COMPACT-swift-80-250 Manual de Operacion y Mantenimiento

Dry Air Generator
COMPACT swift 80 - 250
CE-Translation of the original operating manual

Store for reference
02/2022 700-02 EN V0.0.3
Manufacturer
motan holding gmbh
Stromeyersdorfstr. 12
78467 Konstanz / Germany
www.motan-colortronic.com
Copyright
© motan holding gmbh, D-78467 Konstanz
This operating manual is copyright protected, with all usual rights reserved. Reproduction of this operating
manual or parts thereof is only permitted with the authorisation of motan holding gmbh. Non‑compliance
shall result in an obligation to provide compensation for damages and can have consequences under
penal law. The technical information and operating information in this operating and maintenance manual
correspond to the latest state of the art on delivery of the device.
Table of contents
Table of contents
1 User Instructions ............................................................................................................................................ 6

1.1 Serial Number........................................................................................................................................ 6
1.2 Purpose and Target Group .................................................................................................................... 6
1.3 Warranty and Liability ............................................................................................................................ 7
1.4 Validity of the Operating Manual............................................................................................................ 7
1.5 Conventions of Presentation.................................................................................................................. 8
2 Safety............................................................................................................................................................... 9
2.1 General .................................................................................................................................................. 9
2.2 Action-Related Warnings ....................................................................................................................... 9
2.3 Symbols Used...................................................................................................................................... 10
2.4 Intended Use ....................................................................................................................................... 11
2.5 Obligations of Owner ........................................................................................................................... 13
2.6 Personnel Qualification........................................................................................................................ 14
2.7 Hazards Relating to Assembly and Commissioning ............................................................................ 15
2.8 Dangers when Handling ...................................................................................................................... 15
2.9 Hazards Relating to Maintenance and Service.................................................................................... 16
2.10 Dangers during Decommissioning and Disposal ................................................................................. 16
2.11 Sources of Danger............................................................................................................................... 17
2.12 Protective Devices ............................................................................................................................... 19
2.13 Warning Signs ..................................................................................................................................... 20
3 Product Description ..................................................................................................................................... 21

3.1 Structure .............................................................................................................................................. 21
3.2 Operating Principle .............................................................................................................................. 22
3.3 Declaration of Conformity .................................................................................................................... 23
3.4 Name Plate .......................................................................................................................................... 24
3.5 Technical Specifications ...................................................................................................................... 24
3.6 Service Life .......................................................................................................................................... 28
4 Assembly and Commissioning ................................................................................................................... 29

4.2 Delivery and Unpacking....................................................................................................................... 29
4.3 Transport ............................................................................................................................................. 30
4.4 Assembly ............................................................................................................................................. 31
4.4.1 Setting Up the Dry Air Generator ............................................................................................ 31
4.4.2 Connecting the Dry Air Generator........................................................................................... 31
4.5 Commissioning .................................................................................................................................... 38
5 Operation....................................................................................................................................................... 40
5.2 Switching the Dry Air Generator On/Off............................................................................................... 40
5.2.1 Switching On ........................................................................................................................... 40
5.2.2 Switching Off ........................................................................................................................... 41
5.2.3 Switching On Again................................................................................................................. 42
6 Alarm Messages and Troubleshooting ...................................................................................................... 43
iv 700-02 EN V0.0.3
Table of contents
6.1 Alarm Lights Dry Air Generator............................................................................................................ 43
7 Maintenance and Upkeep ............................................................................................................................ 44

7.2 Maintenance Intervals.......................................................................................................................... 44
7.3 Preparation .......................................................................................................................................... 45
7.4 Engagement Points for Maintenance and Service............................................................................... 47
7.5 Maintenance Work To Be Carried Out by the Operating Personnel.................................................... 48
7.5.1 Discharging the Compressed Air Filter ................................................................................... 48
7.5.2 Cleaning Filter for Return Air / Conveying .............................................................................. 49
7.5.3 Cleaning the Screen Filter ...................................................................................................... 51
7.5.4 Replacing the Filter Switch Cabinet Fan................................................................................. 52
7.6 Maintenance Work Qualified Personnel .............................................................................................. 53
7.6.1 Checking the Proximity Switch and the Outlet Flap ................................................................ 53
7.6.2 Check sensor on the glass outlet............................................................................................ 54
7.6.3 Checking the Process Air Pressure Switch............................................................................. 55
7.6.4 Measuring the Resistance of the Regeneration Air Heater..................................................... 56
7.6.5 Replacing the Desiccant ......................................................................................................... 58
7.6.6 Replacing the Temperature Sensor ........................................................................................ 60
7.6.7 Replacing the Process Air Pressure Switch............................................................................ 62
7.7 Servicing Work by Expert Personnel ................................................................................................... 63
7.7.1 Replacing the Switching Valve for Conveying ........................................................................ 63
7.7.2 Replacing the Process Air Switching Valve ............................................................................ 64
7.7.3 Replacing the Regeneration Air Switching Valves.................................................................. 65
7.7.4 Unlocking the Temperature Limiter ......................................................................................... 66
7.7.5 Replacing the Heater .............................................................................................................. 67
7.7.6 Resetting the Circuit-Breaker for the Blower........................................................................... 68
8 Decommissioning and Disposal ................................................................................................................. 69

8.2 Decommissioning the Device .............................................................................................................. 69
8.3 Disposing of Device and Parts of Device............................................................................................. 71
9 Spare Parts.................................................................................................................................................... 72
9.1 Dry Air Circuit....................................................................................................................................... 72
9.2 Conveying Circuit................................................................................................................................. 74
9.3 Operator Controls ................................................................................................................................ 77
9.4 Pneumatic Parts .................................................................................................................................. 78
9.5 Dew Point Display / Dew Point Control................................................................................................ 79
9.6 Pneumatic Suction Box Ø 38 mm........................................................................................................ 80
10 Appendix ....................................................................................................................................................... 81
10.1 Bulk Material Classification.................................................................................................................. 81
10.2 Pneumatic Diagram ............................................................................................................................. 83
10.3 Wiring Diagram .................................................................................................................................... 83
10.4 Handling the Desiccant........................................................................................................................ 84
700-02 EN V0.0.3 v
1 | User Instructions COMPACT swift 80 - 250
1 User Instructions
1.1 Serial Number

The serial number includes the device number. The serial number is shown on the name plate, see
Name Plate [} 24].
Serial number example:
7000A00 B xx xxxxx
This operating manual is a component of the devices referred to in the following:
– COMPACT swift 80
This operating manual applies exclusively to devices with the following device number:
– 7000A00
– 7000B00
– 7000C00
1.2 Purpose and Target Group

The operating manual enables safe, correct work with the device or with the software. The
operating manual must be read and understood by all persons who work with the device or with the
software.
This operating manual is intended for operating and qualified personnel:
▪ Operating personnel
These persons are instructed in operation of the device or the software and informed of
possible dangers in the event of incorrect conduct.
The owner is responsible for instruction of the personnel. The user is also responsible for
observance of the safety measures described.
▪ Qualified personnel
These persons have undergone the relevant specialist training (e.g. as a mechatronics
engineer) and have additional knowledge and experience of using the device or the software.
Qualified personnel are appropriately trained in use of the device or software. Qualified
personnel are able to assess the work assigned to them and recognise possible dangers.
▪ Service personnel of motan
These persons were trained by the manufacturer and have comprehensive knowledge of the
device or software. The service personnel are experts in assembly, commissioning, operation,
maintenance, service and decommissioning. The service personnel are aware of the dangers
entailed in the use of the device or software.
For further information, see Personnel Qualification [} 14].
6 700-02 EN V0.0.3
COMPACT swift 80 - 250 User Instructions | 1
1.3 Warranty and Liability

The General Terms and Conditions of Business of the manufacturer apply. The manufacturer does
not accept warranty claims or liability in the event of personal injury or damage to property due to
one or more of the following causes:
▪ Improper use of the device.
▪ Failure to observe the instructions, requirements and prohibitions in the operating manual.
▪ Unauthorized structural modifications to the device.
▪ Insufficient monitoring of parts subject to wear.
▪ Incorrect and overdue maintenance and service work.
1.4 Validity of the Operating Manual

This operating manual contains important information on the correct operation and maintenance of
the device. This operating manual helps to prevent dangers, to avoid repair expenses and
downtimes and to prolong the service life of the device.
The operating manual must be kept available at the place of operation of the device.
The operating manual is intended for operating and maintenance personnel and is to be read,
understood and applied by all persons who are assigned the following work on the device:
▪ Transport and installation
▪ Assembly and commissioning
▪ Operation
▪ Troubleshooting
▪ Maintenance and service
▪ Decommissioning and disposal
700-02 EN V0.0.3 7
1 | User Instructions COMPACT swift 80 - 250
1.5 Conventions of Presentation

Presentation of instructions
Instructions for operation and use of the device are displayed as follows:
1. Operating step 1
2. Operating step 2
ð Intermediate result of step 2
3. Operating step 3
ü Result
Individual operating instructions are displayed as follows:
► Operating step
ü Result
Display of cross-references
Cross-references to other chapters are indicated by the signal word “see”, the name of the chapter
and the page number of the chapter in “[ ]”, e.g.
See User Instructions [} 6].
Display of lists
Numbered and unnumbered lists are displayed as follows:
1. Numbered list 1
2. Numbered list 2
▪ List point level 1
– List point level 2
8 700-02 EN V0.0.3
COMPACT swift 80 - 250 Safety | 2
2 Safety
2.1 General
This chapter contains basic safety information for handling the dry air generator.
All the instructions in this chapter for operation and maintenance of the unit must be observed.
The electroheating device satisfies class of thermal safety protection 1 according to
EN 605 19-2: 2006, section 13.8.
2.2 Action-Related Warnings

A pictogram with the word “DANGER” warns of an imminent danger to health and life of
persons.
Ignoring these safety instructions will result in very serious or fatal injury.
DANGER w Always observe these measures to prevent such danger.
A pictogram with the word “WARNING” warns of a possible danger to the health and life of
persons.
Ignoring these safety instructions may result in very serious or fatal injury.
WARNING w Always observe these measures to prevent such danger.
A pictogram with the word “CAUTION” warns of a possible danger to the health of persons or
damage to property or the environment.
If these safety instructions are not observed, injury or property damage and/or environmental
damage may occur.
CAUTION
w Always observe these measures to prevent such danger.
Indicates a possible danger which may lead to damage to property if not avoided.
w List of all measures which must be taken to prevent consequences.
NOTICE
Important information.
For identification of important instructions, supplementary information and tips.
INFO
700-02 EN V0.0.3 9
2 | Safety COMPACT swift 80 - 250
2.3 Symbols Used

In this operating manual warnings and danger signs are provided at all points concerning safety
and operation of the units and personal safety.
The following pictograms apply to the various types of dangers:
General warning, danger zone, caution
Irritation of respiratory tract
Warning of hazardous electrical voltage, electrocution
Hand injury
Hot surface
Falling parts
Suspended load
Risk of falling and tripping
10 700-02 EN V0.0.3
Warning of possible damage to device
Supplementary information, tip
2.4 Intended Use

Before using the device, read the safety datasheet of the plastic granulate manufacturer.
NOTICE
No changes must be made to the unit. These could affect the safety of the unit.
In the event of questions relating to permissible use of the device, please consult your contact
partner at motan.
Permissible use
▪ The device may only be used to generate dry air for drying hygroscopic and free-flowing
plastic granulate (category 1) in drying bins.
▪ The bulk density of the plastic granulate must not exceed 0.85 kg/l, granulate specification
type G1, see Bulk Material Classification [} 81].
▪ The device may only be put into operation when it has been ascertained that the unit has
been completed with missing assemblies.
▪ The device may only be used to reduce water constituents from plastic granulate.
▪ Intended for commercial use.
▪ Use is only permitted in enclosed, dry rooms.
Foreseeable misuse, limits of permitted use

▪ The device must not be used to dry food.
▪ Installation of assemblies which are not intended for the dry air generator.
▪ Assembly of unspecified drying bins.
700-02 EN V0.0.3 11
Further restrictions
▪ The device must not be used in the open air.
▪ The device must only be used in commercial systems.
▪ The device must not be used in explosive environments.
▪ The device must not be used with plastic granulates which give off flammable, explosive or
toxic gases.
▪ The device must not be put into operation until the complete unit complies with the Machinery
Directive 2006/42/EC.
▪ The device must not be used to dry and dehumidify rooms, halls and buildings.
▪ use of non-OEM spare parts.
Operation under the following conditions is prohibited:
▪ with non-specified compressed air;
▪ in the event of insufficient maintenance;
▪ outside of the defined operating parameters;
▪ with modifications not approved by the manufacturer;
▪ with defective, deactivated or modified safety devices;
▪ with unspecified plastic granulate.
12 700-02 EN V0.0.3
2.5 Obligations of Owner

The owner is obliged to train safe working practices of the personnel at regular intervals and to
qualify the personnel accordingly for the necessary work with the device or software, see
Personnel Qualification [} 14].
The owner of the device must only allow personnel to work on the device or with the software who:
▪ have been instructed in the processes and operating principle of the machine or software;
▪ are familiar with the health and safety regulations;
▪ have read and understood the safety chapter and warning notices in this operating manual.
Personal protective equipment

The necessary personal protective equipment and protective clothing must be available for
operating and maintenance work.
Observe the following instructions for personal protection in certain situations for operating,
maintenance and service work.
Wear head protection.
NOTICE
Wear safety goggles.
NOTICE
Wear nose and mouth mask.
NOTICE
Wear protective gloves.
NOTICE
Wear safety shoes.
NOTICE
700-02 EN V0.0.3 13
2.6 Personnel Qualification

Instructed personnel
Instructed personnel are persons who have been instructed in correct handling of the device, the
machine and/or the software and are familiar with the dangers entailed in the event of improper
use. In particular, the personnel must be instructed in the safety devices.
Operating personnel
The device or the software may only be operated by trained or instructed personnel. It is
recommended to have the personnel trained by motan.
The operating personnel must be able to read and understand displays on the machine or of the
software and act upon them.
The operating personnel may carry out certain maintenance work after relevant training. This work
is explicitly described at the relevant points in the operating manual.
Qualified personnel
The device may only be assembled, maintained and serviced by trained, qualified personnel. The
qualified personnel must have read and understood the operating manual. It is recommended to
have the personnel trained by motan.
The qualified personnel must be able to read and understand displays on the machine or of the
software and act upon them.
Qualified personnel are in particular:
▪ Mechanics
Work on the mechanical equipment of the device may only be carried out by a trained
mechanic or by personnel under the direction and supervision of a trained mechanic.
Work on gas, pneumatic and hydraulic equipment may only be carried out by specially trained
mechanics.
Only trained mechanics may carry out work on the machine.
▪ Electricians
Work on the electrical equipment of the device may only be carried out by an electrical
engineer or by personnel under the direction and supervision of an electrical engineer in
accordance with the electrical engineering regulations.
Only trained or instructed electricians may carry out work on the machine.
14 700-02 EN V0.0.3
2.7 Hazards Relating to Assembly and Commissioning

Suitable protective equipment must be available for transport, assembly and commissioning and
worn, see Obligations of Owner [} 13].
High electrical voltages may lead to life-threatening body currents and injuries due to electric
shock. Work on the electrical system may only be carried out by trained electricians. Before
beginning work on electrical equipment, it is to be disconnected from the power supply and
protected against being switched on again without authorisation.
In the event of installation at heights, components or parts of components may fall. The hazard
zone is to be cordoned off and marked during assembly work. Use appropriate working platforms
or climbing aids when carrying out work on components that you cannot reach from the ground.
Persons may fall over incorrectly routed pipes, hoses or cables as well as plastic granulate lying on
the floor. Pipes, hoses and cables should be placed in such a way that there is no danger of
tripping, falling or slipping. Regularly remove plastic granulate which is lying around.
During assembly, there is a danger of cutting injuries on sharp edges and packaging material.
Wear safety gloves for all assembly and commissioning work.
During commissioning there is a danger of injury due to pressurised compressed air hoses. Ensure
that compressed air hoses are depressurised before connecting.
During commissioning, the device or parts of the device may heat up. There is a danger of burns in
the event of contact.
To avoid injuries in handling, the device is equipped with protective devices. These must never be
removed, bridged or switched off.
2.8 Dangers when Handling

To avoid injuries in handling, the device is equipped with protective devices. These must never be
removed, bridged or switched off.
During operation, the unit or parts of the unit may heat up. There is a danger of burns in the event
of contact.
700-02 EN V0.0.3 15
2.9 Hazards Relating to Maintenance and Service

For maintenance and service work, appropriate protective equipment is to be provided and worn,
see Obligations of Owner [} 13].
The device is fitted with protective devices to prevent injuries during maintenance and service. This
equipment must never be removed, by-passed or switched off.
The device or parts of the device may heat up during operation. There is a risk of burns on contact.
Allow the device to cool down before all maintenance and repair work and wear safety gloves.
Plastic granulate and dust may lead to irritations and injuries to the eyes and respiratory tract.
Nose, mouth and eye protection must be worn for all work.
During maintenance and service, there is a danger of cutting injuries on sharp edges. Wear
protective gloves for all maintenance and service work.
During maintenance and service there is a danger of injury due to pressurised compressed air
hoses. Ensure that compressed air hoses are depressurised before connecting.
In the event of maintenance and service at heights, components or parts of components may fall.
The hazard zone is to be cordoned off and marked during disassembly work. Use appropriate
working platforms or climbing aids when carrying out work on components that you cannot reach
from the ground.
2.10 Dangers during Decommissioning and Disposal

Suitable protective equipment must be provided and worn for decommissioning and disposal, see
Obligations of Owner [} 13].
In the event of disassembly at heights, components or parts of components may fall. The hazard
zone is to be cordoned off and marked during disassembly work. Use appropriate working
platforms or climbing aids when carrying out work on components that you cannot reach from the
ground.
Plastic granulate and dust may lead to irritations and injuries to the eyes and respiratory tract.
Nose, mouth and eye protection must be worn for all work.
The device or parts of the device may heat up during operation. There is a risk of burns on contact.
Allow the device to cool down before all disassembly and decommissioning work and wear safety
gloves.
During disassembly and decommissioning, there is a danger of cutting injuries on sharp edges.
Wear safety gloves for all disassembly and decommissioning work.
16 700-02 EN V0.0.3
2.11 Sources of Danger

The dry air generator has been constructed with state-of-the-art technology and in accordance with
the recognized safety standards. However, its use may entail dangers for the operating and
maintenance personnel or third parties and damage to the dry air generator.
These components of the dry air generator represent the greatest sources of danger:
▪ Electrical system / switch cabinet
▪ Filter housing
▪ Process air parts
▪ Desiccant
▪ Drying bin
▪ Drying air heater
6 1
2
4 3
Fig. 1: Sources of danger
1 Electrical system / switch cabinet 4 Drying air heater

2 Process air parts 5 Drying bin
3 Filter housing 6 Desiccant
700-02 EN V0.0.3 17
Electrical switch cabinet
Danger of electrocution.
High electrical voltages may lead to life-threatening body currents and injuries due to
electrocution.
DANGER w Work on the electrical system may only be carried out by trained electricians.
w Disconnect the unit from the power supply before starting electrical work and secure it
against unauthorised activation.
Regeneration air heater and process air parts
Danger of burns.
During operation, the device or parts of the device may heat up. There is a danger of burns
in the event of contact with the housing, motors and other parts of the device.
WARNING w Allow the device to cool down before touching it (e.g. for maintenance or operation).
w Observe the warning signs on the device.
Affected parts of the dry air generator:

▪ Regeneration air heater with connecting hoses and connecting pipes.
▪ Process air parts with connected hoses and pipes.
▪ Drying bin
▪ Valves.
▪ Desiccant cartridges.
▪ Cooler, if not insulated.
▪ Process air parts such as blower and filter.
Desiccant
The activated desiccant produces heat when it comes into contact with water.
Irritation of the respiratory tract and eyes due to plastic granulate and dust.
Plastic granulate and dust may lead to irritations and injuries to the eyes and respiratory
tract.
CAUTION w Wear safety goggles and protective gloves.
w Wear nose and mouth mask.
18 700-02 EN V0.0.3
2.12 Protective Devices

Injuries due to non-functioning protective devices.
The device is equipped with protective devices to prevent injuries during operation,
maintenance and service.
DANGER w Ensure correct functioning of protective devices after assembly.
1 2
Fig. 2: Protective devices
1 Master switch (= Emergency Stop switch) 2 Padlock (not included in the scope of
delivery)
The master switch is simultaneously the Emergency Stop switch.
INFO
Only switch the COMPACT swift 80 - 250 off in the following situations:
▪ In case of an emergency.
▪ In the event of operational faults.
▪ For maintenance and service work.
Protect the master switch with a padlock to prevent it being switched on inadvertently.
NOTICE
700-02 EN V0.0.3 19
2.13 Warning Signs

The information, warning and prohibition signs form part of the operating manual. You must
therefore pay as much attention to these as to the operating manual. The signs must always be
clean and legible. They must never be removed, painted over or covered over.
Position of the warning signs
Fig. 3: Position of the warning signs
Meaning of the warning signs
electrocution.
Before starting maintenance and repair work, allow the dry air generator to cool down.
Secure the dry air generator against being switched on without authorisation.
WARNING
Burns from hot surfaces.

The device or parts of the device may heat up during operation. There is a risk of burns on
contact.
WARNING w Let the device cool down before contact (e.g. for maintenance or operation).
w Heed warnings on the device.
w Wear safety gloves.
20 700-02 EN V0.0.3
COMPACT swift 80 - 250 Product Description | 3
3 Product Description
3.1 Structure
18
17 2
3
16
15 4
6
14
7
8
13 9
10
11
12
Fig. 4: Structure COMPACT swift 80 - 250
1 Process return air (from drying bin) 10 Dry air blower

2 Regeneration air exit 11 Regeneration air cooling hose
3 Switching valve for conveying 12 Water cooler
4 Compressed air unit 13 Suction box
5 Desiccant bed 1 14 Drying air heater
6 Dry air switching valve 15 Desiccant bed 2
7 Return air filter 16 Switching valve regeneration air
8 Filter for conveying 17 Drying bin
9 Conveying blower 18 Primary hopper loader
700-02 EN V0.0.3 21
3 | Product Description COMPACT swift 80 - 250
3.2 Operating Principle
1 2 4
3
19
5
18 6
17 7
16
15
14
13
12 11 10 9 8
Fig. 5: Function diagramCOMPACT swift 80 - 250
1 Water cooler 11 Dry air switching valve

2 Return air filter 12 Dry air blower
3 Drying air heater 13 Compressed air valve
4 Primary hopper loader 14 Heater desiccant 1
5 Drying bin 15 Conveying blower
6 Material line 16 Desiccant cartridge 1
7 Secondary hopper loader 17 Filter for conveying
8 Suction box 18 Switching valve for conveying
9 Desiccant cartridge 2 19 Regeneration air switching valve
10 Heater desiccant 2
The drying process

The drying process serves to dry the plastic granulate in the drying bin.
Both desiccant cartridges complement each other in their function: While one desiccant cartridge
dries out the plastic granulate in the drying process, the other desiccant cartridge is regenerated.
Drying of the plastic granulate

The blower sucks the moist air out of the drying bin via the upstream filter.
Moist air is blown into the desiccant cartridge 2, where it is dehumidified. The dried air then flows
into the drying bin. When the desiccant in the desiccant cartridge is saturated, it no longer absorbs
moisture and must be regenerated. To this end, the desiccant cartridges are replaced
automatically.
22 700-02 EN V0.0.3
The regeneration process
The regeneration phase

In the regeneration phase, the desiccant of desiccant cartridge 1 is dehumidified in parallel with the
drying process. Depending on requirements, the desiccant cartridges are replaced between the
regeneration and drying processes. The return air is enriched with relieved compressed air.
This air mixture is heated to over 240 °C by the regenerating heater and flows through the
desiccant cartridge, regenerates the desiccant and the moist air is blown off via the regeneration
outlet.
The regeneration phase is complete when the reference temperature is reached downstream of the
desiccant cartridge. The heater is switched off and the cooling phase begins.
Cooling phase
The cooling phase occurs directly after the regenerating phase and serves to cool the desiccant
down again in order to integrate the desiccant cartridge in the drying process again.
The regeneration circuit is closed. The regeneration air flows through the regeneration air cooler
and cools down the regeneration circuit.
The cooling phase is complete when the reference temperature is reached downstream of the
desiccant cartridge.
Material conveying
The conveying blower generates a vacuum in the primary hopper loader. This allows plastic
granulate to be transported to the drying bin.
The conveying blower generates a vacuum in the secondary hopper loader. This allows plastic
granulate to be transported from the suction box on the drying bin to the machine.
A filter is integrated in the vacuum line to protect the conveying blower.
3.3 Declaration of Conformity

The EC Declaration of Conformity of the device is included with this operating manual as an
external document.
700-02 EN V0.0.3 23
3.4 Name Plate
Fig. 6: Position of the type plate

Explanations of the abbreviations on the name plate:
Abbreviation Designation Abbreviation Designation
No. Drawing number Us Control voltage
Standard Standard applied Back-up fuse
SN Serial number lb Rated current
Ub Rated voltage lcc Short-circuit breaking capacity
mmax Weight of the machine pN Rated value of the compressed
air connection
Year Year of manufacture RA Declaration of Conformity
Number
3.5 Technical Specifications

All length and diameter measurements are given in millimetres [mm]. In exceptional cases,
this is explicitly stated.
INFO
Observe the minimum clearances around the dry air generator when installing.
INFO
24 700-02 EN V0.0.3
COMPACT swift 80 / 150 / 250
Fig. 7: Dimensions and minimum clearances COMPACT swift 80 / 150 / 250
Dimension COMPACT swift 80 COMPACT swift COMPACT swift

150 250
A 1483 1668
B 1201 1341
C 1153 1294
D 1938 2195 2312
E 727 765
F 682 722
G > 500
H (cooling air duct) > 300
I (Passage) > 700
J (Filter cartridge installation 300
depth)
700-02 EN V0.0.3 25
COMPACT swift 250
1 2 3
Fig. 8: Dimensions and minimum clearances COMPACT swift 250
A Work area 1 Air inlet (from drying bin)

B Removal depth, filter cartridge 2 Regeneration air outlet
C Clearance cooling air duct 3 Air outlet (from drying bin)
D Passage
26 700-02 EN V0.0.3
swift Hopper Loaders
Fig. 9: swift hopper loader dimensions
Device-specific information
COMPACT COMPACT COMPACT
swift 80 swift 150 swift 250
Weight approx. 260 kg approx. 275 kg approx. 330 kg
Dimensions (W x H x D) 1175 x 682 x 1938 1175 x 682 x 1938 1294 x 722 x 2312
Dry air capacity approx. 30 m³/h approx. 50 m³/h approx. 90 m³/h
700-02 EN V0.0.3 27
Electrics
Rated voltage 3/N/PE 400 V
Rated frequency 50 Hz
Rated current 18 A 22 A 23 A
Rated output max. 4.7 kW max. 5.7 kW max. 6.1 kW
max. Back-up fuse 30 A
Short-circuit breaking capacity 10 kA
Switch control voltage 24 V DC
Protection type of switch cabinet IP54

Rated voltage 3/N/PE 400 V
Rated frequency 60 Hz
Rated current 18 A 22 A 23 A
Rated output max. 5.0 kW max. 6.0 kW max. 6.5 kW
max. Back-up fuse 30 A
Short-circuit breaking capacity 10 kA
Switch control voltage 24 V DC
Protection type of switch cabinet IP54
Pneumatics
Compressed air connection 5 – 7 bar / Ø 8 mm
Max. permissible pressure 8 bar
max. Consumption max. 15 m³/h
Environmental conditions
Permissible ambient temperature +5 °C to +40 °C
Relative humidity 50% at +40 °C
Permissible altitude (above NN) up to 1000 m
3.6 Service Life

The service life of the dry air generator is determined by the wear of the individual parts and the
valid legislation. Time limits are specified for wear parts of the dry air generator with regard to
maintenance and replacement intervals in accordance with the intended use. The time limits of the
components of the dry air generator must be strictly observed.
Observing the specified maintenance and service intervals in accordance with the maintenance
plan and the operating manual, the dry air generator can be used in three-shift operation without
the occurrence of operational risks for a period of 10 years.
28 700-02 EN V0.0.3
COMPACT swift 80 - 250 Assembly and Commissioning | 4
4 Assembly and Commissioning

Only trained or instructed qualified personnel may carry out transport, assembly and
commissioning work. For further information, see Personnel Qualification [} 14].
4.2 Delivery and Unpacking

Warning of cutting injuries.
When unpacking, there is a danger of cutting injuries due to incorrect removal of the
packaging material.
WARNING w Wear protective gloves.
The device is delivered on a pallet.
1. Remove packaging of the device.
2. Check delivery for completeness.

ð In the event of doubt, ask your contact partner at motan.
3. Check delivery for damage.

ð Damage due to delivery must be immediately reported in writing to the haulage company
and the contact partner at motan.
ü Device is unpacked.
700-02 EN V0.0.3 29
4 | Assembly and Commissioning COMPACT swift 80 - 250
4.3 Transport
Warning of falling or tilting equipment or components.
The machine or individual components thereof may tip or fall during transport.
w Secure and mark danger zone.

WARNING
w Do not remain under suspended loads.
w When working on components which cannot be reached from the ground, use suitable
operating platforms or climbing aids.
w Never climb onto the device or its housing.
w Use suitable transport equipment and lifting gear for handling.

During transport and handling, there is a risk of cutting injuries on sharp edges.
w Wear protective gloves.

WARNING
Provide the following equipment for transport and assembly of the dry air generator, see
Obligations of Owner [} 13]:
▪ Protective gloves
▪ Safety shoes
▪ Safety goggles
▪ Head protection
► You must observe the relevant accident prevention regulations.
Possible damage to the dry air generator due to incorrect operation.

Lifting the dry air generator from the side damages the housing.
w Only lift the dry air generator from the front or back.
NOTICE
w Only use a fork lift or similar lifting gear to transport the dry air generator.
Fig. 10: Lift and transport the COMPACT swift 80 - 250
30 700-02 EN V0.0.3
4.4 Assembly
4.4.1 Setting Up the Dry Air Generator
Risk of falling due to cables or plastic granulate.

Persons may fall over incorrectly routed pipes, hoses and/or cables as well as plastic
granulate lying on the floor.
WARNING w Pipes, hoses or cables are to be installed and routed in such a way that they do not
represent a risk of tripping, falling or slipping.
w Regularly clear the floor of plastic granulate residue.
w Wear suitable safety shoes.
Warning of falling and overturning parts.

When assembling, servicing, maintenance and decommissioning the device in higher
locations, the device or components may crash.
WARNING w Block off and mark the danger area.
w Do not stand under suspended loads.
w Use suitable work platforms or climbing aids when working on components that cannot
be reached from the ground.
w Never climb on the device or its housing.
w Use suitable transport and lifting equipment for handling.
1. Place the COMPACT swift 80 - 250 on a flat, stable surface.
2. Ensure that the control cabinet and panels on the front and rear walls are accessible at all
times for the performance of maintenance work. Observe minimum clearances around the
COMPACT swift 80 - 250, see Technical Specifications [} 24].
ü The COMPACT swift 80 - 250 is installed.
4.4.2 Connecting the Dry Air Generator

The COMPACT swift 80 - 250 is connected in the following order:
1. Connect compressed air.
2. Connect the power supply.
3. Check the rotational direction of the blowers.
4. Connect the water cooler.
5. Connect the secondary hopper loader.
700-02 EN V0.0.3 31
Connecting compressed air
Danger of injury when connecting compressed air hoses.

Pressurised compressed air hoses may cause injuries due to uncontrolled movements.
w Ensure that compressed air hoses are depressurised before connecting.

CAUTION
w Wear safety goggles and protective gloves.
Quality of the compressed air used.

The compressed air used must be free of oil, water and dust.
NOTICE
1
2
Fig. 11: Connecting compressed air
1 Hose coupling 2 Compressed air hose Ø (outer) = 8 mm
1. Connect a suitable compressed air hose to the supplied hose coupling (8 mm) of COMPACT
swift 80 - 250.
2. Adjust operating pressure, see Technical Specifications [} 24].
ü Compressed air connected.
32 700-02 EN V0.0.3
Connecting the power supply
electrocution.
1. Ensure that the technical specifications of COMPACT swift 80 - 250, see Technical
Specifications [} 24], match those of the switch cabinet.
2. Set the master switch to position “0” and secure it against unauthorised activation.
3. Open the control cabinet, open and remove the front and back cover of the process room.
4. Guide the cable through the cable bushing into the switch cabinet. When laying the cable,
ensure that the cable is at a sufficient distance from hot parts (e.g. blower).
5. Connect the cable on the dry air generator in accordance with the wiring diagram, see Wiring
Diagram [} 83].
6. Check the rotational direction of the blowers.
ü Power supply connected.
Checking the direction of rotation of the blower

Before initial commissioning or change of location of the COMPACT swift 80 - 250 check the
rotational direction of the dry air blower and the conveying blower.
electrocution.
Damage caused by material in the drying bin.

Material in the drying bin can cause damage and faults if the rotational direction of the
blower is not correct.
NOTICE w Check the rotational direction of the blower only when the drying bin is empty or without
the drying bin being connected.
w Have the direction of rotation checked by qualified personnel only, see Personnel
Qualification [} 14].
700-02 EN V0.0.3 33
Fig. 12: Master switch (Emergency Stop switch)

Carry out the following work steps if the engagement point has not yet been cleared:
1. Area around the opened COMPACT swift 80 - 250 to be cordoned off. Ensure that no
unauthorized persons remain at the COMPACT swift 80 - 250 .
2. Remove the rear.
3. COMPACT swift 80 - 250 to be switched on and immediately off again with the master switch,
see separate operating manual of the control.
ð The blowers continue to operate for approx. 90 seconds.
4. Check the rotational direction of the process air blower and the conveying blower.
ð There are arrows on both blowers showing the correct rotational direction of the blower.
ð If one or more blowers rotate in the wrong direction: Turn the master switch to “0” position,
protect against being switched on again and reverse the polarity of the blower. Reversal of
polarity must only be carried out by qualified personnel, see Personnel Qualification [} 14].
5. Turn the blowers to the correct direction: Turn the master switch to “0” position.
6. Reattach the rear.
ü Rotational direction checked.
Fig. 13: Check the rotation direction
34 700-02 EN V0.0.3
Connecting the water cooler

COMPACT swift 80 - 250 is equipped with a water cooler for the regeneration air and process
return air.
4 3 2 1
Fig. 14: Connecting the water cooler
1 Cooling water supply 3 Water hose

2 Cooling water return 4 Water cooler
1. Connect the water supply to the water connection of the cooler with a suitable hose (see
Technical Specifications [} 24]).
2. Connect the water drain to the water connection of the cooler with a suitable hose (see
Technical Specifications [} 24]).
Amount and permissible pressure of cooling water (see following section “Technical
specification”) must be observed.
INFO
Technical specifications
Hose diameter 13 mm
Throughput 0.2 - 1.0 m³/h
Permissible water pressure 0.2 – 10 bar
Recommended water temperature < 25 °C
Weight approx. 4.5 kg
For spare parts, see Dry Air Circuit [} 72].
700-02 EN V0.0.3 35
Connecting the loaders
3 3
1 2
6
5
Fig. 15: Connecting the loaders
1 Material line 4 Primary hopper loader

2 Vacuum line 5 Sensor cable
3 Secondary hopper loader 6 Suction pipe
1. Connect the hoses to the hopper loaders.
2. Connect the sensor to the secondary hopper loader.
ü Hopper loaders connected.
36 700-02 EN V0.0.3
Channelling regeneration air out
Fig. 16: Attaching the hose for regeneration air
1 Regeneration air exit
When you want to route out the exhaust air caused by regeneration using a pipe or hose,
please observe the following points:
Length of pipe and hose.
Design of the diameter of pipe and hose.
NOTICE
Condensation from regenerating.
Too high air resistance in the pipe or hose and the moisture may impair the performance and
function of the dryer.
w Consult your local contact partner at motan.
700-02 EN V0.0.3 37
4.5 Commissioning
electrocution.


w Use suitable transport and lifting equipment for operation.


contact.
38 700-02 EN V0.0.3


WARNING
Fig. 17: Commissioning the COMPACT swift 80 - 250
1 Alarm light (red) 3 Master switch (Emergency Stop switch)

2 Operating panel
1. Before switching on the master switch, check all the connections (electric system, compressed
air and water), see Connecting the Dry Air Generator [} 31].
2. Check connections of process supply air and process return air between the COMPACT swift
80 - 250 and the drying bin.
3. Check the connection of the hopper loaders.
4. Check direction of rotation of the blowers (see Connecting the Dry Air Generator [} 31], section
“Checking the direction of rotation of the blowers”).
5. Open the main tap on the compressed air system.
6. Open the main tap of the water supply.
7. Switch the COMPACT swift 80 - 250 on at the master switch.

ð Control is initialized.
ð The COMPACT swift 80 - 250 is on.
ü The COMPACT swift 80 - 250 can be operated, see Operation [} 40].
700-02 EN V0.0.3 39
5 | Operation COMPACT swift 80 - 250
5 Operation
In addition to this documentation, the separate operating manual of the COMP swift control
control is to be observed.
INFO

Only trained or instructed operating personnel may operate the device. For further information, see
Personnel Qualification [} 14].
5.2 Switching the Dry Air Generator On/Off
5.2.1 Switching On
1. Switch the master switch to position “I”.
2. Switch the COMPACT swift 80 - 250 on via the operating panel, see separate operating
manual of the control.
ü The COMPACT swift 80 - 250 is on.
40 700-02 EN V0.0.3
COMPACT swift 80 - 250 Operation | 5
5.2.2 Switching Off

You can switch off the dry air generator in three ways:
▪ Drying process STOP, for short interruptions;
▪ Disconnecting from the power supply, for longer interruptions and for maintenance and
service work;
▪ Switching off in an emergency.
STOP drying process

► Switch the COMPACT swift 80 - 250 off via the operating panel, see separate operating
ð The dry (process) air blower runs on for approximately 90 seconds.
ü The COMPACT swift 80 - 250 is off.
Disconnecting from the power supply

1. Switch the COMPACT swift 80 - 250 off via the operating panel, see separate operating
ð The dry air blower continues running for approximately 90 seconds.
2. Wait until the blowers come to a standstill.
3. Turn master switch to the “0” position.

ð The power supply is interrupted. No more voltage is applied downstream of the master
switch.
ð The COMPACT swift 80 - 250 is off.
The master switch can also be locked with a padlock (not included in the scope of delivery).
Switching off in case of emergency

The master switch is also the Emergency Stop switch.
► Turn master switch to the “0” position.

ð The power supply is interrupted.
ð The blower stops immediately.
ü The COMPACT swift 80 - 250 is off.
The temperature limiter can trigger after an Emergency stop.
w Reset the temperature limiter if necessary, see Unlocking the Temperature Limiter
[} 66].
NOTICE
700-02 EN V0.0.3 41
5 | Operation COMPACT swift 80 - 250
5.2.3 Switching On Again

The switch on routine is dependent upon the time at which the COMPACT swift 80 - 250 was
switched off.
Switching on again in the regeneration phase

If the dry air generator was switched off in the regeneration phase, the cycle begins again with the
regeneration phase after being switched on again:
▪ The cycle time and monitoring time are reset.
▪ The position of the desiccant cartridges remains unchanged.
Switching on again in the cooling phase

If the COMPACT swift 80 - 250 was switched off in the cooling phase, the cycle is restarted from
the same point after switching on again.
The elapsed times and positions of the desiccant cartridges remain unchanged.
42 700-02 EN V0.0.3
COMPACT swift 80 - 250 Alarm Messages and Troubleshooting | 6
6 Alarm Messages and Troubleshooting
Danger of injury due to incorrect operation, maintenance and service work.

This may lead to incalculable consequences for persons, the unit and the environment.
w Only qualified and authorised technicians may operate the machine and carry out
WARNING maintenance and service work.
In addition to this documentation, the separate operating manual of the COMP swift control
control is to be observed.
INFO
6.1 Alarm Lights Dry Air Generator
Fig. 18: Displays
1 Operator panel 2 Alarm light (red)

Faults on the drying station are displayed by alarm messages on the operator panel and indicated
by the alarm light:
▪ The red alarm light is lit.
700-02 EN V0.0.3 43
7 | Maintenance and Upkeep COMPACT swift 80 - 250
7 Maintenance and Upkeep

Only reliable, trained and instructed maintenance personnel may carry out cleaning, maintenance
and repair work.
Knowledge of the operating manual is required.
For further information, see Personnel Qualification [} 14] and Obligations of Owner [} 13].
7.2 Maintenance Intervals

When defining maintenance intervals, 3-shift operation was assumed.
The actual maintenance intervals depend on the individual conditions.
► Check whether the maintenance intervals have to be reduced for your specific application.
Interval Work to be carried out Personnel
Weekly Discharging the Compressed Air Filter [} 48]. Operating
personnel
Weekly Cleaning Filter for Return Air / Conveying [} 49]. Operating
personnel
Weekly Cleaning the Screen Filter [} 51]. Operating
personnel
Annually Check material inlet. Qualified
personnel
Annually Checking the Proximity Switch and the Outlet Flap [} 53]. Qualified
personnel
Annually Checking the Process Air Pressure Switch [} 55]. Qualified
personnel
Annually Measuring the Resistance of the Regeneration Air Heater Qualified
[} 56]. personnel
Annually Check water cooler. Qualified
personnel
Every three Replacing the Filter Switch Cabinet Fan [} 52]. Qualified
years personnel
Every three Replacing the Temperature Sensor [} 60]. Qualified
years personnel
Every three Replacing the Process Air Pressure Switch [} 62]. Qualified
years personnel
44 700-02 EN V0.0.3
COMPACT swift 80 - 250 Maintenance and Upkeep | 7
7.3 Preparation
electrocution.




WARNING
Danger of burns.
During operation, the device or parts of the device may heat up. There is a danger of burns
in the event of contact with the housing, motors and other parts of the device.
WARNING w Allow the device to cool down before touching it (e.g. for maintenance or operation).
w Observe the warning signs on the device.
Danger of injury when connecting and disconnecting compressed air hoses.

Pressurised compressed air hoses may cause injuries due to uncontrolled movements.
w Ensure that compressed air hoses are depressurised before connecting and
CAUTION disconnecting.
w Wear safety goggles and protective gloves.
700-02 EN V0.0.3 45
Before carrying out any maintenance or service work, observe the safety instructions, see Safety
[} 9], and carry out the following work:
1. Switching off the COMPACT swift 80 - 250.

3. Turn master switch to position “0”.

switch.
4. Allow the COMPACT swift 80 - 250 to cool before work begins.
ü The COMPACT swift 80 - 250 is prepared.
For some maintenance and service work, the COMPACT swift 80 - 250 must be switched
on. This is only possible when the compressed air system is connected.
w For the duration of this maintenance work, connect the compressed air system and turn
on the device.
NOTICE
46 700-02 EN V0.0.3
7.4 Engagement Points for Maintenance and Service
12 2
7 3
4
8
11 9
10 6
13 13
15 14
14
Fig. 19: Access points for maintenance and servicing
1 Regeneration air switching valve 9 Process air filter pressure switch

2 Switching valve for conveying 10 Filter for conveying
3 Desiccant cartridge 11 Return air filter
4 Temperature sensor 12 Filter, switch cabinet fan
5 Water cooler 13 Screen filter
6 Compressed air filter 14 Proximity switch
7 Regeneration air heater 15 Outlet flap
8 Drying air heater
700-02 EN V0.0.3 47
7.5 Maintenance Work To Be Carried Out by the Operating

Personnel
7.5.1 Discharging the Compressed Air Filter
Functional errors
If the level of the condensate tank is above the top mark, then condensate may ingress into
the pressure regulator and cause functional errors (setting errors).
NOTICE w Empty the condensate tank before the condensate reaches the top mark.
Fig. 20: Emptying the condensate tank
1 Button
► Keep the button pressed until the condensate tank is empty.
ü Compressed air filter emptied.
48 700-02 EN V0.0.3
7.5.2 Cleaning Filter for Return Air / Conveying
tract.
1 2
5 4 3
Fig. 21: Remove the filter cartridge
1 Washer 4 Cover lid

2 Filter cartridge 5 Star grip nut
3 Hexagon nut
The return air filter and the filter for conveying can be cleaned or exchanged through the opening in
the front door.
1. COMPACT swift 80 - 250 to be prepared for maintenance, see Preparation [} 45].
2. Unscrew star grip nut and remove cover.
3. Unscrew the hexagon nut and remove the filter cartridge from the housing.
Damage to the unit resulting from contamination of the desiccant

When blowing out the filter housing, impurities may be blown into the desiccant.
For this reason, the filter housing is not to be blown out with compressed air.
NOTICE
700-02 EN V0.0.3 49
4. Vacuum out the filter housing.
5. Clean the filter cartridge inside and/or outside using a vacuum cleaner. If necessary, use a soft
brush in addition to the vacuum cleaner.
Fig. 22: Cleaning the filter cartridge
6. Reassembly is carried out in reverse order.
7. Dispose of the filter cartridge as special waste in accordance with local official regulations, see
Decommissioning and Disposal [} 69].
ü Return air filter is cleaned.
50 700-02 EN V0.0.3
7.5.3 Cleaning the Screen Filter
tract.
1
1
Fig. 23: Clean screen filter
1 Screen filter
1. Prepare the COMPACT swift 80 - 250 for maintenance, see Preparation [} 45].
2. Open toggle-type fasteners on the cover.
3. Open the cover.
4. Remove screen filter.
5. Check the screen filter for damage and wear.
6. In the event of damage or wear, replace the screen filter, see Spare Parts [} 72].
7. Knock dirt off screen filter and remove with a vacuum cleaner.
Always remove the dirt from the inside and clean from the outside inwards.
INFO
8. Insert the screen filter and close the cover.
9. Close the spring clips on the cover.
ü Screen filter cleaned.
700-02 EN V0.0.3 51
7.5.4 Replacing the Filter Switch Cabinet Fan
Danger of injury from rotating fan impeller.

A rotating fan impeller may cause injuries to hands.
w Only replace the filter when the impeller is stopped.

CAUTION
3
4
Fig. 24: Switch cabinet fan
1 Fan impeller 3 Lever

2 Filter 4 Louvered grille
1. Unlock lever.
2. Fold open the louvered grille.
3. Remove filter.
4. Place new filters on the louvered grille.
5. Close the louvered grille until the lever clicks into place.
ü Filter on the switch cabinet fan is replaced.
52 700-02 EN V0.0.3
7.6 Maintenance Work Qualified Personnel
7.6.1 Checking the Proximity Switch and the Outlet Flap
Risk of crushing in the area of the flap when switching on the loader.
When switching on the loader, there is a risk of crushing injuries at the outlet flap.
w Do not reach into the area of the flap when the loader is on.
CAUTION
1 2 3
Fig. 25: Check outlet flap
1 Outlet flap 3 Phase out

2 Weight 4 Proximity switch
1. Prepare the COMPACT swift 80 - 250 for maintenance, see Preparation [} 45].
2. Disconnect the proximity switch and remove the hopper loader.
3. Perform a visual inspection of the following items:

▪ At equilibrium, the outlet flap must be open 6 to 8 mm.
▪ The outlet flap and the weight must be free from deposits.
▪ The outlet flap must be easily movable.
▪ The discharge flap must not be twisted or damaged.
▪ In closed position, the outlet flap must lie flush against the outlet.
▪ The fastening screws of the outlet flap must not be loosened.
▪ Check the outlet flap and screw connection for wear.
▪ The proximity switch must be free from deposits.
▪ The distance between the proximity switch and the weight must be approx. 3 to 4 mm.
4. Connect the proximity switch again.

ð The proximity switch switches (LED at the proximity switch is active).
5. In case of a malfunction, check the distances and the state of the flap again.
6. Replace the proximity switch, if required.
7. Replace worn components.
ü Check the proximity switch and the outlet flap.
700-02 EN V0.0.3 53
7.6.2 Check sensor on the glass outlet
4
3
2
Fig. 26: Sensor on the glass outlet
1 Setscrew 3 Sensor nut

2 Capacitive sensor 4 Vitreous body
2. Disconnect the sensor and remove the hopper loader.
3. Perform a visual inspection of the following items:

ð The sensor must not be twisted or damaged.
ð The sensor must be free from deposits.
ð The sensor must have a space of approx. 5 mm.
4. Loosen the nut from the sensor to configure the height.

ð You can use a screwdriver and the adjusting screw next to the cable to configure the
sensitivity of the sensor. Turning to the left (+) increases the sensitivity. Turning to the right
(-) reduces the sensitivity.
5. Re-attach hopper loader.
6. Connect sensor.
7. Configure sensor.
ð The LED on the sensor illuminates if the material is recognized.
ð The LED on the sensor must go out if no material is available.
8. If the sensor does not function as expected, check the gap between the sensor and the
vitreous body, or reconfigure this.
9. Replace sensor if required.
10. Replace worn components.
ü Request sensor on the glass outlet checked.
54 700-02 EN V0.0.3
7.6.3 Checking the Process Air Pressure Switch
3
2
Fig. 27: Checking the process air pressure switch
1 Pressure switch 3 Pressure side of the pipe connection

2 Negative pressure side of the pipe
connection
2. Open the door of the switch cabinet.
3. Unscrew the hose on the pressure side of the pipe connection.
4. Close the switching cabinet door.
5. COMPACT swift 80 - 250 to be switched on.

ð If the alarm light illuminates and the message “No air flow” appears, the pressure switch is
operational.
ð For replacement of the pressure switch, see Replacing the Process Air Pressure Switch
[} 62].
7. Open the door of the switch cabinet.
8. Screw on the hose on the pipe connection again.
9. Close the switching cabinet door.
10. COMPACT swift 80 - 250 to be switched on.

ð The alarm message disappears.
ü Pressure switch checked.
700-02 EN V0.0.3 55
7.6.4 Measuring the Resistance of the Regeneration Air Heater
electrocution.
The measurement must not be performed with voltage applied.

The power supply does not have to be connected in order to measure the resistance.
NOTICE
If the resistance of the heater is “0 Ohms” or infinite, the heater is to be replaced.

The resistance of the heater should be approx. R = U²/P.
NOTICE
1
2
Fig. 28: Measure resistance
1 Regeneration heater 1 3 Drying bin heater

2 Regeneration heater 2
56 700-02 EN V0.0.3
2. Open the switch cabinet.

ð The electrical system is freely accessible.
3. Measure the resistance at the heater circuit breaker or directly at the terminals, see Wiring
Diagram [} 83].
4. Close the switch cabinet.
ü Resistance of the heater measured.
700-02 EN V0.0.3 57
7.6.5 Replacing the Desiccant
Irritation of the eyes and the respiratory system due to dust.

The activated desiccant produces heat when it comes into contact with water. There is a
danger of burns and drying out of the skin. Irritation and itching of the eyes due to dust is
possible. For further information, see Handling the Desiccant [} 84].
CAUTION
w Wear safety goggles.
Observe safety instructions of the desiccant, see Handling the Desiccant [} 84].
Dispose of used desiccant as special waste in accordance with local regulations, see
Decommissioning and Disposal [} 69].
The manufacturer assumes no liability in the event of contamination of the desiccant by dust
NOTICE or condensates, which are produced by plastic granulate and can lead to a reduction in
drying power.
The used desiccant may contain impurities.
12 34 5 6
Fig. 29: Replace desiccant
1 Cover lid 4 Profile ring with seal

2 Sieve plate 5 Switching valve regeneration air
3 Desiccant 6 Dry air generator cover
58 700-02 EN V0.0.3
2. Remove the rear wall.
3. Mark the hoses and disconnect them from the valve.
4. Disconnect the hoses from the switching valve for regeneration air.
5. Remove the cover from the dry air generator together with the switching valve.
6. Remove the profile ring and take off the cover.
7. Remove the silicone residue on the filler opening, cover and seal.
8. Remove the sieve plate.
9. Vacuum the desiccant out thoroughly using a vacuum cleaner.
ü Desiccant emptied.
Assembly
1. Pour new desiccant in, see Spare Parts [} 72].
2. Insert the sieve plate at the three points around the edge with silicone.
3. Check profile seal for damage. Replace profile seal if damaged.
4. Set cover in place.
5. Fix the cover with the clamping ring.
6. Fasten the cover of the dry air generator together with the switching valve for regeneration air.
7. Attach the hoses to the switching valve for regeneration air.
8. Connect hoses to the valve.
9. Attach the rear wall.
ü Desiccant replaced.
700-02 EN V0.0.3 59
7.6.6 Replacing the Temperature Sensor
electrocution.
1
2
4
5
6
Fig. 30: Replacing the Temperature Sensor
1 Exit regeneration air temperature sensor 5 Screw

32B3
2 Entrance regeneration air temperature 6 Temperature sensor
sensor 32B2
3 Entrance regeneration air temperature 7 Entrance drying bin temperature sensor
sensor 32B1 32B4
4 Nozzle
Four temperature sensors are installed in COMPACT swift 80 - 250. The procedure for removing
and installation described in the following is valid for all temperature sensors.
60 700-02 EN V0.0.3
Removing the temperature sensor

1. Prepare the COMPACT swift 80 - 250, see Preparation [} 45].
2. Remove the rear wall and open the control cabinet.

3. Loosen the screw and pull the temperature sensor out of the nozzle.
4. Disconnect the temperature sensor from the power supply, see Wiring Diagram [} 83].
ü Temperature sensor removed.
Installing the temperature sensor

1. Insert the temperature sensor in the nozzle.
2. Insert the temperature sensor so that the slit is parallel to the air flow direction and is
approximately in the centre of the pipe.
3. Clamp the temperature sensor in this position with the screw and secure.
Ensure that the temperature sensor is not deformed by excessive tightening of the screw.
NOTICE
4. Connect the electrical connections of the temperature sensor.
5. Attach the rear wall and close the control cabinet.
ü Temperature sensor installed.
700-02 EN V0.0.3 61
7.6.7 Replacing the Process Air Pressure Switch
electrocution.
4
1
3 2
Fig. 31: Replacing the pressure switch of the regeneration air heater
1 Hoses 3 Cables
2 Pressure switch 4 Strain relief
1. Prepare the COMPACT swift 80 - 250 for servicing, see Preparation [} 45].

3. Mark the hoses and disconnect them.
4. Remove the cover.
5. Mark the cable and disconnect.
6. Unscrew the strain relief screws.
7. Unscrew the pressure switch.
8. Carry out assembly with the new pressure switch in reverse order.
9. Then carry out a functional test, see Checking the Process Air Pressure Switch [} 55].
10. Close the switching cabinet.
ü Pressure switch replaced.
For further information on the connection of the pressure switch, see Wiring Diagram [} 83].
62 700-02 EN V0.0.3
7.7 Servicing Work by Expert Personnel
7.7.1 Replacing the Switching Valve for Conveying
3 2
Fig. 32: Removal of the switching valve for conveying
1 Flange 3 Switching valve

2 Pneumatic cylinder
Removal
1. Prepare the COMPACT swift 80 - 250 for servicing, Preparation [} 45].
3. Mark the compressed air hoses at the pneumatic cylinders and detach them.
4. Remove the hoses from the switching valve.
5. Undo the screws on the switching valve.
6. Detach the switching valve from the cover.
ü Switching valve removed.
Installation
1. Place the gasket and the switching valve on the cover of the dry air generator and tighten them
with the screws and washers.
ð Make sure the installation position is correct.
2. Mounting is performed in reverse order.
3. Use new screws and spring washers and replace damaged gaskets and sleeves if necessary.
4. Finally, check tightness of the hose connection.
ü Switching valves installed.
700-02 EN V0.0.3 63
7.7.2 Replacing the Process Air Switching Valve
3 2 1
Fig. 33: Removal of the process air switching valve
1 Pneumatic cylinder 3 Switching valve

2 Flange
Removal
3. Mark the compressed air hoses at the pneumatic cylinder and detach them.
4. Loosen the hoses on the switching valve.
5. Undo the screws on the switching valve.
6. Remove the switching valve.
Installation
1. Position the switching valve on the screw holes.
2. Mounting is performed in reverse order.
ü Switching valve installed.
64 700-02 EN V0.0.3
7.7.3 Replacing the Regeneration Air Switching Valves
3 2
Fig. 34: Removal of the regeneration air switching valve
1 Flange 3 Pneumatic cylinder

2 Switching valve
Removal
3. Mark the compressed air hoses at the pneumatic cylinder and detach them.
4. Loosen the hoses from the switching valve.
5. Remove the cover from the dry air generator.
6. Loosen the screws from the switching valve.
7. Detach the switching valve from the cover.
Installation
1. Place the switching valve and the gasket on the cover of the dry air generator and tighten them
with washers and screws.
2. Assembly is done in the reverse sequence to disassembly.
4. Then check tightness of the hose connections.
ü Switching valve installed.
700-02 EN V0.0.3 65
7.7.4 Unlocking the Temperature Limiter
electrocution.
Before unlocking the temperature limiter, the heater must have cooled down.
Depending on the operating situation, cooling down may take several minutes.
NOTICE
Fig. 35: Unlocking the temperature limiter
1 Cap 2 Reset button

3. Wait until the heater has cooled down.
4. Unscrew the cap of the heater cover.
5. Press down the reset button carefully with a small screwdriver.
6. Screw the cap back into place.
7. Close the switching cabinet.
ü Temperature limiter unlocked.
66 700-02 EN V0.0.3
7.7.5 Replacing the Heater
electrocution.
The circuit-breaker has tripped.

Clarify the cause of tripping and eliminate the fault.
w Reset the circuit breaker.

INFO
2 1
Fig. 36: Replacing the heater
1 Heater 2 Gasket

3. Wait until the heater has cooled down.
4. Disconnect the cable of the heater.
5. Loosen the screws and remove the heater from its housing.
6. Assembly is done in the reverse sequence to disassembly.
ü Heater replaced.
For further information on the connection of the heater, see Wiring Diagram [} 83].
700-02 EN V0.0.3 67
7.7.6 Resetting the Circuit-Breaker for the Blower
electrocution.
Reset the circuit-breaker.

Clarify the cause of tripping and eliminate the fault. Reset the circuit-breaker.
INFO
1 2
Fig. 37: Resetting the blower motor circuit-breaker
1 Circuit breaker dry air blower 12Q1 2 Circuit breaker conveying blower 13Q1
1. Prepare the dry air generator for maintenance work, see Preparation [} 45].
2. Open cabinet.
3. Check why the circuit-breaker tripped and eliminate the fault.
4. Reset the circuit-breaker again.
5. For electrical current values, see Wiring Diagram [} 83].
6. Close the switch cabinet.
ü Circuit-breaker reset.
68 700-02 EN V0.0.3
COMPACT swift 80 - 250 Decommissioning and Disposal | 8
8 Decommissioning and Disposal

Only trained or instructed qualified personnel may carry out decommissioning work. For further
information, see Personnel Qualification [} 14].
8.2 Decommissioning the Device

Before beginning decommissioning work, observe the safety instructions, see Safety [} 9].
electrocution.

contact.

w Use suitable transport and lifting equipment for handling.
700-02 EN V0.0.3 69
8 | Decommissioning and Disposal COMPACT swift 80 - 250



WARNING
Irritation of respiratory tract due to plastic granulate.

Plastic granulate may lead to irritations and injuries to the eyes and respiratory tract.
w Wear safety goggles for all maintenance, service and disassembly work.
CAUTION
w Wear nose and mouth protection for all maintenance, service and disassembly work.

3. Turn master switch to the “0” position.

switch.
4. Switch off the electrical supply to the dryer and disconnect from the power supply.
5. Disconnect the COMPACT swift 80 - 250 on the quick coupling of the compressed air system.
6. Disconnect the COMPACT swift 80 - 250 from the water supply.
7. Disconnect the device from the power supply.
ü COMPACT swift 80 - 250 decommissioned.
70 700-02 EN V0.0.3
COMPACT swift 80 - 250 Decommissioning and Disposal | 8
8.3 Disposing of Device and Parts of Device

If parts are replaced during maintenance work, the used parts are to be disposed of in an
environmentally friendly way according to the valid regulations.
If the device is permanently decommissioned and scrapped, the materials are to be separated and
the material groups disposed of in an environmentally friendly way in accordance with the valid
statutory and local regulations.
Metals and aluminium

Metals and aluminium are to be recycled and disposed of correctly in accordance with the valid
local regulations.
Rubber
Dispose of rubber in an environmentally friendly way according to local regulations.
Operating materials
Dispose of operating materials as special waste in an environmentally friendly way according to
local regulations.
Electrical components
Dispose of electrical components in an environmentally friendly way in accordance with the valid
regulations for electronic waste. Observe EC Directive 2012/19/EC (WEEE).
Special waste
Dispose of insulations, filters, hoses and gaskets as hazardous waste in an environmentally
friendly way in accordance with local regulations.
700-02 EN V0.0.3 71
9 | Spare Parts COMPACT swift 80 - 250
9 Spare Parts
All length and diameter measurements are given in millimetres [mm]. In exceptional cases,
this is explicitly stated.
INFO
9.1 Dry Air Circuit
11
4
5
10 7
9 8 3 2 1
Fig. 38: Spare parts dry air circuit
72 700-02 EN V0.0.3
COMPACT swift 80 - 250 Spare Parts | 9
Pos. Pcs. Designation Item no. Comment

1 1 Pressure switch, replacement kit 8800008
2a 1 Heating element 1.5 kW 230 V, COMPACT 80 514041B
replacement kit
2b 1 Heating element 2.5 kW 230 V, COMPACT 150 / 520197B
250 replacement kit
3 1 Heating element 1.5 kW 230 V, replacement kit 514041B
4 n. req Silicone spiral hose, black Ø 46 mm 417277A Delivery quantity
uired 4 m unit
* n. req Hose clamp Ø 32 - 50 mm 513556B Pack of 10
uired
5a 1 Desiccant, replacement kit COMPACT 80 8800001 2 x 3 kg
5b 1 Desiccant, replacement kit COMPACT 150 8800002 2 x 4.5 kg
5c 1 Desiccant, replacement kit COMPACT 250 8800034 2 x 5.5 kg
6 3 Temperature sensor 416516A
7 1 Filter cartridge return air 406633A
8a 1 Blower replacement kit, dry air 8800003
COMPACT 80
8b 1 Blower replacement kit, dry air 8800004
COMPACT 150
8c 1 Blower replacement kit, dry air 8800035
COMPACT 250 (400 V / 50 Hz)
9 1 Water cooler replacement kit 8800005
10 1 4-way valve replacement kit 8800006
11 1 Switching valve regeneration air, replacement kit 8800007
* Not shown in figure
700-02 EN V0.0.3 73
9.2 Conveying Circuit
6
3
5 2
Fig. 39: Spare parts conveying circuit
Pos. Pcs. Designation Item no. Comment

1 1 Conveying blower COMPACT dryer, 8800010
replacement kit
2 1 Filter cartridge for conveying 415041A
3 n. PVC hose Ø 38 mm 8400180 Delivery quantity 15
requir m piece
ed
* n. Hose clip Ø 32 - 50 mm 513556B Pack of 10
requir
ed
4 1 Switching valve for conveying, replacement kit 8800009
5 1 Suction box Ø 38 mm 515958B
6 1 COMPACT dryer, hopper loader 8500013
* Not shown in figure
74 700-02 EN V0.0.3
1
5
4 3 2
Fig. 40: Spare parts hopper loader
Pos. Pcs. Designation Item no.

1 1 Cover lid 903129A
2 1 Proximity switch, replacement kit 8800012
3 1 Accessories, replacement kit 512944B
4 1 Outlet flap, replacement kit 8800011
5 1 Hopper loader screen filter 903130A
700-02 EN V0.0.3 75
4
1
2
Fig. 41: Spare parts hopper loader with glass outlet

1 1 Cover lid 903129A
2 1 Capacitive sensor 8400408
3 1 Vitreous body with sensor 8500254
4 1 Hopper loader screen filter 903130A
76 700-02 EN V0.0.3
9.3 Operator Controls
Fig. 42: Spare parts operating elements

1 1 Alarm lamp, replacement kit 8800030
2 1 Operator panel, replacement kit 8800013
3 1 Main switch 903896A
700-02 EN V0.0.3 77
9.4 Pneumatic Parts
Fig. 43: Spare parts pneumatic system
Pos. Pcs. Designation Art.-No.

1 1 Valve block, replacement kit 8800015
2 1 Solenoid valve, replacement kit 8800016
3 1 Compressed air filter, replacement kit 8800017
78 700-02 EN V0.0.3
9.5 Dew Point Display / Dew Point Control
3
1
Fig. 44: Spare parts dew point control

1 r.m. Hose PTFE Ø 4x1 404460 A
2 1 Dew point sensor 903045 A
3 r.m. Hose PU Ø 4x1 403705 A
700-02 EN V0.0.3 79
9.6 Pneumatic Suction Box Ø 38 mm

1
Fig. 45: Spare parts pneumatic suction box

1 1 Pneumatic suction box Ø 38 mm 8500014
80 700-02 EN V0.0.3
COMPACT swift 80 - 250 Appendix | 10
10 Appendix
10.1 Bulk Material Classification

The behaviour of the plastic bulk material in conveying, mixing and drying applications greatly
differs, depending on its:
▪ grain size,
▪ grain shape,
▪ cohesion,
▪ bulk density and
▪ other properties.
For some special plastic bulk materials, devices have been developed which enable the processing
of these plastics.
The classification of plastic bulk materials is used to describe the capacity and the limits of the
device.
Motan classification of plastic bulk materials

Motan specification Properties from DIN ISO 3435
Type General Grain Grain Cohesion Properti Bulk density Examples
designation size shape es [kg/dm³]
Max.
Temperature
[°C]
G1 free-flowing 2 – 5 I, II, IV, 2, 3 n, w 0.4 – 0.85 ABS, PA, PE
V
G2 free-flowing 5 – 20 W 2, 3 n, w 0.85 – 1.5 Glass fibres
G3 shooting 1–5 IV 1 n, w 0.85 – 1.5 Hollow glass
spheres
G5 poorly flowing 3 - 10 IV, V 4, 5 n, w 0.7 – 0.8 TPU
R0 free-flowing 2-5 I, II, IV, 2, 3 n, w 0.4 – 0.85 ABS, PA, PE
V
R1 free-flowing 5 – 20 III 3,4 n, t, w 0.3 - 0.5 Shavings, flakes
R2 poorly flowing 5 – 20 III 5 n, w 0.2 – 0.4 ABS-PC
P1 fluidizing <1 I, III 1 n, t, w 0.2 – 1.5
P2 free-flowing 2–5 I 3,4 n, t, w 0.2 – 1.5 Uncoated chalk,
semolina
P3 poorly flowing 1–2 I 5 n, t, w 0.2 – 2 Coated chalk,
talcum
P4 sticky 2–5 I, III 5, 6 n, t, w 1.25 – 4 Carbon black
P5 poorly flowing 1–5 I, III 4, 5 n, t, w, s 0.4 – 1.5 Plastic powder
F1 self-lubricating - 0.1 – 10 s 140
F2 non-self- - 0.1 – 1.5 s 70
lubricating
700-02 EN V0.0.3 81
10 | Appendix COMPACT swift 80 - 250
Type
G Granulate P Powder
R Regrind F Liquids
Grain shape
I Sharp edges All edges similar or equally long (e.g. dice).
II Sharp edges One edge clearly longer than the other two (e.g. prism, blade).
III Sharp edges One edge significantly shorter than the other two (e.g. plate, scales).
IV Round edges All edges similar or equally long (e.g. sphere).
W Round edges One edge clearly longer than the other two (e.g. cylinder, rod).
VI Fibrous, filamentous, curl-shaped, twisted
Cohesion
1 The material can hover in the air and 4 Hard flowing material.
flows like liquid. Slope angle α between 45° and 60°.
2 Easy flowing material. 5 Coherent material.
Slope angle α between 0° and 30°. Slope angle α greater than 60°.
3 Normally flowing material. 6 Non-slipping material, catching, bridging,
Slope angle α between 30° and 45°. hard to separate.
Properties
n Expanding under pressure or by itself s combustible
(non-flowing)
o abrasive t dusting (dust content > 0.01 % by weight)
p corrosive w hygroscopic
r explosive k outgassing hydrocarbons
82 700-02 EN V0.0.3
10.2 Pneumatic Diagram
3 4 5
7 2
Fig. 46: Pneumatic diagram
1 Throttle 5 Switching valve for conveying

2 Pressure switch 6 Compressed air filter
3 Dry air switching valve 7 Compressed air solenoid valve
4 Regeneration air switching valve
10.3 Wiring Diagram

The wiring diagram is attached to this operating manual as an external document.
700-02 EN V0.0.3 83
10 | Appendix COMPACT swift 80 - 250
10.4 Handling the Desiccant

When handling the chemicals used as desiccants, observe the following information:
Replacing the desiccant

When replacing the desiccant, only use the desiccant specified in the spare parts.
Physical and chemical properties

Shape: Spherical, firm
Colour: Beige
Odour: Odourless
State change: Melting point to 700 °C (1290 °F)
Solubility in water: Insoluble (20 °C (70 °F))
PH value: Approx. 11 (at 100 g/l H2O at 20 °C (70 °F))
Additional details: Non-combustible
Dangerous components
This alkali aluminium silicate does not contain any hazardous substances in the sense of
EU directive 88/379/EEC.
Possible hazards
▪ The activated product produces heat when it comes into contact with water. Skin burns
possible.
▪ The product has an absorbent effect and can cause drying of skin in the event of long
exposure.
▪ When the MAC value (6 mg/m3 in fine dust) is exceeded, a mechanical overload of the
respiratory tract is possible.
▪ Irritation and chemical burn of eyes possible.
84 700-02 EN V0.0.3
Protective equipment
Wear protective gloves.
NOTICE
Wear safety goggles.
NOTICE
Wear nose and mouth mask.
NOTICE
First aid
Eye contact: Immediately rinse eyes for at least 15 minutes under running water with the
lid open as far as possible.
In the event of skin Wash with water.
contact:
If ingested: After ingestion, drink plenty of water.
If inhaled: Go into fresh air.
Additional details: The product produces heat when it comes into contact with water. The used
product may contain dangerous impurities. Symptomatic treatment according
to impurity.
Disposal
Used desiccant may contain impurities. Dispose of the used desiccant as special waste in
accordance with local regulations.
For further information, please consult your contact partner at motan.
700-02 EN V0.0.3 85
Notes
Notes
SO WHERE CAN YOU FIND US?
WORLDWIDE.
= motan company with production

= motan company
= sales & service partner
AFRICA • ASIA • EUROPE • NORTH AMERICA • SOUTH AMERICA • OCEANIA
www.motan-colortronic.com

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Dry Air Generator

COMPACT swift 80 - 250

CE-Translation of the original operating manual

1 User Instructions ............................................................................................................................................ 6

3 Product Description ..................................................................................................................................... 21

4 Assembly and Commissioning ................................................................................................................... 29

6 Alarm Messages and Troubleshooting ...................................................................................................... 43

6.1 Alarm Lights Dry Air Generator............................................................................................................ 43

7 Maintenance and Upkeep ............................................................................................................................ 44

8 Decommissioning and Disposal ................................................................................................................. 69

1.1 Serial Number

1.2 Purpose and Target Group

1.3 Warranty and Liability

1.4 Validity of the Operating Manual

1.5 Conventions of Presentation

Individual operating instructions are displayed as follows:

2.2 Action-Related Warnings

DANGER w Always observe these measures to prevent such danger.

WARNING w Always observe these measures to prevent such danger.

w List of all measures which must be taken to prevent consequences.

2.3 Symbols Used

General warning, danger zone, caution

Irritation of respiratory tract

Warning of hazardous electrical voltage, electrocution

Risk of falling and tripping

Warning of possible damage to device

Supplementary information, tip

2.4 Intended Use

Foreseeable misuse, limits of permitted use

2.5 Obligations of Owner

Personal protective equipment

Wear head protection.

Wear safety goggles.

Wear nose and mouth mask.

Wear protective gloves.

Wear safety shoes.

2.6 Personnel Qualification

2.7 Hazards Relating to Assembly and Commissioning

2.8 Dangers when Handling

2.9 Hazards Relating to Maintenance and Service

2.10 Dangers during Decommissioning and Disposal

2.11 Sources of Danger

Fig. 1: Sources of danger

1 Electrical system / switch cabinet 4 Drying air heater

Electrical switch cabinet

Regeneration air heater and process air parts

w Observe the warning signs on the device.

Affected parts of the dry air generator:

CAUTION w Wear safety goggles and protective gloves.

w Wear nose and mouth mask.

2.12 Protective Devices

DANGER w Ensure correct functioning of protective devices after assembly.

Fig. 2: Protective devices

The master switch is simultaneously the Emergency Stop switch.

2.13 Warning Signs

Position of the warning signs

Fig. 3: Position of the warning signs

Meaning of the warning signs

Burns from hot surfaces.