Parker Zander KE-MT Series User manual

KE-MT 120–600
Adsorption dryer
Operating manual
22/04/2021 rev05 EN
Cod: 398H271932

EN | User Manual
KE-MT 120-600 1
Index
Machine passport 3
General information 4
Manufacturer’s details .............................................................................................................. 4
Details on the dryer................................................................................................................... 4
About these operating instructions........................................................................................... 5
For your own safety 6
General safety notes................................................................................................................. 6
Intended use of the dryer.......................................................................................................... 7
Safety notes on specic operating phases............................................................................... 7
Signs, instruction plates and danger zones at the dryer........................................................... 9
Transportation, installation and storage 11
Information on transportation packaging................................................................................ 11
What to do in the case of transport damage occurring? ........................................................ 11
Transporting and installing the dryer....................................................................................... 11
Anchoring the dryer ................................................................................................................ 13
Storing the dryer ..................................................................................................................... 14
Technical product description 15
Summary Drawing ................................................................................................................. 15
Function description ............................................................................................................... 16
Available options..................................................................................................................... 18
Installation 21
Preconditions for installation .................................................................................................. 21
Connect piping ....................................................................................................................... 22
Installing the electrical connection.......................................................................................... 23
Start-up 25
Requirements for initial start-up ............................................................................................. 25
Setting times of the operating phases .................................................................................... 26
Overview of operating and control elements .......................................................................... 26
Start up dryer.......................................................................................................................... 29
Changing cycle mode (optional) ............................................................................................. 31
Monitoring dryer operation 32
With dewpoint-sensing control (optional) ............................................................................... 32
Shutdown and restart dryer 33
Emergency shutdown ............................................................................................................33
Depressurising and shutting down the dryer .......................................................................... 33
If work is to be carried out on the electrical system ............................................................... 34
Restart .................................................................................................................................... 34
Maintenance and repair of the dryer 35
Notes on maintenance............................................................................................................ 35
Regular maintenance intervals................................................................................................ 36
Instructions for use of the dongle ........................................................................................... 37
Daily maintenance tasks ......................................................................................................... 38
Maintenance work to be completed every 12 months............................................................ 38
Notes on further maintenance work........................................................................................ 41
Identify and eliminate faults 42

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2 KE-MT 120-600
Summary of faults................................................................................................................... 42
Annex with technical documentation 46
Technical data......................................................................................................................... 47
Replacement and wear part list .............................................................................................. 48
Logic control diagram............................................................................................................. 50
Flow diagram .......................................................................................................................... 52
Dimensional drawing .............................................................................................................. 53

EN | User Manual Machine passport
KE-MT 120-600 3
Machine passport
Type designation
Order no.
Order ID.
Build no.
Vessel no.
Vessel no.
Year of manufacture
It is the responsibility of the owner,
◊ to enter for the rst time any appliance data not stated above,
◊ to keep these appliance data up to date.
The above-stated appliance data provide for a clear identication of the dryer and its compo-
nents, and signicantly 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 )

EN | User Manual General information
4 KE-MT 120-600
General information
Manufacturer’s details
Name and address
Parker Hannifin Manufacturing S.r.l.
Sede Legale: Via Privata Archimede, 1- 2009 Corsico (MI) Italy
Sede Operativa: Gas Separation and Filtration Division EMEA - Strada Zona Industriale, 4
35020 S.Angelo di Piove (PD) Italy
tel [phone]- fax [phone]
Web-site: www. parker.com/hzd
e-mail: [e-mail]
Details on the dryer
Standard equipment
Standard dryer*, consisting of
◊ 2 vessels, lled with desiccant
◊ Piping and mufer
◊ Control system
Associated documents
◊ Operating instructions (present)
◊ Technical documentation (see annex)
◊ Circuit diagrams (see separate document)
Notes on supplementary documents
Supplementary documents such as operating manuals for options or pertaining components
must always be heeded. They contain additional information, e.g. regarding maintenance,
and are therefore necessary for safe operation of the plant.
* Planned dryers may be equipped with special components

EN | User Manual General information
KE-MT 120-600 5
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 tri-
angles.
◊ 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-threa-
tening 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. tters 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.

EN | User Manual For your own safety
6 KE-MT 120-600
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-qualied personnel,
◊ not used within its intended design specications,
◊ is repaired or maintained incorrectly.
Note:
For your own safety and to prevent machine damage, please note the informa-
tion and safety notes in these operating instructions when working with the
dryer.
General safety notes
For your own safety, when carrying out any work on the dryer comply with all
applicable national safety regulations!
Warning against sudden air ejection
When the hollow section vessels are depressurised, air flows suddenly out of
the sound absorber.
◊ This causes a sudden loud cracking 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.
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.
Risk of injury due to voltage-carrying parts!
The electrical supply cable and external power lines are live even after the
dryer is switched off and, in the event of body contact, may cause serious
injury! Before carrying out any work on the electrical system, the electrical
supply cable and all external power lines must be made voltage-free!
Personnel qualification
Only authorized and qualied 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 modications must be made
to the dryer! Any non-approved modications may restrict the operational safety of the dryer
and cause damage to property or personal injury.
Handling drying agents
The drying agents used do not pose any risk to health. However, when lling and emptying
the hollow section vessels with drying agents, increased dust generation may occur. Please
comply with the following instructions:
◊ When lling drying agents, 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

EN | User Manual For your own safety
KE-MT 120-600 7
skidding!
Disassembly and disposal
◊ Dispose all parts of the dryer, the drying agent, and all other operating materials in an envi-
ronmentally safe way and in accordance with all current statutory regulations.
Intended use of the dryer
The dryer is exclusively intended for drying compressed air. Depending on dened 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.
As standard, the dryer is intended to be sited within a building and protected against the
weather.
The dryer may be operated only in accordance with the data on the type plate and in accord-
ance with the contractual conditions.
Suspected misuse
The dryer must not be misused as a climbing aid! Pipes, valves, and similar ttings have not
been designed for such loads. They could fracture, tear off, or become damaged in another
way.
Safety notes on specific operating phases
Transportation and siting
◊ Only use suitable and technically perfect lifting gear with a sufcient carrying capacity.
◊ Carefully secure the dryer during transportation.
Start-up
◊ 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 “Shutdown and restart
dryer” a pagina 33
Monitor operation
◊ Only operate the dryer within the permissible limits (see type plate). By operating the dryer
in conditions that go beyond the dened 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. There-
fore, 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 ofce or person.
◊ In the event of an emergency or if a safety-relevant disruption occurs (e.g. escaping com-
pressed air, defective component), the dryer must be shut down immediately as described
in the section on page 33 ). The unit may only be restarted after all defects have been
eliminated.
Maintenance of the dryer and fault removal
◊ 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.

EN | User Manual For your own safety
8 KE-MT 120-600
◊ 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 ttings 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 ange and bolt connections for leak tightness
and secure seating.
◊ Only use replacement parts that are suitable for the relevant function and meet the techni-
cal requirements stipulated by the manufacturer. This is always the case, if you use original
replacement parts only.
Disassembly and disposal
◊ 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 manufac-
turer’s address see page “General information” a pagina 4).

EN | User Manual For your own safety
KE-MT 120-600 9
Signs, instruction plates and danger zones at the dryer
Signs and instructions
Please note the above plates and instructions attached to the dryer. Ensure that they are not
removed and are always readable.
Type plate of
the dryer
Vessel plate Vessel plate

EN | User Manual For your own safety
10 KE-MT 120-600
Hazard areas on the dryer
Symbol Hazard area
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 ows suddenly out of the sound absorber:
◊ This causes a sudden loud cracking noise.
◊ Due to particles carried in the air ow, there is a very considerable risk of eye
injury.
When working on the dryer, always wear eye and ear protection equipment.
Risk of crushing
At the universal shaft and the drives, there is a risk of injury from crushing during
the switching from absorption to regeneration.
Skid risk
When emptying and lling the vessels with drying agent, there is a risk of skidding
caused by spilt drying agent.
Hazard caused by overpressure
Hazard caused by electrical
voltage
Hazard caused by sudden air
ejection during expansion

EN | User Manual Transportation, installation and storage
KE-MT 120-600 11
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 pre-
vention must be complied with. Otherwise there is a risk of personal injury.
Always adhere to the stickers and notes on the packaging of the dryer!
◊ Only use suitable and technically perfect lifting gear with a sufcient 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 instruc-
tions on page 14.
Information on transportation packaging
Depending on the type of transportation, the dryer is delivered in different types of packag-
ing:
◊ 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 lm material
and in a wooden box.
If the packaging is undamaged
The undamaged packaging should be removed only at the nal installation site, as it
offers protection against any weather inuences.
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.
Warning!
A damaged dryer must not be taken into operation! Damaged components may
lead to functional faults and possibly cause further damage.
Transporting and installing the dryer
Requirements for the installation site
The conditions at the installation site have a large inuence 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. Protect the dryer against moisture.
◊ The ambient temperature must not drop below +1,5 °C (34,7 °F).
◊ Heed the dryer’s noise emission when selecting the installation location.
◊ The installation area must be level, rm and vibration-proof. It must have the necessary car-
rying capacity for the weight of the dryer. The weight of the dryer is specied in the technical
data section of the annex.

EN | User Manual Transportation, installation and storage
12 KE-MT 120-600
◊ The dryer should be installed with sufcient
spacing at the top, sides, and rear, in order to
be able to carry out maintenance work and
change the drying agent without any hindranc-
es (see gure).
If in doubt, the installation site must be inspect-
ed by specialists. If you have any queries in this
regard, please contact the manufacturer (see
pag. 4
Necessary spacing at the top and sides
= min. 1 m
Transporting the dryer
Remove packaging.
Attach suitable lifting gear to the eyebolts on
the vessels (see gure).
Eyebolt at vessel
Note:
The vessels are filled with layers of various desiccants. They should therefore
be transported in an upright position in order to prevent the mixing of these
desiccants, as this could impair the operation of the dryer.
Risk of tilting!
The dryer should only be transported in an upright position. However, this me-
ans that the centre of gravity of the unit is located in the middle of the dryer, so
that there is a serious risk that the unit might tilt over.
Therefore, adhere to the transport instructions outlined as follows.

EN | User Manual Transportation, installation and storage
KE-MT 120-600 13
Transport by crane
Transport the dryer in an upright position to
its location of installation.
For this purpose, attach a girder with suit-
able xtures to ensure that the dryer is lifted at
the centre and that the upper pipe bridge is not
crushed between the vessels (see gure).
Transport by forklift
When using a forklift, ensure that the dryer is
always in an upright position.
Secure the dryer to ensure that it cannot tilt
or fall from the forklift.
Eyebolt at vessel
Anchoring the dryer
The upright stand proles of the dryer are pro-
vided with four pre-drilled anchorage bores.
Use suitable attachment material to anchor
the dryer to the oor (see gure).
In the case of vibrating oors: place the
dryer on suitable vibration dampers
Bores at the foot of the dryer

EN | User Manual Transportation, installation and storage
14 KE-MT 120-600
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).
In order to store the dryer proceed as follows:
Take dryer out of operation as described on page 33.
Ensure that the compressed air inlet valve installed by the owner, and the installed
compressed air outlet valve installed by the owner, are both closed, and that the dryer is
depressurised.
Disconnect dryer from the compressed air system.
Disconnect the dryer from the electrical power supply and all external lines.
Use lm material or similar to close the compressed air inlet apertures and compressed
air outlet apertures on the dryer in order to protect them against contamination.
If possible cover dryer with a protective sheet.
The dryer can now be stored for long periods.
Note:
If you wish to take the dryer back into service after an extended period of sto-
rage, please proceed as described for its first commissioning and start-up (see
page 29).
Store drying agents
Do not store drying agents in the open air.
Protect drying agents against humidity.

EN | User Manual Technical product description
KE-MT 120-600 15
Technical product description
Summary Drawing
Front view
Rear view
Regeneration gas orice
Filling point
(Option: Safety valve
connection)
Power supply
Check valve V3
On/Off-Switch
Compressed air outlet
Compressed air inlet
Expansion valve V5
Main inlet valve V1
Pressure gauge (PI)
Vessel
Drain point
Check valve V2
Eyebolt
Filter for control gas
Control box
Solenoid valve block (Y1-Y4)
Expansion valve V4
Mufer

EN | User Manual Technical product description
16 KE-MT 120-600
Function description
The dryer dries the compressed air supplied by the compressor and makes it available for
industrial use.
If so, installed up- and downstream lters purify the compressed air, feeded to resp. dissipat-
ed from the dryer.
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. 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 ves-
sel, compressed air is de-humidied (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.
Adsorption
Via a compressor, humid compressed air is
supplied to the compressed air inlet of the
dryer. From here, the compressed air ows
upwards through the absorption vessel, which
is pressurised. In so doing, the drying agent
dehumidies the air. The dry compressed air is
supplied to the pipe network via the com-
pressed air outlet of the dryer.
Here, adsorption is shown in the left
vessel.
Regeneration (running in parallel to the adsorption)
At the same time the other chamber is prepared for a renewed take-up of humidity. This
process is called regeneration.
The regeneration is subdivided into three phases: expansion, dehumidication, and pres-
sure build-up.
With the dewpoint-sensing control option, the regeneration phase is followed by a standby
phase.

EN | User Manual Technical product description
KE-MT 120-600 17
Expansion phase
During the expansion phase the pressure in the
right chamber is released via the mufer down
to ambient pressure within just a few seconds.
The outow of the compressed air becomes
noticeable due to a sudden powerful ow noise
at the mufer.
Dehumidification phase
Prior to being released into the pipe network,
dried compressed air is bled by means of an
orice plate. This separate regeneration air ow
is fed through the depressurised chamber. The
humidity stored in the drying agent is taken up
by the air ow and expelled into atmosphere via
the mufer.
Here, regeneration is shown in the right
vessel.
Pressure build-up phase
After dehumidication the pressure in the
regenerated hollow section vessel is built up to
operating pressure, so that the switchover from
regeneration to adsorption can take place at
operating pressure level.
Pressure build-up
Standby phase (only with the dewpoint-sensing control option)
When in standby phase, the fully regenerated vessel is ready for absorption operation. The
system is switched to this vessel, as soon as the measured dewpoint at the compressed air
outlet has reached the set dewpoint value for switchover.
Switchover
When the drying agent in the adsorbing chamber has taken up a sufcient 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.

EN | User Manual Technical product description
18 KE-MT 120-600
Available options
The following options are available for the dryer:
◊ Start-up device
◊ Outside installation
◊ Auxiliary heater
◊ Bypass line
◊ Signalling contacts of control system
◊ Compressor synchronisation
◊ Dewpoint-sensing control
◊ Pneumatic control
◊ Paint compatible design
◊ Pre- and after-lter
◊ Condensate drain systems for pre- and after-lter
Start-up device
A start-up device basically consists of a pressure holding device, which is located at the rear
of the dryer. The pressure holding device ensures that pressure can build up in the dryer and
adsorption take place.
It is always required when an empty compressed air reservoir or an empty compressed air
system must be lled downstream of the dryer (e.g. following weekend shutdowns and when
the pressure in the compressed air system can frequently drop below the stated operating
pressure).
Outside installation
As standard, the dryer is not suitable for outside installation, as its function and service life is
inuenced by the following factors:
◊ Environmental humidity due to rain (or other deposit)
◊ Corrosion caused by environmental humidity or a salt-containing environment
◊ Freezing of valves, cocks, aps, and other components at low temperatures
Therefore, a planned outside installation must always be discussed in advance with the
manufacturer to allow specic technical design measures to be provided for the installation
location.
Auxiliary heater
For installation sites with temperatures under +1 ºC, the wet side of the dryer must be
equipped with an auxiliary heater to prevent valves, cocks, aps, and other components from
freezing up.
Bypass line
The bypass line is a “detour line”, which allows the compressed air system to continue oper-
ating even whilst maintenance of the dryer is in progress. However, during this time the air is
not dried but ows 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 efcient 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. Dryers with the optional
dewpoint-sensing control are equipped with such a contact as standard. It is used for the