top part on the reservoir and
fixing the 4 housing bolts. (Max. Torque 6Nm).
Make sure the gaskets are secured properly to
ensure IP65 rating and make sure the electronics
have not been in contact with water.
WARNING: Please make sure the cable connected to
the electronics part does not get damaged while
re-assembling the components!
9. Switch on the electrical supply by
replacing the connector and connector
screw (max. torque 1Nm). Make sure the
gasket is secured properly to ensure IP65
rating.
Make sure the display lights up to check if the
power supply is successfully connected.
10. Slowly open the ball valve to restore normal
system pressure.
11. Press and hold down the TEST button
to check the valve function.
12. Your KAPTIV-CS-HP-S is ready for
operation!

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SERVICE CHART
Date Description Name

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TECHNICAL SPECIFICATIONS
Maximum compressor capacity 100 m
3
/min.
Min./max. system pressure 0 bar / 50 bar – 0 psi / 725 psi
Valve type 2/2 way, direct acting
Valve orifice 1.8 mm – 0.07 inch
Valve seals FPM
Inlet connection 1/2" (BSP or NPT)
Outlet connection 1/4" (BSP)
Max. Inlet height 11 cm (top) – 4.3 inch (top)
Minimum medium temperature 1° Celsius – 34° F
Maximum medium temperature 50° Celsius - 122° F
Supply voltage options 230VAC or 115VAC or 24VAC or 24VDC
Connectors DIN 43650-B
Serviceable valve Yes
TEST feature Yes
Environmental protection IP65 (NEMA4)
Integrated mesh strainer Yes
Housing Material Stainless Steel
Alarm feature type Contact output switch (voltage free) available in two
versions; A1 and A2
A1 = Normally open contacts, closed when in alarm
phase. Light on the drain is OFF when in operation
and ON when in alarm mode.
A2 = Normally closed contacts, open when in alarm
phase. Light on the drain is ON when in operation
and OFF when in alarm mode.
Alarm feature specification Max. 230VAC, max 4A, 1000VA
or 200VDC, 100W and min 5VDC, 100mA
DIMENSIONS (MM)
179
147
114
86