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Keltech KRAD M Series - User Manual

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COMPRESSED AIR DRYERS
KRAD M SERIES (KRAD 30M to KRAD 250M)
INSTRUCTION
MANUAL
WARRANTY NOTICE
Failure to follow the instructions and
pirocedures in this manual or misuse of this
equipment will VOID its warranty !
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Do you have a question about the Keltech KRAD M Series and is the answer not in the manual?

Summary

Warranty Notice

Warranty Disclaimer

Failure to follow instructions or misuse voids the warranty.

Important Safety Notes

General Safety Precautions

Operator must apply safe methods and observe local safety instructions and regulations.

Installation and Maintenance Personnel

Installation, operation, maintenance, and repair by authorized, trained, and skilled engineers.

Transportation Safety

Use care during transport, avoid dropping, use forklift correctly.

Positioning Requirements

Install horizontally with 50cm clearance; consider ambient temperature and atmosphere.

Installation Procedures

Only skilled engineers should install; do not modify safety devices; use pressure relief valves.

Pre-Operation Checks

Review safety, check piping, ensure correct pressure, and open drains to atmosphere.

Introduction to the Dryer

Purpose of the Dryer

Designed to remove water vapor from industrial compressed air for indoor operation.

Dryer Label Information

Details on the label affixed to the refrigerant compressed air dryer cabinet.

Refrigerant Circuit Breakdown

The refrigerant circuit is divided into low-pressure, high-pressure, and control sections.

Water-Cooled Dryer Specifics

Components specific to water-cooled dryers: water valve and high-pressure switch.

Refrigerant Circuit Operation

Describes the cycle of refrigerant compression, condensation, expansion, and evaporation.

Compressed Air Circuit Operation

Explains how compressed air is cooled, condensed, and separated.

Compressed Air Dryer Working Principle

Diagram Explanation

Key components and their roles in the compressed air dryer working principle diagram.

Refrigerant Compressor Function

Function of the refrigerant compressor and common types used.

Condenser Operation Modes

How the condenser dissipates heat, including air-cooled and water-cooled types.

Condenser Maintenance (Water Cooled)

Points to consider for condenser maintenance, especially regarding clogging and water quality.

Refrigerant Circuit Protection

Klixon Compressor Protection

Thermal sensitive switch for compressor temperature and overintensity.

High Pressure Security Switch

Manually reset switch protecting the refrigerant line against bursts.

Filter Dryer Role

Ensures total water removal and traps solid particles in the refrigerant circuit.

Water-Cooled Dryer Safety Switch

Safety switch stops the dryer on cooling water failure; requires manual reset.

Refrigerant Circuit Controls

Liquid Refrigerant Injection Control

Control valve maintains constant over-heats of refrigerant in the evaporator.

Constant Evaporating Pressure Method

Achieved via hot gas injection to maintain constant evaporating pressure.

Condensate Drain and Trap Assembly

Drain Assembly Details

Details on the condensate drain and trap assembly for easy isolation and maintenance.

Heat Exchanger Modular Design

Heat Exchanger Assembly Components

Composed of economizer, air/refrigerant heat exchanger, and centrifugal separator.

Air Cooled System Diagram

Diagram illustrating the air-cooled system with key components and flow.

Accessories

Temperature Switch Function

Adjustable temperature switch located inside the dryer (0°C to 35°C).

Digi-Pro Controller Features

Features energy saving, dew point monitoring, status reports, and run time meter.

ESD3 Energy Saving Device

Energy saving device for dryer efficiency, offering dew point and status reports.

Operation

KRAD M Series Control Panels

Details the control panel elements for KRAD M series, including monophase and digital controller.

Filter Element Maintenance Recommendation

Recommends changing filter elements for efficiency and keeping spares in stock.

Pressure Drop Warning

Warns against using KRAD M dryers with dryers having higher pressure drop without confirmation.

During Operation Monitoring

Regularly check the digital temperature controller Digi-Pro on the dryer.

Start-up and Shut-down Procedures

Warning about leaving the dryer off while compressed air is flowing.

Initial Start-up and Long Stop Restart

Set rotary switch to 'I' for preheating; allow minimum 4 hours preheating after a long stop.

Daily Start-up and Shut-down

Procedure for daily operation: push ON button, stop airflow before setting switch to '0'.

Electrical Controller

DIGI-PRO Controller Description

Features: dew point monitoring, energy saving, status reports, run time, temp selection.

DIGI-PRO Controller Operation Overview

Overview of the Digi-Pro controller display and its functions.

DIGI-PRO Menu Button Functions

Explanation of SET, PROGRAM, POWER, MENU, and MANUAL DRAIN buttons.

Alarm Display and Codes

Lists alarm codes, descriptions, and reasons for alarms like temperature, pressure, filter.

Mode Display Indicators

Explains indicators for Dryer Active, Automatic Drain, Energy Saving, Units, and Service modes.

Filter Kit Replacement with Encryption

Step-by-step guide for replacing filter kits using an encryption code for DigiPro controllers.

Correct Drain Hose Connection

Drain Hose Connection Guidelines

Guidelines for connecting drain hoses: length, height, diameter, and atmospheric pressure.

Technical Specifications

KRAD Model Specifications Table

Detailed specifications for KRAD models including capacity, voltage, power, and pressure drop.

Air Cooled Models Technical Data

Nominal working pressure, temperature limits, and water pressure for air-cooled models.

Water Cooled Models Technical Data

Maximum working pressure, water temperature limits, and water pressure for water-cooled models.

Diagrams

Air Flow Diagrams (KRAD 15 M - KRAD 25 M)

Diagram and component list for the air flow of KRAD 15M and KRAD 25M models.

Air Flow Diagrams (KRAD 40 M - KRAD 80 M)

Diagram and component list for the air flow of KRAD 40M to KRAD 80M models.

Air Flow Diagrams (KRAD 100 M - KRAD 150 M)

Diagram and component list for the air flow of KRAD 100M to KRAD 150M models.

Air Flow Diagrams (KRAD 200 M - KRAD 250 M)

Diagram and component list for the air flow of KRAD 200M to KRAD 250M models.

Electrical Diagrams (KRAD M Series)

Protective Earth Conductor Requirements

Provides information on protective earth conductor requirements for the dryer.

Electrical Diagram (KRAD 15 M - KRAD 25 M)

Detailed electrical diagram for KRAD 15M and KRAD 25M models with component labels.

Electrical Diagram (KRAD 40 M - KRAD 125 M)

Detailed electrical diagram for KRAD 40M to KRAD 125M models with component labels.

Electrical Diagram (KRAD 150 M - KRAD 250 M)

Detailed electrical diagram for KRAD 150M to KRAD 250M models with component labels.

ID Diagrams and General Arrangements

KRAD 15 M ID Diagram Drawings

Dimensional drawings and component layout for the KRAD 15M model.

KRAD 25 M ID Diagram Drawings

Dimensional drawings and component layout for the KRAD 25M model.

KRAD 40 M ID Diagram Drawings

Dimensional drawings and component layout for the KRAD 40M model.

KRAD 60 M ID Diagram Drawings

Dimensional drawings and component layout for the KRAD 60M model.

KRAD 80 M ID Diagram Drawings

Dimensional drawings and component layout for the KRAD 80M model.

KRAD 100 M ID Diagram Drawings

Dimensional drawings and component layout for the KRAD 100M model.

KRAD 125 M ID Diagram Drawings

Dimensional drawings and component layout for the KRAD 125M model.

KRAD 150 M ID Diagram Drawings

Dimensional drawings and component layout for the KRAD 150M model.

KRAD 200 M ID Diagram Drawings

Dimensional drawings and component layout for the KRAD 200M model.

KRAD 250 M ID Diagram Drawings

Dimensional drawings and component layout for the KRAD 250M model.

General Arrangements

Model and Replacement Kit Overview

Table listing models, replacement kits, control type, dimensions, and weight.

General Model Specifications

Key operational parameters applicable to all models, including pressure and temperature settings.

Exploded Diagrams and Spare Parts

KRAD 15 M Exploded Diagram

Visual representation of components for KRAD 15M, with numbered parts.

KRAD 15 M Spare Part List

Detailed list of parts for KRAD 15M, including item number, part number, description, and quantity.

KRAD 25 M Spare Part List

Detailed list of parts for KRAD 25M, including item number, part number, description, and quantity.

KRAD 40 M Spare Part List

Detailed list of parts for KRAD 40M, including item number, part number, description, and quantity.

KRAD 60 M Spare Part List

Detailed list of parts for KRAD 60M, including item number, part number, description, and quantity.

KRAD 80 M Spare Part List

Detailed list of parts for KRAD 80M, including item number, part number, description, and quantity.

KRAD 100 M Spare Part List

Detailed list of parts for KRAD 100M, including item number, part number, description, and quantity.

KRAD 125 M Spare Part List

Detailed list of parts for KRAD 125M, including item number, part number, description, and quantity.

KRAD 150 M Spare Part List

Detailed list of parts for KRAD 150M, including item number, part number, description, and quantity.

KRAD 200 M Spare Part List

Detailed list of parts for KRAD 200M, including item number, part number, description, and quantity.

KRAD 250 M Spare Part List

Detailed list of parts for KRAD 250M, including item number, part number, description, and quantity.

Components Location

Electrical Components List

Lists electrical components like transformers, lights, relays, switches, and motors.

Refrigerant Components List

Lists components within the refrigerant circuit: receiver, drier, valve, condenser, gauges.

Compressed Air Components List

Lists components related to the compressed air path: inlet prefilter, drain filter, pneumatic drain.

Troubleshooting Guide

Compressor Not Turning On

Diagnoses for when the compressor does not start, covering phase issues, protection trips, and temperature.

Fan Not Running

Troubleshooting for when the fan is not running, checking airflow and pressure switch.

Compressor Vibration and Noise

Addresses issues with excessive compressor vibration and mechanical noise, often related to liquid refrigerant.

Troubleshooting - Continued

Unit Cycles Off and On

Diagnoses for intermittent operation, including ambient temperature, clogged fins, and refrigerant issues.

High Pressure or Dew Point Issues

Addresses high pressure, low/high dew point, and airflow problems, linking them to condenser and refrigerant.

Troubleshooting - Final Issues

Unit Not Running or Cycling

Covers excessive ambient temperature, clogged condenser fins, and refrigerant shortage causes.

Digital Display Error Signs

Troubleshoots error signs on the digital temperature control, related to dew point and working conditions.

Drain Failure Diagnosis

Addresses drain port issues, back pressure, and recommended drain hose specifications.

Warranty Statement

Warranty Terms and Conditions

Details warranty terms, limitations, exclusions, and service procedures for Keltec Air Dryers.

Keltech KRAD M Series Specifications

General IconGeneral
BrandKeltech
ModelKRAD M Series
CategoryDehumidifier
LanguageEnglish