Labotek Desiccant Flex Dryer Manual
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Labotek Desiccant Flex Dryer Manual

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MANUAL
Desiccant Flex Dryer
DFD
Serial No....................
ISO 08.01.02.39.GB
LT nr.: 986408
Rev. 01
Maskine indeks:

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Summary of Contents for Labotek Desiccant Flex Dryer

  • Page 1 MANUAL Desiccant Flex Dryer Serial No....ISO 08.01.02.39.GB LT nr.: 986408 Rev. 01 Maskine indeks:...

  • Page 2: Table Of Contents

    Rev. 01 Desiccant Flex Dryer DFD Side 1 af 40 1.0 CONTENTS ......................1 GENERAL INFORMATION ................2 Application ..........................2 Restrictions ........................... 2 Design ........................... 3 Relevant directives ........................ 4 Operating principles ......................4 Certificates ..........................6 TECHNICAL DATA ..................8 Technical specifications ......................

  • Page 3: General Information

    The right to carry out changes in the design is reserved to Labotek or his representative without Labotek undertaking any obligation to change the design, neither for equipment already supplied.

  • Page 4: Design

    Power switch R2647 The Desiccant Flex Dryer (DFD) operates in a closed system and is fitted with two desiccant beds to dehumidify the air before use. One of the desiccant beds will always be operative in the drying cycle while the other bed will be regenerating or in stand-by mode ready for activation into the drying cycle.

  • Page 5: Relevant Directives

    Rev. 01 Desiccant Flex Dryer DFD Side 4 af 40 The adsorption and regeneration processes take place without chemical transformation of the desiccant which therefore has a long life. Deterioration of the desiccant is caused solely by soiling of the surface of the desiccant with oil, dust etc. The desiccant in the DFD dryer is therefore protected by an efficient dust filter which can easily be cleaned and replaced.
  • Page 6 Rev. 01 Desiccant Flex Dryer DFD Side 5 af 40 After the drying air has heated the raw material and transformed the moisture to water vapour, it is fed back through the return air cartridge filter (8). The humid air may then be cooled by the return air cooler (9) (optional) just before it reaches the blower (10).

  • Page 7: Certificates

    Rev. 01 Desiccant Flex Dryer DFD Side 6 af 40 2.6 Certificates 2.6.1 IQ-Net Certificate...
  • Page 8 Rev. 01 Desiccant Flex Dryer DFD Side 7 af 40 2.6.2 ISO- Certificate...

  • Page 9: Technical Data

    Rev. 01 Desiccant Flex Dryer DFD Side 8 af 40 3.0 TECHNICAL DATA 3.1 Technical specifications Tekniske specifikationer DFD 100 DFD 150 DFD 200 Supply voltage: 3 ~50/60 Hz , 380/415/440 V Installed power excl. DH [kW] 5,5/5,8 5,5/5,8 7,3/7,7...

  • Page 10: Typeplate

    Rev. 01 Desiccant Flex Dryer DFD Side 9 af 40 3.2 Typeplate The identification number consists of a code (A) and (B), a type number (C) and a serial number (D). A) Identify the year in which the machine was manufactured. Example: 0SA8 = 2008 B) The first letter identifies the machine.

  • Page 11: Dimensioned Drawings

    Rev. 01 Desiccant Flex Dryer DFD Side 10 af 40 3.3 Dimensioned drawings R1877 DFD 100 660 1600 660 720 DFD 150 660 1600 660 720 DFD 200 660 1600 660 720 All measurements are in mm.

  • Page 12: Capacity Table

    Rev. 01 Desiccant Flex Dryer DFD Side 11 af 40 3.4 Capacity table Rawmaterial Recom- Recom- Drying capacity kg/h at bulk density mended mended dry time drying DFD100 DFD150 DFD200 temp. °C Acrylnitril-Butadien-Styrol Polyamid 6/6.6/10 46,5 Polyamid 11/12 52,5 Polycarbonat...

  • Page 13: Noise Level

    Rev. 01 Desiccant Flex Dryer DFD Side 12 af 40 If over-temperature (excess temperature) occurs in the DFD dryer, the signal to the DH hoppers, the heating elments and the blowers in the DFD dryer is interrupted. A communication cable between the drying hoppers and the DFD dryer ensures that none of the drying hoppers can be operated if the desiccant air blower of the DFD dryer is not running.
  • Page 14 Rev. 01 Desiccant Flex Dryer DFD Side 13 af 40 Installation of compressed air 1/4" BSPF (5-7 Bar)* Connection for water supply 1/2" RG (max. 8 Bar)** * Where a pneumatic slide valve (optional) is fi tted under the DH hoppers.

  • Page 15: Operating The System

    Rev. 01 Desiccant Flex Dryer DFD Side 14 af 40 OPERATING THE SYSTEM 1: Main switch (1) for connection of voltage and emergency stop. Main switch should not be used for on / off function of the machine as this can cause overheating of heating elements.
  • Page 16 Rev. 01 Desiccant Flex Dryer DFD Side 15 af 40 DFD is equipped with automatic calculation of drying time, based on the recorded amount of moisture in desiccant beds. The automation ensures minimal energy consumption. Attention! LAB-DRY contains control programs for several machine types. It is therefore important the correct machine type be chosen and its icon shows in the lower right hand corner of the screen.
  • Page 17 Rev. 01 Desiccant Flex Dryer DFD Side 16 af 40 Normal operations 4-5 seconds after the machine is turned on, the screen will show the operating menu. 5.1.1 Operating menu Start / Stop Setup menu Alarm info Lock / Unlock Lock /Unlock-button.
  • Page 18 Rev. 01 Desiccant Flex Dryer DFD Side 17 af 40 5.1.2 Setup menu Temp. Process air, alarm Temp. process air, cooler Temp. Return air, cooler Filter alarm Options menu, Clock/time (password required) Options menu: A password is required before admittance to this menu can be gained.
  • Page 19 Rev. 01 Desiccant Flex Dryer DFD Side 18 af 40 5.1.3 Options menu DFD can have various options. A common setup of these options is that after installation, they must be activated via the options menu. The chosen options and their status will thereafter be shown on the operating screen.
  • Page 20 Rev. 01 Desiccant Flex Dryer DFD Side 19 af 40 Section on the left: Six buttons for options, for the Drying system. Section on the right: Four buttons for options, for the total machine. Drying system Total machine Dew point sensor Process air temp./alarm...
  • Page 21 Rev. 01 Desiccant Flex Dryer DFD Side 20 af 40 Alarm-log External start Language I/O-Status Total machine, DFD Alarm-log. All alarms will be recorded in this log, including the time. Maximum capacity is 10 alarms. Alarm-log can be deleted, however, active alarm states will return.
  • Page 22 Rev. 01 Desiccant Flex Dryer DFD Side 21 af 40 5.1.4 Options Set-up Process air temperature alarm: The option allows the monitoring of the process air temperature to DH hoppers. Required implementation of Pt 100 sensor for use option. If the selected alarm limit temperature is exceeded the blower of dry air and DH hoppers stop.
  • Page 23 Rev. 01 Desiccant Flex Dryer DFD Side 22 af 40 Process air cooler: The option allows to regulate the cooling of the process air to DH hoppers. This required implementation of cooler and solenoid valve to apply the option. UP/DOWN: These buttons allow access to select the regulated max. process air temperature.
  • Page 24 Rev. 01 Desiccant Flex Dryer DFD Side 23 af 40 Return air cooler: The option allows to regulate the max. return air temperature from the DH hoppers. This required implementation of cooler and solenoid valve to apply the option. UP/DOWN: These buttons allow access to select the regulated max. return air temperature.
  • Page 25 Rev. 01 Desiccant Flex Dryer DFD Side 24 af 40 Setup menu – Clock/Timer LAB-DRY control system has both a real-time clock and delayed start capabilities. The delayed start function allows the machine to be programmed to start at a predetermined time and day.
  • Page 26 Rev. 01 Desiccant Flex Dryer DFD Side 25 af 40 Adjusting current time via the numeric keypad, calendar and clock buttons. Set time Set date Numeric keys 0 to 9. Back: Erases input value. Enter: After password is input, press enter.
  • Page 27 Rev. 01 Desiccant Flex Dryer DFD Side 26 af 40 5.1.5 Operating Menu – Alarms LAB-DRY has a number of alarms that warn against incorrect functions. All alarms can light external lamps (if mounted). All alarms will reset themselves when the malfunction is corrected.
  • Page 28 Rev. 01 Desiccant Flex Dryer DFD Side 27 af 40 Operating menu – Alarm info - Troubleshooting guide The text shows the most common faults and their remedies. ESC: Brings you back to Alarm info.
  • Page 29 Rev. 01 Desiccant Flex Dryer DFD Side 28 af 40 5.1.6 Menu system...

  • Page 30: Troubleshooting

    Rev. 01 Desiccant Flex Dryer DFD Side 29 af 40 6.0 TROUBLESHOOTING On every error check/restart it is recommended to check: • Connection voltage • Fuses (6F1-3) • Hose connections • Cable connections and the settings for the LAB DRY control.

  • Page 31: Machine Gives En Error Message

    Rev. 01 Desiccant Flex Dryer DFD Side 30 af 40 6.1 Machine gives en error message Alarms The machine continually monitors the system to ensure correct functionality. An alarm will show if the machine is not operating properly, the alarm will be shown with a blinking icon on the operating screen.

  • Page 32: Maintenance

    Rev. 01 Desiccant Flex Dryer DFD Side 31 af 40 7.0 MAINTENANCE 7.1 Maintaining the desiccant bed The basic maintenance principle of the DFD dryer is to prevent plastic granules and dust from entering the blowers, coolers, heating elements and the desiccant beds (2) and (3) in particular as this will adversely affect the performance and life of the machine.

  • Page 33: Cleaning/Checking The Regeneration Cooler

    Rev. 01 Desiccant Flex Dryer DFD Side 32 af 40 7.2.3 Cleaning/checking the fresh air filter a. Stop the machine by turning the power switch to position “0”. b. Remove the filter cover. c. Clean the filter housing using compressed air before dismantling the filter to remove loose dust and granules.

  • Page 34: Repairs

    Rev. 01 Desiccant Flex Dryer DFD Side 33 af 40 8.0 REPAIRS General repair instructions The following measures must be taken before carrying out repairs: - Turn off the power switch and disconnect the main supply. - Allow the DFD dryer to cool down.
  • Page 35 Rev. 01 Desiccant Flex Dryer DFD Side 34 af 40 R1875 8.1.2 Removing the desiccant bed assembly Remove the cables from the heating elements and the thermistors in the terminal box (143). Remove the tension rod (133) that runs between the two valve units (20) and (21). To remove the tension rod dismount the locking rings (134) on the toggle joints (135).
  • Page 36 Rev. 01 Desiccant Flex Dryer DFD Side 35 af 40 8.1.3 Reassembly of the desiccant bed assembly Clean the joining surfaces on the valve units (20) and (21) and apply new sealing material. Fasten the desiccant bed assembly by tightening the valve bolts (136) to 4.5 ± 0.5 Nm.

  • Page 37: Replacement Of Balls In The Valve Unit

    Rev. 01 Desiccant Flex Dryer DFD Side 36 af 40 8.1.4 Fitting the desiccant bed assembly See drawing R1875 1. Fit the desiccant bed assembly in the MDFD dryer and tighten screws (33) and (34). 2. Fit hoses (31) and (32) and the clip.
  • Page 38 Rev. 01 Desiccant Flex Dryer DFD Side 37 af 40 Black ball (176): dry air ball and inner regeneration ball, moderate heat resistance, somewhat harder than the yellow ball. Yellow ball (175): lower regeneration ball, outer, high heat resistance, soft.

  • Page 39: Replacement Of The Motor For The Change-Over Valve

    Rev. 01 Desiccant Flex Dryer DFD Side 38 af 40 8.3 Replacement of the motor for the change-over valve 1. Remove the right side plate. 2. Unclip the strip holding the condensator (21). 3. Remove plug (29) by unscrewing the screws.

  • Page 40: Replacement Of Blowers

    Rev. 01 Desiccant Flex Dryer DFD Side 39 af 40 8.4 Replacement of blowers Important: During the whole of this process it is of the greatest importance that no foreign objects enter the blower casing. Try, therefore, to keep the entry and exit holes covered as long as possible.

  • Page 41: Replaceing The Fresh Air Valve

    Rev. 01 Desiccant Flex Dryer DFD Side 40 af 40 8.4.2 Regeneration blower See drawing R1883 1. Remove fresh air valve (12) and the hose on the flange (67). 2. Remove the cables in terminal block (68) on the regeneration blower (13).

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