PNEUDRI MAXI MX102 – MX110 SERVICE MANUAL
Contents
1. 8 3 2 Service Intervals 8 3 3 Service Kits 9 3 4 Service A Exhaust Silencer Replacement 10 3 5 Service B Filter Element Change 11 3 6 Service C Hygrometer Sensor Replacement 12 3 7 Service D Valve Overhaul 13 3 7 1 Inlet Valve Overhaul2. 14 3 7 2 Exhaust Valve Overhaul 15 3 7 3 Outlet Valve Overhaul 16 3 7 4 5 2 Control Valve Overhaul 17 3 8 Service E Desiccant Change 18 4 Wiring Schematics 21 5 Pneumatic Control Schematics 24 4 1 Safety Warnings Important Do not operate this equipment until the safety information and instructions in this user guide have been read and understood by all personnel concerned Only competent personnel trained qualified and a
3. Dryer Replace the Desiccant Recommended Service E Check Replace 9 3 3 Service Kits Service Kit Description Kit No Quantity A Silencer Service Kit Silencer Element MX 608620090 See table below B Filter Service Refer to Filter user guide 171184000 C Hygrometer Service Replacement dewpoint transmitter DDS Units only 608203580 1 Kit Valve Overhaul lt 9 Barg 608620091 1 D Valve Service Kit Valve Overhaul gt 9 Barg 608620092 1 AA 11 2 Litre Bag 608203661 See table below MS 11 2 Litre Bag 608203662 See table below WS 11 2 Litre Bag 608203663 See table below Kit Column Seals MX 608620098 1 E Desiccant Service Snow storm filler 608201051 1 MX102C MX103C MX103 MX104 MX105 MX106 MX107 MX108 MX109 MX110 20 40 70 20 40 70 20 40 70 20 40 70 20 40 70 20 40 70 20 40 70 20 40 70 70 70 Dryfil AA 9 8 13 12 16 14 21 19 26 24 31 28 36 33 41 37 Dryfil MS 1 7 2 11 2 13 3 17 3 21 4 25 4 29 6 30 37 42 Dryfil WS 2 3 4 5 6 7 8 9 10 11 Seals 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Silencer 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 10 3 4 Service A Exhaust Silencer Replacement Kit No 608620090 Ensure that the dryer is electrically and pneumatically de energised and fully de press
4. column and lower manifold desiccant bed support screens for signs of damage Fill the columns with the replacement desiccant using a snowstorm filler 4 Ensure that all the columns are equally filled and that there is no desiccant in the column bolt holes N B Failure to use the appropriate snowstorm filler will result in degraded performance and generation of dust due to a reduced packing density 19 Insert guide bars 5 into the column bolt holes as shown and using suitable lifting equipment carefully lower the top manifold down onto the columns Once in position secure the manifold using the M12 x 50 bolts Torque setting 27Nm 20ft lb Start with the bolts in the centre of the manifold and work outwards Once the bolts are secured repeat the process to an increased torque setting of 40Nm 20ft lb Reconnect the pressure gauge tubes to the upper manifold and refit front fascia Route the HMI cable to the controller via the HMI cable routing holes provided at the front and rear of the upper manifold Feed the cable into the controller enclosure ensuring that cable glands are tight and reconnect to the controller connections are detailed in the section 5 of this manual Reconnect the outlet valve assembly and pipe work ensuring that the flange o ring is replaced N B Torque settings for the M10 Hex head bolts 34Nm 25 ft lb Reset the desiccant service countdown timer 20 21 4 Wiring Schematics 24 5 Pneumatic
5. Control Schematics
6. PNEUDRI MAXI MX102 MX110 SERVICE MANUAL 2 3 CONTENTS 1 Safety Warnings 4 1 1 Markings and symbols 5 1 2 Hazardous Substances 5 2 0 Technical Specification 6 2 1 Dimensions 7 3 0 Servicing 8 3 1 Cleaning
7. Procedure The combination of filters on the inlet and outlet of the dryer is dependent upon the dryer size and installation configuration The replacement element codes can be found on the filter housings When multiple grades of filtration are used care should be taken to ensure that the replacement elements are fitted in the correct housing Failure to do so will result in reduced dryer performance If the dryer is fitted with a controller mounting plate shroud it will need to be removed in order to gain access to the control air filter To do this remove the 6 x M4 retaining screws that hold the shroud in place Lift the shroud clear of the dryer and store it safely Refer to the instruction leaflets provided with the filter for specific details on element replacement After the dryer has been tested refit the shroud Reset the filter service countdown timers MXA amp MXS only 12 3 6 Service C Hygrometer Sensor Replacement Kit No 608203580 Ensure that the dryer is electrically and pneumatically de energised and fully de pressurised before continuing with this procedure Procedure The hygrometer sensor is located on the dryer controller mounting plate located at the rear of the dryer Disconnect the hygrometer sensor cable at the DIN plug Unscrew the hygrometer sensor and filter assembly from the hygrometer sensor block and fit the replacement sensor and filter assembly After the dryer has been tested reset the hygrometer sen
8. anifold retaining the 5 2 control valve to the valve manifold Replace the valve ensuring that the o ring seal is in place N B Torque settings for the M10 Hex head bolts 34Nm 25 ft lb If the entire 5 2 control valve assembly is being replaced replace the valve assembly and reconnect the tubing and solenoid plugs 18 3 8 Service E Desiccant Change Kit No AA 11 2 Litre Bag 608203661 See table below MS 11 2 Litre Bag 608203662 See table below WS 11 2 Litre Bag 608203663 See table below Kit Column Seals MX 608620098 1 Snow storm filler 608201051 1 MX102C MX103C MX103 MX104 MX105 MX106 MX107 MX108 MX109 MX110 20 40 70 20 40 70 20 40 70 20 40 70 20 40 70 20 40 70 20 40 70 20 40 70 70 70 Dryfil AA 9 8 13 12 16 14 21 19 26 24 31 28 36 33 41 37 Dryfil MS 1 7 2 11 2 13 3 17 3 21 4 25 4 29 6 30 37 42 Dryfil WS 2 3 4 5 6 7 8 9 10 11 Seals 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Silencer 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 Ensure that the dryer is electrically and pneumatically de energised and fully de pressurised before continuing with this procedure Ensure that the condensate drain isolation ball valves are closed on the inlet filters Failure to do so could result in pressurised condensate being forced into the depressurised filter housing resul
9. e the 4 M6 socket head retaining bolts 6 and carefully lift the cylinder off the valve housing Fit the replacement cylinders ensuring that the nose o rings 7 are in place N B Torque settings for the M6 socket head bolts 20Nm 15ft lb Extend the cylinder shaft and fit the replacement valve discs onto the shaft ensuring that they are in the correct sequence and retain using the M8 Binx nut Re mount the inlet valve assembly and the exhaust valve assembly onto the dryer ensuring that all o ring seals are replaced Reassemble the pipe work ensure flange o ring is replaced electrical connections and tubing 15 3 7 2 Exhaust Valve Overhaul Remove the exhaust silencer assembly as described in 3 4 Make a note of the pneumatic tube configuration on the exhaust valve cylinder and disconnect the tubes at the push in fittings Remove the 8 x M10 retaining bolts 2 that secure the exhaust valve assembly 1 on to the lower manifold Lift the assembly off the manifold and rest it on a clean cushioned surface Remove the exhaust strike plate 3 and the end plate 4 Extend the cylinder shaft slightly and position a spanner on the machined flat of the cylinder shaft Remove the M8 Binx nut 5 retaining the valve discs to the cylinder shaft and remove the valve discs from the cylinder If the cylinder is to be replaced remove the 4off M6 socket head bolts 8 retaining it to the exhaust housing Fit the replacement exhaust valve cylinder ensur
10. e valve assembly away from the strike plate and discard The replacement valve will be pre assembled so insert it into the strike plate from the bottom Ensure that the check valve bush 6 is pushed in from the top of the strike plate Place the outlet strike plate assembly onto the outlet valve housing ensuring that the conical spring is sitting correctly on the locating disc in the bottom of the valve housing Re mount the outlet valve housing and outlet strike plate assembly onto the dryer ensuring that all o ring seals are replaced N B Torque settings for the M10 Hex head bolts 34Nm 25 ft lb Reconnect the outlet pipe work to the dryer outlet flange and the PTFE DDS pipe to the push in fitting located on the underside of the outlet housing 17 3 7 4 5 2 Control Valve Overhaul Disconnect the pneumatic tubes at the push in fittings on each of the 5 2 control valves being replaced 1 N B Make a note of which pneumatic tube is connected to which fitting for re assembly If the entire 5 2 control valve assembly is being replaced disconnect the tube at the manifold push in fitting 2 Disconnect the solenoid plug on each of the 5 2 control valves being replaced 3 N B Make a note of which solenoid plug is connected to each solenoid for re assembly Remove the 4off screws 4 retaining the valve manifold to the dryer controller mounting plate If replacing single valves remove the 2off M3 x25Skt Head screws located on the rear of the m
11. ervice procedures identified in table 5 2 and all other repair and calibration work should be undertaken by a domnick hunter trained qualified and approved engineer 3 1 Cleaning Clean the equipment with a damp cloth only and avoid excessive moisture around any electrical sockets If required you may use a mild detergent however do not use abrasives or solvents as they may damage the warning labels on the equipment 3 2 Service Intervals Description of Service Requirement Typical Recommended Service Interval Component Operation Daily Weekly 3 Months 6 Months 12 Months 24 Months 30 Months Dryer Check POWER ON indicator is illuminated Dryer Check STATUS FAULT indicators located on the controller Dryer Check for air leaks Dryer Check the pressure gauges during purging for excessive back pressure Dryer Check the condition of electrical supply cables and conduits Dryer Check for cyclic operation Dryer Replace the active exhaust silencers Recommended Service A Filtration Replace the inlet outlet and control air filters and service drains Recommended Service B Dryer Replace Calibrate dewpoint transmitter DDS Units only Recommended Service C Dryer Replace the valve seats and seals Recommended Service D
12. g 13 190 1 3 Inlet Temperature oC oF 2 50 35 122 Inlet Connection Inches 2 2 1 2 Outlet Connection inches 2 2 1 2 Dewpoint 40 oC 40 oF Dewpoint 70 oC 100 oF Dewpoint 20 oC 4 oF Model cfm m 3 min m 3 hour cfm m 3 min m 3 hour cfm m 3 min m 3 hour MX102c 240 6 80 408 168 4 76 285 264 7 48 449 MX103c 360 10 19 611 252 7 14 428 396 11 21 673 MX103 450 12 75 765 315 8 92 535 495 14 02 841 MX104 600 17 00 1020 420 11 89 713 660 18 69 1121 MX105 750 21 25 1275 525 14 87 892 825 23 36 1402 MX106 900 25 50 1530 630 17 84 1070 990 28 03 1682 MX107 1050 29 75 1785 735 20 82 1248 1155 32 70 1962 MX108 1200 34 00 2040 840 23 79 1427 1320 37 38 2243 MX109 945 26 76 1605 MX110 1050 29 73 1783 Note Stated flows are for operation at 7 bar g 102 psi g with reference to 20 oC 1 bar a 0 relative water vapour pressure The MX 109 and MX110 are for 70 oC pdp 100 oF pdp applications only Parameter Units MX102 MX110 Supply Voltage V ac 100 240V ac 50 60Hz 10 Power W MXS 18W Max MXA 35W Max Fuse A Breaking Capacity A Parameter Units MX102 MX110 Temperature oC oF 2 45 35 113 Humidity 50 40 oC 80 MAX 31 oC IP Rating IP65 gt NEMA 13 Pollution De
13. gree 2 Installation Category II Altitude m ft lt 2000 6562 Noise dB A lt 80dBA 7 2 1 Dimensions Model A mm inches B mm inches C mm inches D mm inches E mm inches F mm inches G mm inches Weight Kg MX102C 1461 57 52 1647 64 84 360 5 14 17 550 21 65 500 19 7 696 27 4 326 12 83 235 MX103C 1461 57 52 1647 64 84 360 5 14 17 550 21 65 500 19 7 865 34 06 495 19 49 316 MX103 1706 67 17 1892 74 49 360 5 14 17 550 21 65 500 19 7 865 34 06 495 19 49 355 MX104 1706 67 17 1892 74 49 360 5 14 17 550 21 65 500 19 7 1034 40 71 664 26 14 450 MX105 1706 67 17 1892 74 49 360 5 14 17 550 21 65 500 19 7 1203 47 36 833 32 8 543 MX106 1706 67 17 1892 74 49 360 5 14 17 550 21 65 500 19 7 1372 54 02 1002 39 45 637 MX107 1706 67 17 1892 74 49 360 5 14 17 550 21 65 500 19 7 15 41 60 67 1171 46 10 731 MX108 1706 67 17 1892 74 49 360 5 14 17 550 21 65 500 19 7 1710 67 32 1340 52 76 825 MX109 1706 67 17 1892 74 49 360 5 14 17 550 21 65 500 19 7 1879 73 98 1509 59 41 919 MX110 1706 67 17 1892 74 49 360 5 14 17 550 21 65 500 19 7 2048 80 63 1678 66 06 1013 8 3 0 Servicing The recommended S
14. ing that the nose o ring 9 is in place N B Torque settings for the M6 socket head bolts 20Nm 15ft lb Extend the cylinder shaft and fit the replacement valve discs onto the shaft ensuring that they are in the correct sequence and retain using the M8 Binx nut Reconnect the exhaust strike plate ensure that the o ring is replaced N B Torque settings for the M10 Hex head bolts 34Nm 25 ft lb Re mount the exhaust valve housing onto the dryer ensuring that all o ring seals are replaced including those retained on the 8off M10 socket head bolts N B Torque settings for the M10 Hex head bolts 34Nm 25 ft lb Reconnect the exhaust silencer and tubing 16 3 7 3 Outlet Valve Overhaul If the dryer is fitted with DDS disconnect the PTFE from the push in fitting located on the underside of the outlet housing Disconnect the outlet pipe work from the dryer at the dryer outlet flange N B Ensure the outlet pipe work is securely supported Whilst supporting the assembly remove the 8 x M10 Hex head bolts 2 that secure the outlet valve housing and outlet strike plate assembly 1 to the upper manifold The outlet valve housing and outlet strike plate assembly are not fastened together Remove the assembly from the dryer and rest it on a clean cushioned surface Lift the strike plate assembly 4 away from the outlet valve housing Carefully remove the M10 Binx nut 7 that retains the valve assembly 5 on the strike plate Remove th
15. invalidate your warranty Use of the equipment in a manner not specified within this user guide may impair safety and invalidate your warranty Should you require an extended warranty tailored service contracts or training on this equipment or any other equipment within the domnick hunter range please contact your local domnick hunter office Details of your nearest domnick hunter sales office can be found at www domnickhunter com Reference Materials This maintenance manual outlines procedures for carrying out service activities on the domnick hunter Ltd MX dryer range For details of the dryer function specification and limitations refer to the following documents a MX Dryer User Guide dh part no 178620001 b Advanced Controller Addendum dh part no 178620002 c MXA Controller Maintenance Engineer Guide available from domnick hunter service department d MXS Controller Maintenance Engineer Guide available from domnick hunter service department 5 1 1 Markings and symbols The following markings and international symbols are used on the equipment and within this user guide Caution Read the User Guide May start automatically without warning Risk of electric shock Wear ear protection Highlights actions or procedures which if not performed correctly may lead to personal injury or death Use lifting equipment Highlights actions or procedures which if not performed correctly may lead to damage to this equi
16. pment Use a forklift truck Highlights actions or procedures which if not performed correctly could lead to electric shock When disposing of old parts always follow local waste disposal regulations Pressurised components on system Conformit Europ enne 1 2 Hazardous Substances The chambers of the dryer are filled with DRYFIL desiccant material This is a powerful desiccant and will dry out the atmosphere eyes nose and mouth If the desiccant comes into contact with the eyes or skin wash the affected area with copious amounts of water DRYFIL may contain some dust therefore an orinasal dust respirator should be worn when handling the equipment Adequate ventilation should be provided when working with desiccant The desiccant is classified as non hazardous for transportation DRYFIL will evolve heat on contact with moisture and may generate pressure in a confined space DRYFIL should therefore be stored in a dry place in its original packaging DRYFIL is non flammable Any fire should be fought by means appropriate to the material causing the fire DRYFIL should be disposed of into a licensed land fill site 6 2 0 Technical Specification This specification is valid when the equipment is located installed operated and maintained as specified within this user guide Parameter Units MX102 MX104 MX105 MX110 Minimum Inlet Pressure bar g psi g MPa g 4 58 0 4 Maximum Inlet Pressure bar g psi g MPa
17. pproved by domnick hunter should perform commissioning service and repair procedures Improper operation or maintenance of the dryer could be dangerous and result in an accident causing injury or death When handling installing operating and maintaining this equipment personnel must employ safe engineering practices and observe all related regulations health amp safety procedures and legal requirements for safety Ensure that the equipment is depressurised and electrically isolated prior to carrying out any of the scheduled maintenance instructions specified within this user guide Most accidents that occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules and procedures Accidents can be avoided by recognising that any machinery is potentially hazardous domnick hunter can not anticipate every possible circumstance which may represent a potential hazard The warnings in this manual cover the most known potential hazards but by definition can not be all inclusive If the user employs an operating procedure item of equipment or a method of working which is not specifically recommended by domnick hunter the user must ensure that the equipment will not be damaged or become hazardous to persons or property Only use genuine domnick hunter ltd spare parts The use of non genuine spare parts of the application of procedures not outlined in this manual could result in the dryer becoming unsafe and will
18. sor service countdown timers MXA amp MXS only 13 3 7 Service D Valve Overhaul Kit No 608620091 lt 9 Barg 608620092 gt 9 Barg Ensure that the dryer is electrically and pneumatically de energised and fully de pressurised before continuing with these procedure Procedure This Service covers the following inlet valve exhaust valve outlet valve and 5 2 control valve assemblies 14 3 7 1 Inlet Valve Overhaul If the dryer is fitted with a controller shroud remove the 4off M8 retaining bolts and lift the shroud clear of the dryer Make a note of the pneumatic tube configuration on the inlet valve cylinders and inlet head and disconnect the tubes at the push in fittings If fitted disconnect the inlet pressure sensor cable DIN plug and the inlet temperature sensor cable plug Disconnect the inlet pipe work to the dryer at the dryer inlet flange which is retained by 4off M10 x 50mm Hex head bolts N B Ensure the inlet pipe work is securely supported Remove the exhaust valve assembly 2 as described in 3 7 2 Exhaust Valve Overhaul to allow unrestricted access to the inlet valve assembly fixings Remove the 8 x M10 retaining bolts 1 that secure the inlet valve assembly in place Lift the assembly off the dryer and rest it onto a clean cushioned surface Extend the cylinder shaft 3 slightly and remove the M8 Binx nut 4 that holds the valve discs 5 to the cylinder shaft If the cylinders are to be replaced remov
19. ting in damage or injury It is recommended that suitable gloves be worn when handling used filter elements It is recommended that suitable respiratory mask is worn when handling used dust filter elements Suitable lifting equipment is required when lifting the upper manifold Procedure Remove the outlet valve assembly as described in section 3 7 3 Remove the lid of the controller enclosure and disconnect the HMI cable from the controller Withdraw the HMI cable from the control box removing the cable gland if necessary Remove the M5 screws retaining the front fascia to the dryer body Disconnect the pressure gauge tubes at the push in fittings on the upper manifold endplates Make a note of which pneumatic tube is connected to which fitting for re assembly Withdraw the HMI cable through the HMI cable routing holes provided at the front and rear of the upper manifold The front fascia is now fully disconnected from the dryer body can be placed to one side to prevent risk of damage Remove the M12 x 50 bolts 1 that secure the upper manifold 2 to the dryer columns 3 Using suitable lifting equipment lift the upper manifold clear of the dryer Tapped holes are provided in the upper manifold for eyebolts to ease lifting Once clear of the dryer replace the o ring seals on the manifold Remove the desiccant from the columns using an industrial vacuum cleaner Ensure that the columns are completely empty and free of dust Visually inspect the
20. urised before continuing with this procedure It is recommended that suitable gloves be worn when handling used filter elements Procedure The exhaust silencer is located under the lower manifold Unscrew the exhaust silencer assembly from the exhaust flange plate and remove the exhaust silencer Remove the exhaust silencer 1 from the baffle 2 and replace The element should be inserted into the groove 3 in the baffle end cap N B The exhaust silencer baffle is intended for reuse however this should be checked for any damage prior to refitting Screw the exhaust silencer assembly back into the exhaust flange plate 4 ensuring that the exhaust silencer element is inserted into the groove in the exhaust flange plate Reset the exhaust silencer service countdown timers MXA amp MXS only 11 3 5 Service B Filter Element Change Kit No Refer to the Filter User Guide 171184000 Ensure that the dryer is electrically and pneumatically de energised and fully de pressurised before continuing with this procedure Ensure that the condensate drain isolation ball valves are closed on the inlet filters Failure to do so could result in pressurised condensate being forced into the depressurised filter housing resulting in damage or injury It is recommended that suitable gloves be worn when handling used filter elements It is recommended that suitable respiratory mask is worn when handling used dust filter elements
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