DESICCANT(HEATLESS TYPE) AIR DRYER

Instruction & Operating Manual

of
Desiccant( Heatless Type ) Air Dryer

306-1 NAEYU-DONG, DEOGYANG-GU, GOYANG-SI, KYONGGI-DO, KOREA

TEL : 031) 963 - 0080 / 963 - 7832 / 962 - 7830 / 962 - 7837
FAX : 031) 962 - 0180

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 DESICCANT(HEATLESS TYPE) AIR DRYER

CONTENTS

Page

1. PRINCIPAL 3

2. INSTALLATION AND PIPING 3

3. STRUCTURE 4

4. FUNCTION 6

5. OPERATION AND MAINTENANCE 7

6. TROUBLE SHOOTING GUIDE 8

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 DESICCANT(HEATLESS TYPE) AIR DRYER

1. PRINCIPAL

1) It is widely recognized that the ultra air is very useful in the industrial field. To get this ultra dried air,
Heatless Pressure Swing type (heatless regeneration type) is the most preferable equipment in the
economic and secure respect.
2) It has been observed that the air supplied into air dryer from compressor has lots of dust, moisture.
The heatless air dryer is equipment that discharge air agter absorbs moisture from the compressed air
using a desiccant in the tower.
3) The air dryer of heatless pressure swing type is the most economic desiccant dryer eliminated costs
on exchanging of electric heater line needed for regenerating dryer and on spending electronic power
compared with a traditional air dryer.
4) Desiccant Air Dryer is designed as double tower structure to repeat drying and regeneration,
generally applied where requires dew point below -40℃ dew point.
5) To use products safely and efficiently, you should read usage instruction before installation.

2. INSTALLATION AND PIPING

When installing dryer, it is necessary to select suitable places as below.

1) Avoid the place trembling.
2) Install the unit in the hard and flat place.
3) Prepare for the trembling of compressor.
(When the compressor trembling, connect the high-pressure hose or flexible hose so as to absorb
trembling in connecting part of piping.)
4) Wide space is recommended ror easiness of installation and servicing.
5) Install the unit where is no sudden change in temperature and not exceeding 0~45℃ limit.

♦ OIL MIST WATER SEPARATOR

It is necessary to install a filter for eliminating dusts and high performance oil mist condensate separator
in the unit as the desiccant has to be avoided from the condensed water.

▷ Pre-Filter (Recommended item)

KHDM Model is equipped with pre-filter supplying both function of separator and filter additionally.
Pre-filter well compounded the separated type of centrifugal force, collision, and the drain of condensed
water is discharged into auto trap. Internal filter element is constructed of 0.01micron and 1 micron
of particle and neede periodical check. (Once per 3 months)

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 DESICCANT(HEATLESS TYPE) AIR DRYER

▷ After-Filter (Recommended item)

As the air passed by dryer may have sometimes debris of deseccant. It is necessary to install after-filter
outlet of dryer to prevent the unit from trouble by debris.
KHDM Model is equipped with after-filter additionally.
The particle is 1micron, and life of filter is 3~6 months.
However, it is necessary to clean the filter element once per 1~2 month for 6 months.

♦ Wiring

1) Confirm the sequence between power supply and the rated voltage of the unit.
2) Wiring in the system finished by connecting the electronic power to an outlet box.

3. STRUCTURE
3-way shuttle valve of KHDM Model is a simple structured unit as non-oiling type, has the function of
preventing the temperature falling off by sudden insulation expasion, improving degumidification capacity
and reducing exhaust noises by falling compressed air pressure to atmospheric condition as a poppet
type having certain sealing capacity. And there is no stagnation in case of electronic power failure.
But make sure of installing filter inlet part because the airtightness is not working by inflow
of solid particles.

2) 2-way purge solenoid valve

It discharges regenerated air outside on pressurizing and regenerating. Occasionally in case of making
troubles by inflow of a desiccant or debris, dissolve and clean the coil part.

3) Pressure gauge
Two pressure gauges are installed in both tower respectively, it shows dryness and regeneration pressure
of tower. The higher pressure shows dryness of tower, the lower shows regeneration of tower.
When the pressure is equalized, the lower increases the pressure up to the higher.
After making an equalization of pressure, it shifts to the opposite direction.

4) Control panel
KHDM dryer control panel has PCB controlled by simple timer. There are lamps shows operating
condition like dryness, pressurizing at a glance and on/off switch.
As the inner part of the panel is very sensitive against moisture and dust, do not touch and open
the cap frequently. It may cause malfunction of the unit.
The special caution is required for corrosion by sea wind.

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 DESICCANT(HEATLESS TYPE) AIR DRYER

The power supply for the model is 220V, single-phase current, 60Hz and below 25VA
in consumption power.

♦ Adjustment of Timer

The hour of dryness and regeneration can be extended under the condition below.
1. Dry winter season
2. When dry smaller flows compared with the design size.
3. When dry lower temperature compressed air compared with the design size.
(But, maximum extended hour can not be exceed 10 minutes)

♦ The method of adjustment of Timer

See appendix A
- Adjustment method of dryer timer and demonstration of terminal board.

5) Vessel
The vessel of KHDM model produced on JIS, KS standard passed the pressure regulation exam,
prevent outflows of a desiccant by sticking the strainer made of mesh stainless screen.

6) Desiccant
The desiccant is made of activated alumina gel that has excellent moisture adsorption capacity
exclusively used for compressed air dryer. Desiccant maintains maximum dehumidification capacity
by perfect regeneration. When the temperature of inlet part is below 50℃ and the 7 kg/cm2.g pressure.
The dew point below -40℃ can be acquired. Desiccant has limited life about 3years.
If sample color of desiccant changed into brown or black color, it is necessary to change desiccant
immediately. But minor change in color can be disregarded.

7) Silencer
The inside component of Silencer is a sound-absorbing materials which could reduce noise occurred in
desiccant regeneration. After a long time operation, if you notice that Silencer couldn’t exhaust air or
there is too much noise at Silencer, change or clean the Silencer.

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 DESICCANT(HEATLESS TYPE) AIR DRYER

4. FUNCTION

1) Dehumidification
KHDM Model improves the effectiveness of dehumidification by eliminationg moisture physically
as passing the compressed air into tower having excellent desiccant. (Desiccant : Activated Alumina Gel)

2) Dryness
The compressed air flows into one tower through 3-way shuttle valve in inlet part.
During the air goes up to the upper level of desiccant in the tower, moisture and other debris is eliminated
and outflow to outlet part in the state of the ultra dried air(Dew point -40℃ ). In this procedure,
small quantity of dried air descends to the lower part, regenerating desiccant in the opposite tower
after adiabatic expansion passing the orifice since decompressed in the regeneration adjustment valve.
That is, during the dried air produced in one tower, desiccant referated automatically in the other tower.

① Time
After 5minutes dehumidfication, regenerate desiccant for 5 minutes.
PCB timer controls this dehumidification-regeneration cycle.

② Dew Point
As alumina gel is very sensitive against moisture and dust, the temperature in inlet part has to be
below 50℃ in any occasion.

3) Regeneration
KHDM Dryer is the dryer of heatless type that don't make use of heat in generation of desiccant.
The theory of desiccant regeneration is using the differences in pressure. It makes the regeneration air
for dehumidification by expanding a portion of dried air, and the expanded air actually makes the more
quantity of air for dehumidification than the quantity of pressure air.

① Time
The regeneration cycle is 10 minutes. While one tower is drying 5 minutes, the other tower goes
through a mode of desiccant regeneration and purge for about 4 minutes and then the purge
exhaust valve closes to allow the tower to pressurize for 1 minute.

② Regeneration Air
The regeneration air makes use of a portion of dried air. The ideal quantity of air can be
properly adjusted.

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 DESICCANT(HEATLESS TYPE) AIR DRYER

③ Pressurization
Pressurizing procedure is one of the very important performances in regenerating adsorption.
This procedure runs automatically due to fixing up PCB timer. The time of pressurizing is around
60 seconds.
And regeneration tower pressurized sufficiently prevent air from pulsation and impulsive load.

4) Control system
The every function of air dryer works by PCB timer which handing is convenient depends on the condition
of humidity in four seasons. The basic setting of operation is 5 minutes drying, 4 minutes regeneration
and 1 minute pressurization. It is possible to operate by adjusting PCB timer based on the condition of
the open air, to adjust of the time based on dew point.

5. OPERATION AND MAINTENANCE

Dryer consists of 2 Tower, 2-way purge solenoid valve, 2 check valve, 2 3-way shuttle valve.
It is not necessary of high technology or maintenance.

1) Operation ( See appendix " B " )

2) Test-working checkpoint.
- Before operating, increase the quantity of flow into the air dryer gradually and pressurize the tower to
operation pressure. Then turn on the switch.
- Check out the lamp on. Inspect the function of the wire connection and the bulb when the lamp is out.
- Check out the pressure of the gauge attached to the tower. The pressure lower than the designated
criteria causes overload to the air dryer.

2) Maintenance
Exchange desiccant in case that cannot keep up the dew point neede level in operation. The durability of
desiccant is 3 years. But debris like mist or dust in the compressed air lowers the adsorption ability and
causes shortening durabilityof desiccant by locking out the capillary tube.

3) The exchange order of adsorption

① Turn off the air dryer.
② Lower the pressure of tower to the atmospheric pressure.
③ Extract the adsorption through the discharge pipe installed at the bottom of the tower.
and seal the plug of discharge pipe using teflon tape.

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 DESICCANT(HEATLESS TYPE) AIR DRYER

④ Fill up the adsorption through the injection pipe installed at the top of the tower,
and seal the plug pipe using teflon tape.

6. TROUBLE SHOOTING GUIDE

Symptoms Cause Remedy

1. Increase the quantity of regeneration air by
1. Shortage of regeneration air
checking out regeneration-adjusting valve.

2. Bad pressure adjusting of compressor or

2. Low pressure in entrance.
high differences in pressure.
A. Dew point rising up
3. Low the temperature in entrance by checking
3. High temperature in entrance
out air refrigerator.(Applied)

4. Check out the and air filter, exchange

4. Contaminated desiccant
element, replace the desiccant with new one.

1. Check out the power supply equipment of

1. Power off
panel and switch.

B. Trouble in
2. Malfunction of PCB timer 2. Check out the PCB timer and exchange timer.
exchanging tower
3. Check out the solenoid coil and dismantle the
3. Bad running in the solenoid valve.
valve. Reassemble the seat and components.

1. Control pressure by adjusting the regeneration

1. Bad inflow of the regeneration air
regulator or checking out the valve.

C. Bad exhaustion 2. Clogged muffler 2. Check out and clean the muffler or exchange it.

3. Check out the solenoid valve and exchange

3. Malfunction in the solenoid valve.
the valve.

1. Check out and exchange the solenoid valve.

D. Heavy pressure loss 1. Malfunction of the solenoid valve. Adjust regeneration regulator in case of excess

in the regeneration air adjustment.

1. Check out and exchange the 3-way shuttle

E. Heavy pressure when 1. Malfunction of the entrance
exchanging the tower 3-way shuttle valve. valve after dismantles valve.

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 DESICCANT(HEATLESS TYPE) AIR DRYER
** Appendix. A : THE METHOD OF ADJUSTMENT OF TIMER

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 DESICCANT(HEATLESS TYPE) AIR DRYER
** Appendix B : OPERATION ( See P&ID drawing )

OPERATION ( See P&ID drawing )

1). Compressed air enters through lnlet 3-way shuttle valve, passes through and is dried
by the desiccant in tower A, and is directed by system of outlet check valve
to air outlet.

2). A portion of dried air is expanded to near atmospheric pressure through orifice
and check valve.

3). This expanded is directed through Tower B where it removes moisture from the
desiccant (Re-activating) and exhausted to atmoshere through regeneration
2-way purge solenoid valve (R.T) and silencer.

) After four minutes (for

4). ( dryers
y operating
p g on a 10 minute cycle)
y ) 2-wayy purge
p g solenoid
valve (R.T) closes allowing tower B to repressurize slowly.

5). After five minutes 2-way purge solenoid valve (L.T) open allowing tower A to
de-pressurise through 2-way purge solenoid valve (L.T) also inlet valve(3-way shuttle valve)
position is transferred to tower B on-line position.

6). Air now flows through tower B and is dried while the desiccant in tower A is
being regenerated.

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