OPERATING AND MAINTENANCE INSTRUCTIONS Small Compact ...

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OPERATING AND 

MAINTENANCE INSTRUCTIONS 

Small Compact Dryer MDE 40 

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

Details relating to the unit MDE 40 

2 Details relating to the unit 

2.1 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 m 3 /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 40/15 

max. kg/h* 

MDE 40/30 

max. kg/h* 

MDE 40/30 

max. 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 

2.1


Small compact 

drier 

Drying bins 

15 liters 

30 liters 

60 liters 

Connecting flange 

* Connection for hopper loader prepared 

** Option 

Fig. 2-1 

Dimensions: Small compact drier and drying bins 

2.2


Fig. 2-6 

Dimensions with drying bin on the machine 

2.5

Assembly MDE 40 

3 Assembly 

Return air 

12 

4 th step 

13 

Process air 

1 

2 

12 

3 

3 rd step 

Black 

Grey 

7 

4 

2 

5 

6 

7 

8 

9 

10 

1 st step 

2 

11 

2 nd step 

Fig. 3.1 

Assembly – one drying bin 

Item No.off Designation 

Item No.off Designation 

1 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 

3.1


12 

14 

12 

Return air 

13 

Process air 

14 18 17 

12 

17 

12 14 18 

17 

16 

15 

17 

Return air 

17 

See 

Fig. 3-1 

13 

12 

14 

12 

17 

Process air 

12 

Grey 

See 

Fig. 3-1 

12 

Black 

2 

16 

6 

2 

Fig. 3-2 

Assembly – two drying bins 

Item No.off Designation Item No.off Designation 

1 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 screw 

19 2 Hexagon screw M8x130 

M10x20 DIN 912 

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 

3.2


Move the small compact drier to the 

designated location and fix casters 

Mount drying bin onto the injection moulding 

machine, 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 the 

drying bin 

Operating Instructions for hopper loaders 

1 

2 

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 

Return air 

Process air 

Pipe socket: 

black 

Pipe socket: 

grey 

Multiple socket 

(option) 

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 multiple 

socket 

3.3

Function MDE 40 

4 Function 

4.1 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). 

1 

2 

3 

4 

5 

7 

6 

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 must 

be regenerated. This regeneration process operates in parallel with the drying process in the desiccant 

cartridge 1. 

A part of the dried air from desiccant cartridge 2 flows through desiccant cartridge 1, where it is heated by 

the regeneration heater (7) and dries the saturated desiccant. Then, the air flows through the reversing valve 

into the open air. 

After a preset time the reversing valve switches over. The moist air arrives in desiccant cartridge 1 where it 

is dried. The regeneration heater (6) is activated and the desiccant in the desiccant cartridge 2 is 

regenerated. 

4.1

Operation MDE 40 

5 Operation 

5.1 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 regenerating 

air has to be carried off! 

Safety instructions of the manufacturer have to be 

observed! 

During operation with maximum 

temperature, some parts of the system 

might become hot. 

Don't touch the system! Risk of injury! 

5.1.1 Displays and settings at the drying bin control 

1 

2 

3 

4 

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 

Displaying the drying temperature press briefly 

4 SET 

Modifying the drying temperature press approx. 2 s 

Confirming the input 

press briefly 

5.1


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 actual 

temperature. 

1 

2 

Displaying the drying temperature: 

Briefly press "SET" (3) 

display is shown for 5 seconds 

3 

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 

4 

The actual temperature is displayed again after 5 

seconds. 

Fig. 5-2 

Adjusting the drying temperature 

NOTE 

In case of faulty operation: 

Wait 5 seconds and the display will automatically show the actual 

temperature. 

5.2


5.1.3 Switching on the small compact dryer 

1 

2 

3 

Fig. 5-3 

Operating panel on the small compact dryer 

Item Designation Function / Display 

1 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 

NOTE 

The blower runs on for approx. 20 seconds. 

For short operation interrupts (< 20 seconds) the drying bin control 

does not have to be switched off. 

5.3 Manual filling of the drying bin 

CAUTION 

While filling the drying bin with granulate take care that the cover of the 

drying bin will not close inadvertently. 

Risk of injury! 

5.3


5.4 Trouble-shooting 

Always disconnect the mains plug of the small compact 

dryer and the drying bin heater from the power supply 

before carrying out any fault rectifications. 

Secure EMERGENCY-OFF switch at the small compact dryer 

against unauthorised reconnection. 

Faults may only be rectified by authorised, trained and 

properly 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 Rectification 

lluminated "ON-OFF" Small compact dryer is not plugged in 

Plug in small compact dryer 

switch (2, Fig. 5-3) 

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

switch 

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 connection 

for leaks 

Temperature limit switch for desiccant cartridge 1 Reset 6.3.1 

has switched off 

Temperature limit switch for desiccant cartridge 2 Reset 6.3.1 

has switched off 

Temperature limit switch defective 

Change 

Sensor or capillary tube of the temperature limit Change 

switch defective 

Wrong position of valve flap Adjust valve flap 6.3.6 

Temperature at 

drying bin does not 

reach set temperature 

Air flow too weak 

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

defective 

Check hoses and 

connections for leaks 

Check 6.3.5 

change if necessary 

Safety thermostat has tripped Reset 6.3.4 

Heater defective 

Measure resistance, 

change if necessary 

5.4

Maintenance and repair MDE 40 

6 Maintenance and repair 

6.1 Maintenance intervals 

Prior to any repair work: Allow the drying system to cool 

down. 

All works concerning electrical installation and repair may 

only be carried out by appropriately trained electric 

engineers. 

Prior to electrical installation works: 

Disconnect the unit from the power supply and secure 

against inadvertent reconnection. 

Recommendation: Wear safety glasses and nose/mouth 

guard when carrying out dusty works. 

Weekly 

No. Test point / Designation Action Set value / Remarks 

1.1 Dry air filter Clean See section 6.2.1 

Clean more frequently in the 

event of high dust built-up 

1.2 Screen at air outlet Check for cleanliness, 

clean if necessary 

Clean more frequently in the 

event of high dust built-up 

1.1 

1.2 

Fig. 6-1 

Weekly maintenance works 

6.1


Annually 


2.1 Dry air filter Change See section 6.2.1 

2.2 Regeneration air heater Measure resistance Approx. 52 , 

see section 6.2.2 

Triennially 


3.1 Desiccant Change See section 6.2.3 

2.1 

3.1 

2.2 

Fig. 6-2 

Annual and triennial maintenance intervals 

6.2


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 

Recommendation: 

Wear safety glasses 

and nose/mouth guard. 

Blow dry air filter through with compressed air, 

from the inside to the outside 

see Fig. 6-3 

CAUTION 

The air filter housing must not be blown out 

with compressed air, since this could cause 

contamination of the desiccant. 

Disposal of the dry air filter as special refuse in 

accordance with the local offical regulations. 

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 by 

authorised and trained specialists. 

Power Voltage Resistance 

1,0 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 air 

heaters 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 

6.3


6.2.3 Changing the desiccant 

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

silicone profile ring 

Remove cover 

Remove silicone (2) 

Remove screen plate (3) 

Remove desiccant (4) completely of the 

desiccant 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 the 

edge with silicone 

Restore silicone profile ring 

Put cover in place and secure with the 

clamping ring 

1 

2 

3 

4 

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 for 

desiccant cartridge 1: 

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

Reset temperature limit switch for desiccant 

cartridge 2: 

Press button at 12S6 (2) 

1 

2 

Fig. 6-6 

Resetting the temperature 

limit switch 

6.4


6.3.2 Changing the temperature sensor at the drying bin 

NOTE 

The temperature sensor (1, Fig. 6-7) must 

be fitted in a way that the slot lies in 

parallel to the air flow direction 

Fig. 6-7. 

1 

Air flow 

direction 

Fig. 6-7 

Fitting position of the 

temperature sensor 

6.3.3 Checking the air pressure monitor 

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

monitor (1) 

Air pressure monitor alright if 

 

 

alarm display lights up 

regeneration air heater switches off 

(in case the regeneration air heater is 

switched on) 

1 

2 

Fig. 6-8 

Checking the air pressure monitor 

6.5


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 

1 

1 

2 

3 

Fig. 6-9 

Checking the differential pressure 

monitor 

Fig. 6-10 

Checking the differential 

pressure monitor 

6.3.6 Changing the valve 

Disconnect the small compact dryer from the 

power supply 

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

them 

Remove the cover at the valve (3) and 

disconnect the cable 

Unscrew the two nuts (2) and remove the 

valve in forward direction 

3 

1 

1 

2 

1 2 

1 

1 

Assembly is carried out in reverse order. 

Fig. 6-11 

Changing the valve 

6.6

Spare parts MDE 40 

7 Spare parts 

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

1 

13 

12 

2 

3 

4 

11 

10 

5 

9 

6 

4 

7 

8 8 

Fig. 7-1 MDE 40 

Spare parts Fig. 7-1 

1 2 3 4 5 

Item No. off Designation / Type Part no. Remarks 

1 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 

7.1

Spare parts MDE 40 

1 

2 

3 

4 

5 

6 

10 

7 

8 

9 

Fig. 7-2 

Drying bin 

Spare parts Fig. 7-2 

1 2 3 4 

Item No. off Designation / Type 15, 30 and 60 litres 

1 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 

7.2

Option MDE 40 

A 

After cooler 

The after cooler is required for drying with very 

high temperatures (approx. > 120 °C). 

The cooler the return air temperature, the better 

the air absorption of the return air, i.e. efficiency 

of the drying system increases. 

The return air from the drying bins passes 

through the heat exchanger (1, Fig. A-1). 

1 

2 

The heat exchanger is cooled by the cooling air 

of the filter fan (2) during the entire time of 

operation. 

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 

A.1

Option MDE 40 

A 

After cooler 








1 

2 



operation. 

Fig. A-1 

After cooler 

Maintenance 



Spare parts 

Spare parts 




2 1 Filter fan 403 652 

A.1

Option MDE 40 

A 

After cooler 








1 

2 



operation. 

Fig. A-1 

After cooler 

Maintenance 



Spare parts 

Spare parts 




2 1 Filter fan 403 652 

A.1

Option MDE 40 

A 

After cooler 








1 

2 



operation. 

Fig. A-1 

After cooler 

Maintenance 



Spare parts 

Spare parts 




2 1 Filter fan 403 652 

A.1

Option MDE 40 

A 

After cooler 








1 

2 



operation. 

Fig. A-1 

After cooler 

Maintenance 



Spare parts 

Spare parts 




2 1 Filter fan 403 652 

A.1

Option MDE 40 

A 

After cooler 








1 

2 



operation. 

Fig. A-1 

After cooler 

Maintenance 



Spare parts 

Spare parts 




2 1 Filter fan 403 652 

A.1

Option MDE 40 

A 

After cooler 








1 

2 



operation. 

Fig. A-1 

After cooler 

Maintenance 



Spare parts 

Spare parts 




2 1 Filter fan 403 652 

A.1

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