06 / 2004 040/04 748-00.0.81 V2.0

DryingLine motanpower to change

OPERATING ANDMAINTENANCE INSTRUCTIONS

Small Compact Dryer MDE 40

Details relating to the unit MDE 40

2.1

2 Details relating to the unit2.1 Use in accordance with specifications

The small compact drier MDE 40 is used exclusively to dry hygroscopic plastics granulates.

2.2 Technical data

2.2.1 Small compact drier

Dry air volume ........................................................................................................................................ 40 m3/h

Heating capacity of regeneration air heater, per cartridge ..................................................................... 1,0 kW

Inductive load (motor) .......................................................................................................................... 0,25 kVA

Ohmic load ...................................................................................................................................... max. 1,0 kW

Operating voltage ............................................................................................................ 1 / 230 V/N/PE/50 Hz

Power consumption ......................................................................................................................... approx. 6 A

Max. connected load .............................................................................................................................. 1,3 kW

Weight .......................................................................................................................................... approx. 60 kg

Noise level ........................................................................................................................................... < 70 dBA

Dimensions ...................................................................................................................................... see Fig. 2-1

2.2.2 Drying bins

Temperature range ........................................................................................................................ 60 to 140 °C

Heating capacity, per bin ........................................................................................................................ 1,5 kW

Operating voltage ............................................................................................................ 1 / 230 V/N/PE/50 Hz

Connected load with 230 V, per bin ................................................................................................ approx. 7 A

Max. connected load ............................................................................................................................ 1,55 kW

Volume ................................................................................................................................. 15, 30 and 60 liters

Number of drying bins, volume 15 and 30 liters ................................................................................. max. 2 off

Number of drying bins, volume 60 liters ...................................................................................................... 1 off

Weight (net)15/30/60 liters ................................................................................................. approx. 12/15/20 kg

Dimensions ...................................................................................................................................... see Fig. 2-1

Performance range (in kg/h at a residual moisture content of 0,02 %)

Examples

Material MDE 40/15max. kg/h*

MDE 40/30max. kg/h*

MDE 40/30max. kg/h*

ABS 4,5 9,0 18,0

PA 6 1,5 3,0 9,0

PA 6.6 1,5 3,0 9,0

PC 4,5 9,0 18,0

PEEK 4,0 8,0 16,0

PBTP 3,0 6,0 12,0

LCP 3,0 6,0 12,0

PPS 4,0 8,0 16,0

PSU 4,0 8,0 16,0

*dependent of bulk density, residence time and initial humidity

Details relating to the unit MDE 40

2.2

Fig. 2-1 Dimensions: Small compact drier and drying bins

* Connection for hopper loader prepared** Option

Small compactdrier

Drying bins

60 liters30 liters15 liters

Connecting flange

Details relating to the unit MDE 40

2.5

Fig. 2-6 Dimensions with drying bin on the machine

Assembly MDE 40

3.1

3 Assembly

Fig. 3.1 Assembly – one drying bin

Item No.off Designation Item No.off Designation1 4 Hexagon screw M8x45 DIN 933 8 2 Spring washer B10 DIN 127

2 10 Washer 8,4 DIN 125 9 2 Cheese-head screw M10x20 DIN 912

3 1 Shut-off slide (option) 10 2 Caster with brake dia. 75

4 1 Suction box 11 2 Hexagon screw M8x80 DIN 933

5 4 Spring washer DIN 127 12 4 Hose clamp dia. 38-50

6 4 Hexagon nut DIN 934 13 2 Hose

7 4 Square stopper

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12Return air

Process air

GreyBlack 7

3rd step

step

step

1st step

2nd step

4th step

Assembly MDE 40

3.2

Fig. 3-2 Assembly – two drying bins

Item No.off Designation Item No.off Designation1 8 Hexagon screw M8x45 DIN 933 11 2 Hexagon screw M8x80 DIN 933

2 22 Washer 8,4 DIN 125 12 8 Hose clamp dia. 38-50

3 2 Shut-off slide 13 4 Hose

4 2 Suction box 14 2 T piece dia. 45

5 8 Spring washer DIN 127 15 2 Pipe clip dia. 45

6 10 Hexagon nut DIN 934 16 2 Hexagon screw M8x130

7 8 Square stopper 17 6 Pipe clamp coupling dia. 45, assembled

8 4 Spring washer B10 DIN 127 18 2 Blind plug

9 4 Cheese-head screwM10x20 DIN 912

19 2 Hexagon screw M8x130

10 4 Caster with brake dia. 75

Bolt support frames

Bolt drying bin on the support frame as per Fig. 3-1

Fit and attach hoses

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1312

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Return air

Process air

Grey

Black

Return air

Process air

SeeFig. 3-1

SeeFig. 3-1

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Assembly MDE 40

3.3

Move the small compact drier to thedesignated location and fix casters

Mount drying bin onto the injection mouldingmachine, if necessary

Check location of the screen insert(1, Fig. 3-3) in the drying bin (2). To do this:- open lid of the drying bin- carry out visual check- if necessary, put screen insert in the correct position

If necessary, mount hopper loader onto thedrying bin

Operating Instructions for hopper loaders

Fig. 3-3 Screen insert in the drying bin

Remove blanking plugs on the sockets

Connect small compact drier and drying bin with the drying hoses and the hose clips as per Fig. 3-4

Fig. 3-4 Attaching the drying hoses

Connect compact drier and drying bin to the power supply (230 V) and plug in drying bin at the multiplesocket

Process air

Return air

Pipe socket:greyPipe socket:

black

1

2

Multiple socket(option)

Function MDE 40

4.1

4 Function4.1 Function principle

The blower (2, Fig. 4-1) pulls moist air from the drying bin air via a preconnected filter (3). This air is mixed

with a small part of ambient air. Via the reversing valve (1) the air mix is blown into the desiccant cartridge 2

(5). At this point, the moisture is extracted from this air by means of a desiccant (absorption medium).

Fig. 4-1 Function layout

The dried air from the desiccant cartridge flows into the heater on the drying bin, where it is heated to the

preselected temperature. A separate heater is allocated to each drying bin. This makes it possible to set a

different temperature for each drying bin.

The hot air flows uniformly distributed from the bottom to the top through the plastic granulate, heating and

drying it. The hot and moist air is then aspirated once again by the blower.

When the desiccant in the desiccant cartridges is saturated, it will not absorb any more moisture, and mustbe regenerated. This regeneration process operates in parallel with the drying process in the desiccantcartridge 1.

A part of the dried air from desiccant cartridge 2 flows through desiccant cartridge 1, where it is heated bythe regeneration heater (7) and dries the saturated desiccant. Then, the air flows through the reversing valveinto the open air.

After a preset time the reversing valve switches over. The moist air arrives in desiccant cartridge 1 where itis dried. The regeneration heater (6) is activated and the desiccant in the desiccant cartridge 2 isregenerated.

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Operation MDE 40

5.1

5 Operation5.1 Switch-on

The prerequisites for trouble-free operation:

Small compact dryer and drying bins are plugged in and connected with the air hoses

Hopper loader on the drying bin is ready for operation or

in case of manual filling: Dummy cover on the drying bin is closed

When granulate with a health risk is dried, the regeneratingair has to be carried off!Safety instructions of the manufacturer have to beobserved!

During operation with maximumtemperature, some parts of the systemmight become hot.

Don't touch the system! Risk of injury!

5.1.1 Displays and settings at the drying bin control

Fig. 5-1 Dixell control

Item Designation Function / Display / Operation

1 LED Lights up: heater switched on

2 LED Flashes: when drying temperature is displayed while button 4 is pressed

3 Arrow For modifying the values

4 SET

Displaying the drying temperature press briefly

Modifying the drying temperature press approx. 2 s

Confirming the input press briefly

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Operation MDE 40

5.2

5.1.2 Displaying/modifying the drying temperature

Switch on the drying bin control at switch(4, Fig. 5-2)

The display always shows the current actualtemperature.

Displaying the drying temperature: Briefly press "SET" (3)

display is shown for 5 seconds

Modifying the drying temperature: Keep "SET" (3) pressed for approx. 2 seconds

LEDs (1) flash

Adjust the drying temperature with the arrow keys(2) or (e.g. 90 °C)

Briefly press "SET" the value is accepted

The actual temperature is displayed again after 5seconds.

Fig. 5-2 Adjusting the drying temperature

NOTEIn case of faulty operation:Wait 5 seconds and the display will automatically show the actualtemperature.

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3

Operation MDE 40

5.3

5.1.3 Switching on the small compact dryer

Fig. 5-3 Operating panel on the small compact dryer

Item Designation Function / Display1 Main switch ON-OFF / EMERGENCY-OFF

2 ON-OFF illuminated switch Switches small compact dryer on/off, lights up white when "ON"

3 Alarm display Lights up red on malfunction

Switch main switch to position "I" (1, Fig. 5-3) and

put illuminated ON-OFF switch (2, Fig. 5-3) to position "I"

illuminated switch lights up white

the small compact dryer is switched on

No further operating procedures are required. The entire granulate drying process operates automatically.

When the heater at the drying bin is heating, the LED (1, Fig. 5-1) lights up.

5.2 Switch-off

Switch off the drying bin control with switch (4, Fig. 5-2)

Put illuminated switch (2, Fig. 5-3) to "O" position

White light (2, Fig. 5-3) goes out the small compact dryer and drying bins are switched off

NOTEThe blower runs on for approx. 20 seconds.

For short operation interrupts (< 20 seconds) the drying bin controldoes not have to be switched off.

5.3 Manual filling of the drying bin

CAUTIONWhile filling the drying bin with granulate take care that the cover of thedrying bin will not close inadvertently.Risk of injury!

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Operation MDE 40

5.4

5.4 Trouble-shooting

Always disconnect the mains plug of the small compactdryer and the drying bin heater from the power supplybefore carrying out any fault rectifications.

Secure EMERGENCY-OFF switch at the small compact dryeragainst unauthorised reconnection.

Faults may only be rectified by authorised, trained andproperly instructed specialists.

At malfunction, the alarm display (3, Fig. 5-3) on the operating panel lights up.

The faults listed are examples only, and are not to be regarded as exhaustive.

Fault Cause Rectificationlluminated "ON-OFF"switch (2, Fig. 5-3)

Small compact dryer is not plugged in Plug in small compact dryer

does not light up EMERGENCY-OFF switch not activated Activate EMERGENCY-OFFswitch

Illuminated switch (2, Fig. 5-3) is not switched on Switch on illuminated switch

Power supply failure Check power supply

Lamp defective Change lamp

Fuse 12 F1 (9, Fig. 7-1) defective Change fuse 12 F1

Blower is not Fuse 11 F3 (8, Fig. 7-1) defective Change fuse 11 F3

operating Blower defective Change blower

Alarm display Air pressure monitor (11, Fig. 7-2) defective Change

(3, Fig. 5-3) lights up Blower is not operating Change fuse 11 F3

Hose loose or leaking Check, change if necessary

Air flow too weak Check hoses and connectionfor leaks

Temperature limit switch for desiccant cartridge 1has switched off

Reset 6.3.1

Temperature limit switch for desiccant cartridge 2has switched off

Reset 6.3.1

Temperature limit switch defective Change

Sensor or capillary tube of the temperature limitswitch defective

Change

Wrong position of valve flap Adjust valve flap 6.3.6

Temperature atdrying bin does notreach set temperature

Air flow too weak Check hoses andconnections for leaks

Differential pressure monitor (5, Fig. 7-3)defective

Check 6.3.5change if necessary

Safety thermostat has tripped Reset 6.3.4

Heater defective Measure resistance,change if necessary

Maintenance and repair MDE 40

6.1

6 Maintenance and repair6.1 Maintenance intervals

Prior to any repair work: Allow the drying system to cooldown.

All works concerning electrical installation and repair mayonly be carried out by appropriately trained electricengineers.

Prior to electrical installation works:Disconnect the unit from the power supply and secureagainst inadvertent reconnection.

Recommendation: Wear safety glasses and nose/mouthguard when carrying out dusty works.

Weekly

No. Test point / Designation Action Set value / Remarks1.1 Dry air filter Clean See section 6.2.1

Clean more frequently in theevent of high dust built-up

1.2 Screen at air outlet Check for cleanliness,clean if necessary

Clean more frequently in theevent of high dust built-up

Fig. 6-1 Weekly maintenance works

1.2

1.1

Maintenance and repair MDE 40

6.2

Annually

No. Test point / Designation Action Set value / Remarks2.1 Dry air filter Change See section 6.2.1

2.2 Regeneration air heater Measure resistance Approx. 52 ,see section 6.2.2

Triennially

No. Test point / Designation Action Set value / Remarks3.1 Desiccant Change See section 6.2.3

Fig. 6-2 Annual and triennial maintenance intervals

2.2

3.1

2.1

Maintenance and repair MDE 40

6.3

6.2 Servicing

6.2.1 Cleaning the dry air filter

Switch off dryer

Lock main switch to secure against switch-on

Unplug mains connection

Disassemble dry air filter

Blow dry air filter through with compressed air,

from the inside to the outsidesee Fig. 6-3

Fig. 6-3 Cleaning the dry air filter

6.2.2 Checking the resistance of the regeneration air heaters

Works at the electrical system may only be carried out byauthorised and trained specialists.

Power Voltage Resistance1,0 kW 230 V Approx. 52

Switch off small compact dryer

Lock main switch to secure against switch-on

Disconnect mains connection

Check resistance of the regeneration airheaters on the terminal strip (Fig. 6-4):

Measure resistance between:

Terminal -X11=4 and terminal -X11=14

Terminal -X11=6 and terminal -X11=16

Fig. 6-4 Check resistance

CAUTIONThe air filter housing must not be blown outwith compressed air, since this could causecontamination of the desiccant.Disposal of the dry air filter as special refuse inaccordance with the local offical regulations.

Recommendation:Wear safety glassesand nose/mouth guard.

Maintenance and repair MDE 40

6.4

6.2.3 Changing the desiccant

Remove clamping ring (1, Fig. 6-5) withsilicone profile ring

Remove cover

Remove silicone (2)

Remove screen plate (3)

Remove desiccant (4) completely of thedesiccant cartridge with a vacuum cleaner

Remove silicone completely

Reassambly: Fill in desiccant (3 kg per desiccant cartridge)

Put screen plate in place

Secure screen plate on three points at theedge with silicone

Restore silicone profile ring

Put cover in place and secure with theclamping ring

Fig. 6-5 Changing the desiccant

6.3 Maintenance and repair

6.3.1 Resetting the temperature limit switch

Open door of the small compact dryer

Resetting the temperature limit switch fordesiccant cartridge 1:

Press button at -12S5 (1, Fig. 6-6)

Reset temperature limit switch for desiccantcartridge 2:

Press button at 12S6 (2)

Fig. 6-6 Resetting the temperaturelimit switch

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Maintenance and repair MDE 40

6.5

6.3.2 Changing the temperature sensor at the drying bin

Fig. 6-7 Fitting position of thetemperature sensor

6.3.3 Checking the air pressure monitor

Remove hose (2, Fig. 6-8) at the pressuremonitor (1)

Air pressure monitor alright if

alarm display lights upregeneration air heater switches off(in case the regeneration air heater isswitched on)

Fig. 6-8 Checking the air pressure monitor

Air flowdirectionNOTE

The temperature sensor (1, Fig. 6-7) mustbe fitted in a way that the slot lies inparallel to the air flow direction

Fig. 6-7.1

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1

Maintenance and repair MDE 40

6.6

6.3.4 Resetting the safety thermostat

Remove cap (1, Fig. 6-9)

Press reset button

6.3.5 Checking the differential pressure monitor

The dryer is switched on.

Remove both hoses (2, Fig. 6-9) at the differential pressure monitor (3)

Blow gently into the hose;the differential pressure monitor is alright if:

temperature is still rising LED "out" (1, Fig. 6-10) lights up

Fig. 6-9 Checking the differential pressuremonitor

Fig. 6-10 Checking the differentialpressure monitor

6.3.6 Changing the valve

Disconnect the small compact dryer from thepower supply

Mark the four hoses (1, Fig. 6-11) and removethem

Remove the cover at the valve (3) anddisconnect the cable

Unscrew the two nuts (2) and remove thevalve in forward direction

Assembly is carried out in reverse order.

Fig. 6-11 Changing the valve

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Spare parts MDE 40

7.1

7 Spare partsSpare parts for electrical items see parts list at the circuit diagrams.

Fig. 7-1 MDE 40

Spare parts Fig. 7-11 2 3 4 5

Item No. off Designation / Type Part no. Remarks1 ar* Spiral hose dia. 45 mm 4072410 Black

2 ar* Hose clip dia. 45 mm 1121860

3 ar* Silicone hose dia. 45 mm 4070660 Red

4 1 Profile clamp 4080580

1 Silicone profile ring 4080570

5 3 kg Molecular sieve (3 kg per desiccant cartridge) 1422200 Order also item 4

6 1 Thermostat 4072500

7 1 Heater 1,0 kW 4083130 Order also item 4

8 4 Castor with lock 4072450

9 1 Blower 5090060

10 1 Differential pressure monitor 4065450

11 1 Valve 5042420

12 1 Dry air filter 4066330 Filter cartridge

ar* Silicone seal 2x10 4060830

13 1 Power supply, multiple socket 5013240 Option

ar* = as required

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Spare parts MDE 40

7.2

Fig. 7-2 Drying bin

Spare parts Fig. 7-21 2 3 4

Item No. off Designation / Type 15, 30 and 60 litres1 ar* Silicone seal 2x10 4060830

2 1 Heating element 1,5 kW 4072430

1 Heating element 2 kW 3056930

3 1 Temperature limiter 4074480

4 1 Seal 4072420

5 1 Differential pressure monitor 4065450

6 ar* Silicone hose 4067530

7 ar* Silicone spiral hose dia. 45 4070660

8 ar* Hose clip dia. 45 mm 1121860

9 1 Temperature sensor 4072230

10 1 Sight glass 4082800

ar* = as required

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Option MDE 40

A.1

A After cooler

The after cooler is required for drying with veryhigh temperatures (approx. > 120 °C).

The cooler the return air temperature, the betterthe air absorption of the return air, i.e. efficiencyof the drying system increases.

The return air from the drying bins passesthrough the heat exchanger (1, Fig. A-1).

The heat exchanger is cooled by the cooling airof the filter fan (2) during the entire time ofoperation.

Fig. A-1 After cooler

Maintenance

Clean the after cooler every three months.

In case very dusty material is dried, clean the after cooler more often.

Spare parts

Spare parts

Item No. off Designation Part no.- 1 After cooler, complete 501 459

1 1 Heat exchanger 407 573

2 1 Filter fan 403 652

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