17 operating and maintenance air dryer

HEATLESS (KSD) TYPE DRYER OPERATION MANUAL

Licensed by Pneumatech U.S.A 9/14 2004.12.10 REV.0

1) PRE FILTER – Recommended item

Because a desiccant must not be in direct contact with condensed water by any means, a

high-quality moisture separator and a pre filter for removing dust should be installed

before the dryer.

The pre filter was made by effectively combining a separation method of a centrifugal

force, collision and filtering, and the drain of the condensed water is discharged by a

drain valve or a trap separately installed.

The internal filter element comes in several grain sizes of 40 / 5 / 1 micron, thus you can

select it according to the conditions of the site and must check it regularly more than

once a month.

2) AFTER FILTER – Recommended item

The air which passed through the dryer may contain desiccant cuttings, so you must

install AFTER FILTER in the outlet of the dryer by all means to prevent the instruments for

process and instrumentation from being out of order due to polluted particles.

The internal filter element comes in grain sizes of 1 / 0.01 micron, thus you can select it

according to the conditions of the site and must check it regularly more than once a

month.

4-3. ELECTRIC WIRING

1) Make sure that the rated power and of power frequency of the dryer is correct.

2) The wiring of the inside of the dryer was done by our company, so you have to connect

the power cord of the dryer to a power supply.

3) After connecting the dryer to a power supply, be sure to measure the voltage and

insulation status.

4) Ascertain the connection status of the instruments on the panel.

5. OPERATION OF THE AIR DRYER

5-1. PREPARATION FOR OPERATION

1) Make sure that the power specification supplied to the panel is correct.

2) Open the by-passes installed toward the inlet/outlet of the dryer and make the pressure

of A, B drying tower the same as the operation pressure.

3) Because the temperature of the air supplied to the dryer must not exceed a maximum

of 40℃, ascertain the temperature of the thermometer installed in the drying tower.



4) Make sure that the set value of the timer, TIC, thermo s/w, etc. are correct.

- Refer to Section 3-11.

5-2. START

: After finishing the preparation of Section 5-1 and ascertaining there is no failure, start

the dryer.

1) Start the dryer by switching on the control power of the panel.

2) Ascertain once more the operating pressure, temperature and the set value of each

instrument after first purge.

3) Set regeneration pressure by adjusting PURGE ADJUSTING VALVE.

4) Ascertain the operation and lighting situation of each valve and lamp if there is any

failure.

5) Make sure that the process is in progress by the time entered in each timer.

6) After having confirming the above-mentioned matters and if there is any failure, start

the dryer normally.

5-3. CONFIRMATION OF OPERATION CYCLE

1) The power switch on – PRESSURIZING LAMP lights (for 1 minute)

2) After 1 minute, PRESSURIZING LAMP goes out – TOWER PURGE - DRYING LAMP of

one side light (for 4 minutes).

3) After 4 minutes, DRYING LAMP goes out – PRESSURIZING LAMP lights (for 1 minute)

4) After 1 minute, PRESSURIZING LAMP goes out – TOWER PURGE – TOWER CHANGE of

one side.

5) Operation is repeated.

Note) The above operation time is based on standard time and, in case of an actual

operation, may be changed according to operation conditions.

5-4. SELECTION OF OPERATION

: The customer can select its desired dew point operation / time operation and local /

remote operation by installing PPD PANEL to which dew point was mounted.

1) Timer operation

: The process of drying, heating, cooling and pressurizing is repeated in a cycle by the

time entered in the timer, and this is standard specifications.

2) Demand operation (dew point operation)

: This is an operation method by dew point and is a kind of energy reduction-type system



which is widely used in the adsorption type dryer.

Ex) In case the dew point measured is higher than the set dew point at the time of

selection by demand operation, a tower change does not occur and the dryer operates

with PURGE V/V closed. The dew point operation time is as extended as the time set in

DEMAND DELAY TIMER separately installed and dry air is not consumed at all during the

extension time.

3) Local / remote operation

If local operation is selected, the stop and start of the dryer can be controlled only in the

panel, but if remote operation selected, the stop and start of the dryer can be controlled

in a separate operation room, and the contact (power point) related to this is prepared in

the internal terminal block.

5-5. STOPPING OPERATION

: When you want to stop operation of the dryer during its operation, it is better to stop its

operation after the tower has changed, and in case the dryer stops about in the middle of

the cycle, the drying timer must be appropriately added as much as the remaining time.

At this time, since the drying tower performs dehumidification for more than the time

entered in the timer, the dew point of the outlet may be temporarily worse.

1) Stop for a short time

Switch off the power supply, and open the by-pass v/v after closing the valves of the

dryer inlet/outlet.

2) Stop for a long time

: Switch off the power supply and close the valve of the dryer inlet. Then completely

remove the pressure of the drying tower and close it. Then open the by-pass v/v.

(Provided that you must stop each utility and switch off the power supply)

3) Emergency stop by LOW PRESSURE ALARM

If LOW PRESS. ALARM occurs, ALARM LAMP lights and PURGE V/V is automatically

closed. At this time, open the by-pass v/v and close the valves of the dryer inlet/outlet.

Then check if air pressure smoothly applies to the valves of the dryer and upstream

devices. (This doesn’t apply to some small models).



6. MAINTENANCE OF THE AIR DRYER

A desiccant and PURGE MUFFLER should be regularly maintained and repaired.

6-1. DESICCANT

: The usual life span of the desiccant is 2 ~ 3 years, but the life span may be greatly

shortened due to the pollution degree of the air. The desiccant must be replaced in any of

following events.

1) Where the necessary outlet dew point can not be maintained.

2) Where the condition of the outlet dew point suddenly increased.

3) Where the differential pressure between the inlet and the outlet of the dryer is greater

than in early time.

4) Where the desiccant of the inside of the tower has changed into dark green or black.

(Provided slight discoloration is disregarded).

6-2. PURGE MUFFLER

The regenerated air is exhausted into the air through PURGE MUFFLER and in case the air

is not smoothly exhausted, damp air is accumulated in the tower and thus has a bad

effect on the desiccant. This muffler must be usually replaced more than once a year, and

must be immediately replaced in any of following events...

1) Where the pressure does not fall after pressurizing.

2) Where the air slightly leaks toward the muffler.

6-3. CHECK VALVE AND ACTUATOR V/V

: Pay careful attention to each valve installed in the pipe of the dryer, because it directly

affects the operation. It is necessary to take it apart more than once a year and remove

foreign substances on the side of DISC and SEAT.

6-4. DEW POINT METER

: To measure reliable dew point, you are required to calibrate a dew point meter more than

once per two year.



7. MAINTENANCE OF THE AIR DRYER

7-1. ORDER FOR REPLACING THE DESICCANT

1) Switch off the dryer for by-pass and remove the internal pressure.

2) Pull out the desiccant by opening the lower nozzle of the drying tower, and seal the

nozzle by using Teflon tape and gasket.

3) Put in a desiccant by opening the upper nozzle of the drying tower and seal the nozzle

by using Teflon tape and gasket.

4) Operate the dryer once again according to explanation of Section 5.

7-2. EXCHANGE OF PURGE MUFFLER

: After stopping operation of the dryer as same as Section 7-1, remove and replace the

existing muffler.

7-3. For the calibration, repair and purchase of other valve and a dew point meter,

contact Business Operation Team of our company at

TEL) 031-989-2700 / FAX) 031-989-2709 or visit www.ksair.co.kr



8. CAUSE AND MEASURES OF FAILURE

Failure Cause Measures

- Regeneration air is

insufficient

- Increase air volumes by adjusting PURGE

ADJUSTING V/V

- Pressure of the inlet is low - Check and repair the pressure regulator

of the compressor.

- Check upstream equipment of the dryer.

- Temperature of the inlet is

high

- Check AFTER COOLER.

- Desiccant was polluted

- The desiccant is almost

dead.

- Because moisture and oil was not

enough removed, the desiccant was

polluted, so replace it with a new one.

1. Dew point

increase

- Failure in Purge v/v and

Muffler

- Check and, if necessary, replace it.

- Element of the pre filter is

almost dead.

- Check upstream filter of the dryer and

replace the element.

- Leak occurred in v/v and the

pipe.

- Repair the part where leak occurs. 2. Pressure loss

is large - Desiccant was polluted.

- Desiccant is almost dead.

- Because moisture and oil was not

enough removed, the desiccant was

polluted, so replace it.

- Temperature of HEATER

outlet is low.

- Adjust PURGE ADJUSTING V/V 3. The air is not

exhausted The muffler is stopped up. Clean or replace the muffler.

- Malfunction of the valve. - Check and replace the sol. v/v of INLET

or PURGE V/V.

- The power supply was cut

off

- Check and replace on/off s/w or the

fuse.

4. The tower can

not be replaced

- Malfunction of the timer - Replace the timer and the panel.

Note) The above table describes the general details. For more detailed information, contact

Business Operation Team and A/S of our company.

17 operating and maintenance air dryer

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