Parker Zander HDK-MT 4-100 User manual

High Pressure Dryer
HDK-MT
4/100–70/350
Operating
Instructions
Revision 04—2014/EN

Declaration of Conformity
Parker Hannifin Manufacturing Germany GmbH & Co. KG
Hiross Zander Division
Im Teelbruch 118
D – 45219 Essen Kettwig
hereby declares with sole responsibility, that the products
high pressure dryer
series HDK-MT 4/100 to 70/350
assembly type: assembly acc. to Art. 3 No. 2.2,
which this declaration refers to, conform to Directive 97/23/EG and were
subjected to a conformity assessment according to Annex III Modules B+D
(for assembly assessment).
For the assembly, the EG type approval certificate DTM0506108 by Lloyd’s
Register Quality Assurance GmbH, Hamburg, is available.
The quality assurance system is monitored by the service provider stated below
Lloyd’s Register Quality Assurance GmbH (identification number 0525)
Am Sandtorkai 41, D - 20457 Hamburg.
The assembly consists of pressure appliances according to the classification list
(attached to the technical documentation provided by the manufacturer).
 The following standards / technical specifications were used:
 harmonized standards: DIN EN ISO 12100:2010, DIN EN 60204,
DIN EN 61000-6-3, DIN EN 61000-6-4
The following other EG directives were used:
 2004/108/EG
 2006/95/EG
Essen,
19.08.2014
Datum / Date i. V. Dr. Jürgen Timmler
Leiter Technik und Entwicklung /
Manager Engineering and Development

Machine passport
Type designation HDK-MT
Order no.
Project no.
Build no.
Vessel no.
Vessel no.
Year of manufacture
It is the responsibility of the owner,
 to enter for the first time any appliance data not stated above,
 to keep these appliance data up to date.
The above-stated appliance data provide for a clear identification of the dryer and
its components, and significantly facilitate any service measures.
Further important data on the dryer such as the details on the permissible
operating pressure and the electrical connection are found on the type plate (for
position of the type plate see page 9).

Table of contents
General information ............................................................................................6
Manufacturer's details ............................................................................................................ 6
Details on the dryer ................................................................................................................ 7
About these operating instructions.......................................................................................... 8
For your own safety ............................................................................................9
Signs, instruction plates and danger zones at the dryer .......................................................... 9
Intended use of the dryer ...................................................................................................... 11
General safety notes ............................................................................................................ 11
Safety notes on specific operating phases ............................................................................ 11
Technical product description .........................................................................14
Summary drawing ................................................................................................................ 14
Function description ............................................................................................................. 14
Available options .................................................................................................................. 16
Transportation, installation and storage.........................................................18
Information on transportation packaging ............................................................................... 18
What to do in the case of transport damage occurring? ........................................................ 18
Transporting and installing the dryer ..................................................................................... 19
Installing and anchoring ........................................................................................................ 20
Storing the dryer ................................................................................................................... 20
Installation..........................................................................................................22
Preconditions for installation ................................................................................................. 22
Connect piping ..................................................................................................................... 23
Installing the electrical connection ........................................................................................ 24
Start-up...............................................................................................................26
Requirements for initial start-up ............................................................................................ 26
Setting times of the operating phases ................................................................................... 27
Overview of operating and control elements ......................................................................... 27
Emergency shutdown ...........................................................................................................
30
Start up dryer ....................................................................................................................... 30
Changing cycle mode (optional) ........................................................................................... 32
Monitoring dryer operation...............................................................................34
With dewpoint-sensing control (optional) .............................................................................. 34
Shutdown and restart dryer..............................................................................35
Emergency shutdown ........................................................................................................... 35
Depressurising and shutting down the dryer ......................................................................... 35
If work is to be carried out on the electrical system ............................................................... 36
Restart ................................................................................................................................. 36

Maintenance and repair of the dryer................................................................37
Notes on maintenance ......................................................................................................... 37
Regular maintenance intervals ............................................................................................. 38
Instructions for use of the dongle ......................................................................................... 39
Carrying out weekly visual checks ....................................................................................... 39
Maintenance work to be completed every 12 months........................................................... 40
Maintenance work to be completed every 24 months........................................................... 41
Identify and eliminate faults .............................................................................42
Summary of faults ................................................................................................................ 42
Index ...................................................................................................................45
Annex with technical documentation..............................................................47
Technical data ..................................................................................................................... 48
Replacement and wear parts list .......................................................................................... 50
Logic control diagram ........................................................................................................... 52
Flow diagram ....................................................................................................................... 54
Dimensional drawing............................................................................................................ 55

Manufacturer's details
6 HDK-MT350_EN_04
General information
Manufacturer's details
Name and address

General information
HDK-MT350_EN_04 7
Details on the dryer
Standard equipment
Dryer, comprising
 2 vessels, filled with desiccant
 1 upstream filter
 1 downstream filter
 1 muffler
 Control system
 1 upper and 1 lower valve block
Associated documents
 Operating instructions (present)
 Technical documentation (see annex)
 Circuit diagrams (see separate document)
Warranty notes
In the following cases, the warranty shall be void:
 If aggressive media in the compressed air and in the environment cause
corrosion damage and functional faults on the dryer.
 If the dryer is used without prior approval and confirmation in writing by the
manufacturer for purposes other than those specified in these operating
instructions or contractually agreed.
 If preset parameters (e. g. on the control system etc.) are changed without
prior approval and confirmation in writing by the manufacturer.
 If the dryer is transported or stored incorrectly.
 If the dryer is sited and installed incorrectly.
 If the dryer is repaired or maintained incorrectly.
 If the dryer is operated by personnel that does not have the requisite
qualifications.
 If modifications are carried out on the dryer, the manufacturer did not
approve that.
In the event of non-compliance the manufacturer will not accept any liability for
any consequential damage whatsoever.

About these operating instructions
8 HDK-MT350_EN_04
About these operating instructions
These operating instructions contain basic information on the safe use of the
dryer.
Characters and symbols used
► Work steps that you have to carry out in the sequence stated are marked by
black triangles.
 Lists are marked by a small box.
Note:
These notes provide you with hints and information on the safe and
efficient handling of machines and devices.
Warning!
These safety notes warn against damage to property and help you to
avoid such damage.
Danger!
These danger notes with a grey background warn against personal injury
and/or danger to life and limb; danger notes help you to avoid serious or
life-threatening situations for yourself and/or third parties.
Target group of these operating instructions
These operating instructions are intended for all persons working on and using
the dryer. We assume that all such persons are specialist personnel, e.g. fitters
or electricians.
Operating instructions: handling
These operating instructions must be continuously available at the site where the
dryer is used. We recommend to prepare a copy and to keep the same in a safe
and freely accessible place next to the dryer. Keep the original document in a
safe place.

For your own safety
HDK-MT350_EN_04 9
For your own safety
The dryer has been built in accordance with the state of the art and the
recognized technical safety regulations. Nevertheless, there is a risk of personal
injury and damage to property when the dryer is used, if
 it is operated by non-qualified personnel,
 not used within its intended design specifications,
 is repaired or maintained incorrectly.
Note:
For your own safety and to prevent machine damage, please note the
information and safety notes in these operating instructions when
working with the dryer.
Signs, instruction plates and danger zones at the dryer
Signs and instructions
Type plate of the filter
Type plate of the dryer
Front view
Please note the above plates and instructions attached to the dryer. Ensure that
they are not removed and are always readable.

Signs, instruction plates and danger zones at the dryer
10 HDK-MT350_EN_04
Hazard areas on the dryer
Hazard caused by overpressure
Hazard caused by electrical voltage
Hazard caused by overpressure
Hazard caused by sudden air ejection during
expansion
Hazard area
Symbol in
operating
instructions
Warning against hazardous electrical voltage
Different parts of the dryer carry electrical current. These parts may be
connected, opened, and maintained by authorized specialist personnel only.
Warning against overpressure
The entire dryer is under pressure. Before commencing any work, the plant
must be depressurised.
Warning against sudden air ejection
When the vessels are depressurised, air flows suddenly out of the sound
absorber:
orber:
 This causes a loud expansion noise.
 Due to particles carried in the air flow, there is a very considerable risk of
eye injury.
When working on the dryer, always wear eye and ear protection equipment.
Skid risk
When emptying and filling the vessels with drying agent, there is a risk of
skidding caused by spilt drying agent.

For your own safety
HDK-MT350_EN_04 11
Intended use of the dryer
The dryer is exclusively intended for drying compressed air. Depending on
defined input conditions, it dries compressed air for industrial use.
The dryer is designed for compressed air, which is free from aggressive water,
oil, and solid matter constituents.
The dryer may be operated only in accordance with the data on the type plate
and in accordance with the contractual conditions.
Suspected misuse
The dryer must not be misused as a climbing aid! Pipes, valves, and similar
fittings have not been designed for such loads. They could fracture, tear off, or
become damaged in another way.
General safety notes
For your own safety, when carrying out any work on the dryer comply with
all applicable national safety regulations!
Personnel qualification
Only authorized and qualified specialist personnel may be tasked with the work
on the dryer described in these operating instructions.
Conversions and modifications
Without prior approval by the manufacturer, no conversions and modifications
must be made to the dryer! Any non-approved modifications may restrict the
operational safety of the dryer and cause damage to property or personal injury.
Handling drying agents
The drying agents are perfectly safe when in an unused condition. However,
when filling and emptying the vessels with drying agents, increased dust
generation may occur. Please comply with the following instructions:
 When filling drying agents into the vessels, wear a dust mask and eye
protection!
 If a spillage occurs, any spilt drying agent must be taken up immediately.
There is a risk of skidding!
Safety notes on specific operating phases
Transportation and siting
 Only use suitable and technically perfect lifting gear with a sufficient carrying
capacity.
 Carefully secure the dryer during transportation.

Safety notes on specific operating phases
12 HDK-MT350_EN_04
Start-up
Warning against sudden air ejection!
During expansion the pressure is released suddenly through the muffler:
 A loud expansion noise is caused which may damage your hearing.
 Particles carried in the air can injure your eyes or skin.
Always wear eye and ear protection, therefore, when you are in the
vicinity of the dryer!
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries. Before carrying out any work on the dryer,
first depressurise the plant.
 Carry out all prescribed tests and checks.
 The factory settings on the control board in the switchbox must not be
changed on any account without prior approval by the manufacturer.
 Before start-up, ensure that no tools or other foreign parts have been left
lying in a part of the dryer where they might pose a hazard to the dryer being
started up.
Emergency shutdown
 In any emergency, proceed as described in the section on page 35.
Monitor operation
Warning against sudden air ejection!
During expansion the pressure is released suddenly through the muffler:
 A loud expansion noise is caused which may damage your hearing.
 Particles carried in the air flow act like bullets and can injure your
eyes or skin.
Always wear eye and ear protection, therefore, when you are in the
vicinity of the dryer!
 Only operate the dryer within the permissible limits (see type plate). By
operating the dryer in conditions that go beyond the defined values, the dryer
is subjected to loads for which it has not been designed. This may cause
functional defects.
 The more powerful the dryer is, the more noise may be generated during
operation. Therefore, the operator must provide suitable protective
equipment (e. g. ear protection).
 Check the dryer regularly for externally visible damage and defects. Any
changes, even in its operating behaviour, must be reported immediately to
the competent office or person.
 In the event of an emergency or if a safety-relevant disruption occurs (e.g.
escaping compressed air, defective component), the dryer must be shut
down immediately as described in the section on page 35). The unit may
only be restarted after all defects have been eliminated.

For your own safety
HDK-MT350_EN_04 13
Maintenance of the dryer and fault removal
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries.
Before carrying out any work on the dryer, first depressurise the plant.
 Carry out maintenance work only when the plant has been shut down and
depressurised!
 The factory settings on the control board in the switchbox must not be
changed on any account without prior approval by the manufacturer.
 Bolt connections must be undone with care! Note ram pressure values!
Otherwise emerging media may cause personal injury.
 Never carry out any welding on a vessel or change the same in any other
way!
 Never use pipes and fittings as steps or holding points! The components
might fracture, or the distortions which occur may cause internal damage on
the dryer. There is a risk of injury by slipping off the components,
components breaking off, and expanding compressed air!
 Never leave tools, loose parts or cloths in, at or on the dryer.
 Following maintenance work always test all flange and bolt connections for
leak tightness and secure seating.
 Only use replacement parts that are suitable for the relevant function and
meet the technical requirements stipulated by the manufacturer. This is
always the case, if you use original replacement parts only.
Disassembly and disposal
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries. Before carrying out any work on the dryer,
first depressurise the plant.
 Dispose all parts of the dryer, the drying agent, and all other operating
materials in an environmentally safe way and in accordance with all current
statutory regulations. The waste code numbers of the drying agents can be
obtained from the manufacturer (for the manufacturer's address see page 6).

Summary drawing
14 HDK-MT350_EN_04
Technical product description
Summary drawing
Front view
Compressed air outlet
Compressed air inlet
Downstream filter
Vessel pressure
gauge
Check valve block
Upstream filter
Hand drain
On/Off-Switch
Control cabinet
Power supply
connector
Vessel
Upright stand profiles Solenoid valve block
Muffler Solenoid valves
Function description
The dryer dries the compressed air supplied by the compressor and makes it
available for industrial use. Upstream filters clean the compressed air and
remove dust, dirt, oil, and water droplets, before the compressed air reaches the
dryer. Thus, an upstream filter is also used for extending the service life of the
drying agent. Downstream filters clean the compressed air from drying agent
abrasions, before it is fed into the compressed air system.
The two vessels contain an extremely porous drying agent by means of which
humidity is removed from the compressed air and stored just as in a sponge.

Technical product description
HDK-MT350_EN_04 15
The stored humidity is then removed again from the drying agent and re-
introduced into the ambient environment. To this end, the two vessels alternate
between different operating modes. Whilst in one vessel, compressed air is de-
humidified (adsorption), in the other vessel the humid drying agent is prepared for
another charge (regeneration). These two states, which run in parallel during
compressed air preparation, are described below.
Functional scheme
Adsorption
Damp and contaminated compressed air is firstly delivered by a compressor to
the upstream filter where the water and oil content is removed. The filtered
content is removed from the system by a condensation drain valve. The
compressed air then flows through the adsorbing vessel which is under pressure
from the bottom upwards. In the process the drying agent takes the moisture out
of the air. The downstream filter at the exit to the dryer filters any remaining solids
from the flow of compressed air. The dry compressed air is then supplied to the
consumers via the network.
Regeneration (running in parallel to the adsorption)
At the same time the other vessel is prepared for a renewed take-up of humidity.
This process is called regeneration. Dry compressed air is branched off before
the exit to the network. A needle valve generates a partial current so that this
regenerated gas flows through the vessel at ambient pressure. The moisture
stored in the drying agent is taken by the current of air and let out into the air via
the sound absorber.
Switchover
When the drying agent in the adsorbing vessel has taken up a sufficient level of
humidity, then the switchover between the vessels will be effected between the
vessels. Following switchover, the above-described process is repeated, with the
adsorption and regeneration now taking place in the respective different vessel.

Available options
16 HDK-MT350_EN_04
Available options
The following options are available for the dryer:
 Start-up device
 Auxiliary heater
 Bypass line
 Signalling contacts of control system
 Compressor synchronisation
 Dewpoint-sensing control
 Condensate drain pipe for preliminary and afterfilter
Pressure maintaining valve (also: start-up device)
A pressure maintaining valve is implemented downstream of the dryer. It ensures
fast pressure build-up and prevents pressure spikes in the drying agent bed. This
also prolongs the drying agent service life. A pressure maintaining valve must be
installed. The operator can either purchase and have the pressure maintaining
valve installed from the manufacturer or assign installation to an authorised fitter.
Auxiliary heater
For installation sites with temperatures under +1 ºC (33,8 °F), the wet side of the
dryer must be equipped with an auxiliary heater to prevent valves, cocks, flaps,
and other components from freezing up.
Bypass line
The bypass line is a "detour line", which allows the compressed air system to
continue operating even whilst maintenance of the dryer is in progress. However,
during this time the air is not dried but flows through the bypass line past the
dryer and through to the actual loads. Filters in the bypass line are meaningful so
that the actual loads are largely protected against dirt, water, and oil droplets
even whilst maintenance is in progress.
Signalling contacts of the control system
The control system is equipped with a digital input for the synchronised operation
with a compressor. This feature allows for synchronised and thus efficient dryer
operation with discontinuous compressor operation.The control system can also
be equipped with an optional operation signalling contact with which the dryer
operation can be monitored from an external device.
Compressor synchronisation
Compressor synchronisation helps reduce energy costs, as the dryer can be
operated independently of the compressor. When the compressor is switched off,
the regeneration gas return ensures that regeneration is continued, as soon as a
certain compressed air volume is reached behind the dryer. The regeneration
process must be continued and ended so that the drying agent does not become
unusable prematurely.
The compressor synchronisation controller is a higher-level controller than the
pressure dew point controller (see below). When both options are in place, the
compressor synchronisation controller is treated as the prime controller.

Technical product description
HDK-MT350_EN_04 17
Dewpoint-sensing control
With a dewpoint-sensing control system, you can operate the dryer in fixed or
variable cycles. In the fixed cycle, switchover is effected after a fixed time period
(usually after 10 minutes). In the variable cycle, the switchover is effected in
relation to the dew point reached and the charging of the drying agent. The
adsorption time in the variable cycle is preset to 60 minutes.
Condensate drain systems for preliminary and afterfilter
Condensate drain systems are installed to drain water that has collected in the
preliminary or afterfilter from the filter. There are two distinct types of condensate
drain system, namely level-controlled systems and time-controlled systems.

Information on transportation packaging
18 HDK-MT350_EN_04
Transportation, installation and storage
Danger due to incorrect transportation!
The dryer must be transported by authorized and qualified specialist
personnel only. During transportation all applicable national regulations
for accident prevention must be complied with. Otherwise there is a risk
of personal injury.
 Only use suitable and technically perfect lifting gear with a sufficient carrying
capacity.
 During transportation the dryer must be carefully secured against falling over.
The manufacturer will not be liable for any damage caused by incorrect storage
or incorrect transportation. Please note therefore the following instructions as well
as the storage instructions on page 20.
Information on transportation packaging
Depending on the type of transportation, the dryer is delivered in different types
of packaging:
 All transportation types: the apertures of the dryer are closed off by means of
plugs.
 In addition, when transportation is effected by air: the dryer is packaged in a
wooden box.
 In addition, when transportation is effected by ship: the dryer is packaged in a
film material and in a wooden box.
If the packaging is undamaged
► The undamaged packaging should be removed only at the final installation
site, as it offers protection against any weather influences.
What to do in the case of transport damage occurring?
► Check whether only the packaging or the dryer itself were damaged.
► Inform the haulier immediately in writing of any damages.
► Contact the manufacturer urgently in order to report the damage. You will find
the telephone number on page 6.
Warning!
A damaged dryer must not be taken into operation! Damaged components
may lead to functional faults and possibly cause further damage.

Transportation, installation and storage
HDK-MT350_EN_04 19
Transporting and installing the dryer
Requirements for the installation site
The conditions at the installation site have a large influence on the functional
capability of the dryer and the service life of the drying agent. In order to ensure a
mode of operation, which is as continuous as possible, and low maintenance, the
installation site must meet the following requirements:
 The installation site must be located within a building - protected against
humidity.
 The ambient temperature must not drop below +1 °C (33,8 °F). If necessary,
an auxiliary heater is to be provided (for information on the auxiliary heater,
see page 16).
 When selecting the installation site, the noise emission of the dryer should be
taken into account (for further information on the noise emission, see also
page 49).
 The installation area must be level, firm and free of vibrations. It must have
the necessary carrying capacity for the weight of the dryer. The weight of the
dryer is specified in the technical data section of the annex.
 The dryer should be installed with
sufficient spacing at the top, sides, and
rear, in order to be able to carry out
maintenance work and change the
drying agent without any hindrances
(see figure).
Necessary spacing at the top and sides
= min. 1 m
If in doubt, the installation site must be inspected by specialists. If you have any
queries in this regard, please contact the manufacturer (for details see page 6).
Transportation using lifting or forklift trucks
Warning against damage to property!
The dryer is delivered lying flat on a pallet. Always transport the dryer
when it is lying on the pallet using a pallet truck or fork-lift truck.
► Secure the dryer on the lifting or forklift truck against sliding movements.
► Transport the dryer to its installation site.

Installing and anchoring
20 HDK-MT350_EN_04
Installing and anchoring
Installing
► Remove the packaging of the dryer.
► Screw the enclosed ring bolts into the drilled
holes on the upper valve block.
► Attach suitable lifting gear to the ring bolts.
► Place the dryer at its installation site.
Transport by crane
Anchoring the dryer
The upright stand profiles of the dryer are provided with four pre-drilled
anchorage bores.
► Use suitable attachment material to anchor
the dryer to the floor (see figure).
► In the case of vibrating floors: place the dryer
on suitable vibration dampers.
Bores at the foot of the dryer
Storing the dryer
If the dryer is to be stored for an extended period of time, the storage location
must meet the following conditions:
 The dryer must not be stored in the open air.
 The storage room must be dry.
 The storage room must be free from dust or the dryer must be covered by a
protective sheet.
 The storage room must have an ambient temperature of at least +1 °C
(33,8 °F).