Parker K-MT 1-8 User manual

Adsorption dryer
ecodry
K-MT 1-8
Operating instructions
Revision 08—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
compressed air adsorption dryer
series K-MT 3–8
assembly type: assembly acc. to Art. 3 No. 2.2,
which this declaration refers to, conform to Directive 97/23/ECand were
subjected to a conformity assessment according to Annex III (Module A). 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 61000-6-2,
DIN EN 60204
The following other EC directives were used:
2004/108/EC
2006/95/EC
Essen,
06.06.2011
Datum / Date i. V. Dr. Jürgen Timmler
Leiter Technik und Entwicklung /
Manager Engineering and Development

Manufacturer's Declaration
We,
Parker Hannifin Manufacturing Germany GmbH & Co. KG
Hiross Zander Division
Im Teelbruch 118, 45219 Essen, Germany,
declare under our sole responsibility that the products
Compressed Air Adsorption Dryer
K-MT 1-2
to which this declaration refers,
comply with the basic requirements of the directive for pressure equipment
97/23/EC,
but must not bear the CE mark due to Art. 3 Para. 3, 97/23/EG.
The quality control system is monitored by Lloyd’s Register Quality Assurance
GmbH, Hamburg (code no. 0525).
The following standards and technical specifications were applied:
harmonised standards:
DIN EN ISO 12100:2010, DIN EN 61000-6-2, DIN EN 60204
The following additional European directives were applied:
2004/108/EC
2006/95/EC
Essen,
06.06.2011
Datum / Date i. V. Dr. Jürgen Timmler
Leiter Technik und Entwicklung /
Manager Engineering and Development

Machine passport
Type designation K-MT
Order no.
Order ID
Build 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
Manufacturer's Declaration ................................................................................3
General information.............................................................................................7
Manufacturer's details...............................................................................................................7
Details on the dryer...................................................................................................................7
About these operating instructions ...........................................................................................8
For your own safety.............................................................................................9
Signs and hazard areas on the dryer........................................................................................9
Intended use of the dryer........................................................................................................11
General safety notes...............................................................................................................11
Safety notes on specific operating phases.............................................................................12
Technical product description.........................................................................15
Summary drawing...................................................................................................................15
Function description................................................................................................................15
Available options.....................................................................................................................17
Transportation, installation and storage.........................................................19
Information on transportation packaging ................................................................................19
What to do in the case of transport damage occurring?.........................................................19
Transporting and installing the dryer ......................................................................................20
Storing the dryer.....................................................................................................................22
Installation..........................................................................................................23
Preconditions for installation...................................................................................................23
Connect piping........................................................................................................................24
Installing the electrical connection..........................................................................................25
Start-up...............................................................................................................27
Requirements for initial start-up..............................................................................................27
Setting times of the operating phases ....................................................................................28
Overview of operating and control elements ..........................................................................28
Emergency shutdown.............................................................................................................30
Start up dryer..........................................................................................................................31
Changing cycle mode.............................................................................................................33
Monitoring dryer operation...............................................................................35
With dewpoint-sensing control (optional)................................................................................35
Shutdown and restart dryer..............................................................................36
Emergency shutdown.............................................................................................................37
Depressurising and shutting down the dryer ..........................................................................37
If work is to be carried out on the electrical system................................................................37
Restart....................................................................................................................................38

Maintenance and repair of the dryer................................................................ 39
Notes on maintenance ...........................................................................................................39
Regular maintenance intervals...............................................................................................40
Instructions for use of the dongle...........................................................................................41
Daily maintenance tasks ........................................................................................................41
Maintenance work to be completed every 12 months............................................................42
Maintenance work to be completed every 24 months............................................................44
Maintenance work to be completed every 48 months............................................................45
Identify and eliminate faults .............................................................................50
Summary of faults ..................................................................................................................50
Index ................................................................................................................... 52
Annex with technical documentation.............................................................. 54
Technical data........................................................................................................................55
Replacement and wear parts list............................................................................................56
Logic control diagram.............................................................................................................57
Flow diagram..........................................................................................................................59
Dimensional drawing..............................................................................................................60

General information
K-MT1-8_EN_08—2014 7
General information
Manufacturer's details
Name and address
Details on the dryer
Standard equipment
Dryer, comprising
1 double-chamber hollow section vessel, fillied with drying agent
1 upstream filter
1 downstream filter
Muffler
Control system
Associated documents
Operating instructions (present)
Technical documentation (see annex)
Circuit diagrams (see separate document)
Operating manual for installed filters (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.

About these operating instructions
8 K-MT1-8_EN_08—2014
About these operating instructions
These operating instructions contain basic information on the safe useof 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
K-MT1-8_EN_08—2014 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 and hazard areas on the dryer
Signs and labels
Operating data plate
Type plate of dryer
Type plate of upstream filter
Type plate of downstream filter
Front view
Please note these signs on the dryer. Keep them complete and always legible.

Signs and hazard areas on the dryer
10 K-MT1-8_EN_08—2014
Hazard areas on the dryer
Hazard caused by overpressure
Hazard caused by electrical voltage
Hazard caused by sudden air ejection during
expansion
Hazard caused by electrical voltage
Front view
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 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.

For your own safety
K-MT1-8_EN_08—2014 11
Risk of skidding
When emptying and filling the hollow section vessels with drying agent, there
is a risk of skidding caused by spilt drying agent.
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.
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 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 used do not pose any risk to health. However, when filling and
emptying the hollow section vessels with drying agents, increased dust
generation may occur. Please comply with the following instructions:
When filling 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 skidding!

Safety notes on specific operating phases
12 K-MT1-8_EN_08—2014
Safety notes on specific operating phases
Transportation and siting
During transportation all applicable national regulations for accident
prevention must be complied with.
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
To emergency shut-down the dryer heed to the following instructions:
►Close shut off valves upstream and downstream of the dryer (if applicable)
►Disconnect the electrical power supply (i.e. by switching the On/Off switch to
0).
The dryer is now off-line.
►If applicable, depressurise the dryer now.
Before re-commissioning of the dryer ensure that the emergency situation has
been solved and that the dryer is not damaged.
Never comission a damaged dryer!

For your own safety
K-MT1-8_EN_08—2014 13
Monitor operation
Warning against sudden air ejection!
During expansion the pressure is released suddenly through the muffler:
A loud cracking noise occurs which can injure 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), immediately close the
compressed air supply line and set the ON/OFF switch of the dryer to 0in
order to disconnect it from the power supply. Afterwards depressurise the
dryer (see also chapter , page 37).The unit may only be restarted after all
defects have been eliminated.
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 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 at or on the dryer.
Following maintenance work always test all flange and bolt connections for
leak tightness and secure seating.

Safety notes on specific operating phases
14 K-MT1-8_EN_08—2014
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.

Technical product description
K-MT1-8_EN_08—2014 15
Technical product description
Summary drawing
Front view
Regeneration gas return RV3–RV4
(Option)
Dewpoint sensor (optional)
Check valve plate (RV1–RV2)
Differential pressure gauge
(only K-MT 6-8)
Differential pressure gauge
(K-MT 6-8)
Compressed air inlet
Compressed air outlet
Upstream filter
Downstream filter
Condensate trap
ON/OFF switch
Manual drain valve
Power connection
Control box with Multitronic control
Double-chamber vessel
Muffler
Solenoid valves (Y1-Y4)
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 chambers of the hollow section vessel 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.

Function description
16 K-MT1-8_EN_08—2014
To this end, the two chambers 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.
Adsorption Via a compressor, humid compressed air is
supplied to the upstream filter. From here, the
compressed air flows upwards through the
absorption chamber, which is pressurised. In so
doing, the drying agent dehumidifies the air. The
dry compressed air is supplied to the pipe
network via the downstream filter.
Here, adsorption is shown in the
left chamber.
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, dehumidification,
and pressure build-up. With the dewpoint-sensing control option, the
regeneration phase is followed by a standby phase.
Expansion phase
During the expansion phase the pressure in the
right chamber is released via the muffler down to
ambient pressure within just a few seconds. The
outflow of the compressed air becomes
noticeable due to
a sudden powerful flow noise at
the muffler.
Dehumidification phase
Prior to being released into the pipe network,
dried compressed air is bled by means of an
orifice plate. This separate regeneration air flow
is fed through the depressurised chamber. The
humidity stored in the drying agent is taken up by
the air flow and expelled into atmosphere via the
muffler.
Here, regeneration is shown in the
right chamber.

Technical product description
K-MT1-8_EN_08—2014 17
Pressure build-up phase
After dehumidification 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 chamber is ready for absorption
operation. The system is switched to this chamber, 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 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
The following options are available for the dryer:
Start-up device
Signalling contacts of the control system & compressor synchronisation
Regeneration gas return
Dewpoint-sensing control
Fine filter muffler
Nozzle kit
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 filled 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).

Available options
18 K-MT1-8_EN_08—2014
Signalling contacts of the control system & compressor synchronisation
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.
Compressor synchronisation helps reduce energy costs, as the dryer can be
operated independently of the compressor.
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.
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 transmission of operating signals and for
the output of dewpoint alarms.
Regeneration gas return
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.
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 5 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 amounts to 60 minutes maximum.
Fine filter muffler
A fine filter muffler is used to reduce the noise emission of the dryer to lower
levels than the standard muffler can provide. If installed, the fine filter muffler
replaces the original installed muffler.
Nozzle kit In the case that the operating pressure deviates from the standard design
pressure (7bare) it is possible that the amount of necessary regeneration air
changes. This effect may have a negative impact on the cost-effectiveness of the
dryer. To prevent this, it is possible to replace the built in regeneration air nozzle
by a nozzle with a modified bore. This replacement optimizes the regeneration air
consumption and therefore restores the energy efficiency of the dryer. To receive
more information on this conversion, please contact the manufacturer.

Transportation, installation and storage
K-MT1-8_EN_08—2014 19
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.
Always adhere to the stickers and notes on the packaging of the dryer!
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 22.
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.
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
20 K-MT1-8_EN_08—2014
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. 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, firm and vibration-proof. 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.
Transporting and installing the dryer
Warning against damage to property!
Dependent on its size, the dryer is delivered in a cardboard box or in
horizontal position on a transport pallet. Top and sides have not been
designed for mechanical loads.
Do not place any load onto the top face. Do not stack.
Therefore, always transport the dryer on a lifting or forklift truck.