Compressed Air Hopper Bank Dryer

Compressed Air Hopper Bank Dryer
TABLE OF CONTENTS
Principle of operation of CAHB……………………………………………………….2
Installation instructions……………………………………………..……………..…..3
Features of ADC Control ………………………………………………………………4
Menu definitions of ADC control
•
Display of hopper status ………………………………………………………6
•
Setting hoppers process temperature ………………………………………7
•
Turning hoppers on/off………………………………………………………..8
•
Alarm Settings………………………………..…………………….................9
•
System Setup …………………………………………………………………12
•
Loader Settings ………………………………………………………………..13
•
Diagnostics and error messages…………………………………………….15
Alarm codes and Solutions………………………………………..…………..……...9
APPENDIX
Temperature Setback Theory and definitions ……………………………22
DRI-AIR INDUSTRIES, INC.
16 Thompson Road
East Windsor, CT 06088
Tel (860) 627-5110
Fax (860) 623-4477
www.dri-air.com
1
COMPRESSED AIR HOPPER BANK DRYER OPERATING MANUAL
Principle of operation:
The DRI-AIR compressed air hopper bank dryer (CAHB) uses compressed air to
provide a source of dry air and to circulate the dry air through the material in a
closed loop system to dry plastic resin. Normal plant compressed air is presumed
to be relatively dry and at or near room temperature. In order to reach -40 degree
dew point process air, the compressed air supply has to be no more than +40
degree dew point at 90 psi. If it is above this level, additional drying of the air will
be required or the ultimate dew point will be above the -40 degree level.
The compressed air is first dried in the CAHB with a membrane dryer capable of
lowering the pressure dew point 40 degrees at the set flow rate. The dried
compressed air is then expanded to atmospheric pressure through the line vac
that is used to move the air through the system. The dew point is lowered to -40
during the expansion and is mixed with the air returning from the hopper. See the
flow diagram on page--.
The air flow is generated by the line vac and moves the air from the top of the
hopper through the heater and through the hopper filled with material. The air
flow is set at the factory via the flow control located prior to the line vac. It is
important that this flow control is not readjusted or the ultimate dew point may not
be achieved.
The DRI-AIR ADC control is used to control the temperatures of the hoppers;
alarms and optional temperature set back functions.
2
INSTALLATION:
ELECTRICAL:
The CAHB is available in 220 volt electrics only. A cord is provided, however the
customer will have to supply the proper plug for his outlet.
COMPRESSED AIR:
NOTE: DO NOT ADJUST THE INTERNAL REGULATOR OR FLOW VALVE
The CAHB is supplied with air filtration to protect the membrane dryer form most
factory compressed air supplies. If your supply has water or oil in it, install a
coalescent filter to remove these contaminates prior to the CAHM.
Connect the compressed air line to the ¼” NPT fitting on the lower left side of the
enclosure. Connect the air using an air line of ¼” capable of 4 CFM. The air
supply must be at least 90 psi for best operation. If the supply is in excess of 110
psi, install a pressure regulator prior to the CAHM and set it for 90 psi.
The CAHB incorporates a pressure switch to prevent the dryer from operating
without the compressed air connected and operating. If the compressed air is not
present, the dryer will not operate and an error message AIR PRESS will appear
on the screen.
3
ADC CONTROL FOR HOPPER BANKS
FEATURES:
The adaptation of the exclusive ADC control from DRI-AIR Industries to control
the hopper bank systems allows the operator more options to select from. In
addition to individual temperature control of each hopper, the new control has the
following features:
•
Individual temperature control of each hopper.
•
On or off control for each hopper.
•
Temperature setback for each hopper
•
Individual timers for each hopper indicating length of drying.
•
Log of events for easy troubleshooting.
•
Individual high temperature alarms.
•
Display of all temperatures within system.
•
Temperature calibration for each hopper.
•
Selection of degrees F or C.
•
Date and time indication with battery backup.
•
Open thermocouple detection.
4
MAIN SCREEN:
The main operating screen is shown as follows:
Hopper *1 - On
Process
180F
Setpoint
(180)
Drying Time 01:20:34
Asterisk * indicates setback mode has been
actuated.
Parenthesis ( ) indicates temperature has
been set back.
Drying time in hours:minutes:seconds.
To display each hopper status, press arrow up or down.
5
OPERATION OF HOPPER BANK ADC CONTROL
DISPLAY OF HOPPER STATUS:
The display screen shows the status of each hopper in the bank. Each individual
screen displays:
• Hopper number, setback on/off, hopper on/off
• Actual process temperature
• Setpoint and whether hopper is in setback or not
• Time material has been drying
To display each hopper status screen, use the arrow up ↑ or
arrow down ↓ keys.
The main operating screen is shown as follows:
Hopper *1 - On
Process
180F
Setpoint
(180)
Drying Time 01:20:34
Asterisk * indicates setback mode has bee
actuated.
Parenthesis ( ) indicates temperature has
been set back.
Drying time in hours:minutes:seconds.
6
SETTING THE TEMPERATURE:
• Press the TEMP SET button or MENU and arrow down key.
• Select the hopper that you want for a temperature change by
selecting the correct number.
• Key in new value (the number will be flashing) and press
ENTER.
• Repeat for other hoppers.
Main Menu
Set Process Temp
↑ or ↓ to Scroll
Select Hopper
1=hopper1 2=hopper 2
3=Hopper3 4=Hopper4
Process Temp =180
Key in new value
Enter key to accept
Or Clear to Exit
7
TO TURN A HOPPER ON OR OFF:
• Press MENU button and arrow down ↓ to the second screen
• Press ENTER, select hopper and press ENTER.
• Press 1 to turn hopper on and 2 to turn hopper off.
• Turn on the corresponding toggle switch for the hopper
Hopper on / off switches
Main Menu
Hopper Control
↑ or ↓ to Scroll
Select Hopper
1=hopper1 2=hopper 2
3=Hopper3 4=Hopper4
Hopper Control
Press 1 to turn ON
Press 2 to turn OFF
CLEAR to exit
8
ALARM SETTINGS:
This screen allows the operator to adjust the HI-TEMP alarm delta for
each hopper. This is a delta setting or the amount over setpoint to
actuate the alarm. It is factory set at 50 degrees F. The hopper bank
will be shut off if the alarm is actuated.
• Press MENU button and arrow down ↓ to the ALARM screen.
• Press ENTER, select hopper, and press ENTER.
• Key in new HI-TEMP ALARM DELTA value and press ENTER.
Main Menu
Alarm Setup
↑ or ↓ to Scroll
Use Enter to Select
Select Hopper
1=hopper1 2=hopper 2
3=Hopper3 4=Hopper4
Hi-Alarm Delta =50
Key in new Value
Enter key to accept
Or CLEAR to Exit
9
TEMPERATURE SETBACK SETTINGS: (Option)
The temperature setback feature prevents over drying of the material
by reducing the process temperature after a period of time form start
up of the hopper. Activation of this feature is indicated by an asterisk
* before the hopper number on the main screen.
This screen allows the operator to turn on/off this feature, set a new
setback delta, and input the time for drying.
• To select this feature, press the MENU button and arrow down
↓ to the SETBACK SETUP screen.
• Press ENTER, select hopper and press ENTER.
• To turn this feature on or off, press ENTER at the SETBACK
ON OFF screen. Press 1 to turn on and 2 to turn off.
• To change the setback delta setting, press ENTER at the
SETBACK DELTA screen. Key in new value and press ENTER.
• To change the drying time, press ENTER at the SETBACK
INHIBIT screen. Key in new drying time in minutes and press
ENTER. This time is adjustable from 10 to 360 minutes.
Main Menu
Setback Setup
↑ or ↓ to Scroll
Select Hopper
1=hopper1 2=hopper 2
3=Hopper3 4=Hopper4
Main Setback Menu
Setback On Off
↑ or ↓ to Scroll
Main Setback Menu
Press 1 to turn ON
Press 2 to turn OFF
10
Main Setback Menu
Setback Delta = 30
Setback Delta
Key in new value
↑ or ↓ to Scroll
Enter key to accept
Main Setback Menu
Setback Inhibit=120
Setback Inhibit
Key in new value
↑ or ↓ to Scroll
Enter key to accept
11
SYSTEM SETUP:
This screen is used to select between degrees F or C and to calibrate
the temperature for each hopper.
To calibrate the temperature, remove the connector for the
thermocouple in question. Place a standard in place of the
thermocouple and read the displayed temperature. Enter the
difference in the Temp Cal screen. A minus entry will display a lower
temperature.
• Press the MENU button and arrow down ↓ to THE SYSTEM
SETUP screen.
• Press ENTER to select SYSTEM SETUP
• Press ENTER to select Degrees F or C.
• Press 1 for degrees F and 2 for degrees C.
• Press ENTER to select.
To calibrate each hopper, scroll down from the Degrees F or C
screen to the TEMP CALIBRATION screen.
• Press enter to select TEMP CALIBRATION.
• Select the hopper, press ENTER, and change the deviation
required to calibrate the temperature and press ENTER. The
up and down arrows are used to make the change.
12
LOADER SETTINGS:
If your hopper bank includes a loading system to load the molding
machine, this screen allows changes to the load and delay time. The
load time controls the amount of material sent to the receiver. The
delay time allows time for the receiver to drop all of the material into
the see through chamber.
• When in the SYSTEM SETUP screen, arrow down to Loader
On Time and press ENTER.
• Key in the amount of load time in seconds and press ENTER.
• To change the delay time, arrow down to the Loader Delay
screen and press ENTER.
• Key in delay time in seconds and press ENTER.
Main Menu
System Setup
↑ or ↓ to Scroll
Main System Menu
Degrees F or C
↑ or ↓ to Scroll
Use Enter to Select
Select F or C
Press 1 for F
Press 2 for C
Main System Menu
Select Hopper
Set Temp Cal =1
Temp Calibration
1=hopper1 2=hopper 2
↑ or ↓ to Change
↑ or ↓ to Scroll
3=Hopper3 4=Hopper4
Enter key to accept
Main System Menu
Loader ON Time=25
Loader On Time
Key in seconds
↑ or ↓ to Scroll
Enter key to accept
Main System Menu
Loader delay = 10
Loader Delay
Key in seconds
↑ or ↓ to Scroll
Enter key to accept
13
Main Menu
Factory Settings
↑ or ↓to Scroll
THIS SCREEN REQUIRES A
PASSWORD TO ACCESS AND
IS USED BY THE FACTORY ONLY.
14
DIAGNOSTICS:
This screen is used for trouble shooting a problem. The View Event
Log shows the last 128 events and the time of the event. All
temperatures can be accessed using the View Temps screen. The up
and down arrows are used to access the different values.
• Press the MENU button and arrow down to the DIAGNOSTICS
screen.
• Press ENTER to select.
• Press enter to select the event log. Arrow down to see the
preceding events.
• Arrow down to the View Temps screen and press enter.
• Arrow down to see all thermocouple temperatures.
Main Menu
Diagnostics
Main Diag Menu
View Event Log
↑ or ↓ to Scroll
↑ or ↓ to Scroll
Event Log
# 1= System Start
Thu 10:35
↑ or ↓ to Scroll
Main Diag Menu
View Temps
Temperatures
H1 Process = 180
↑ or ↓ to Scroll
↑ or ↓ to Scroll
15
ERROR MESSAGES
There are a few conditions that will cause an alarm condition. Check
the following areas:
• Clean or replace return air filter. Turn off the dryer while
cleaning! Blockage in this area will affect the performance of
the dryer and hopper bank and may cause an alarm. There are
three filters used on your hopper bank, one for each hopper
Dryer filter location (3) one for
each hopper
• Check that all hoses are connected and intact. Ground all
material conveying hoses with the imbedded copper wire.
• Check the inlet and outlet of the hopper for proper airflow.
16
“P1 Hi Temp”
Indicates the dryer has been shut down because of a high
temperature condition of the process heater.
• Check the airflow to the hopper in question.
• Check the solid-state relay for operation.
• Check thermocouples and connectors.
“Safety Error”
Indicates that the blower overload has tripped.
• Check the setting of the overload and condition of the blower.
• Check all 3 legs of incoming power.
“Air Pressure” Indicates no air pressure for those models that require
an air supply.
• Check to make sure there is air supply to the dryer.
• Check pressure switch
17
“Loader Alarm”
Indicates the optional closed-loop loader has tried 3 times to load the
receiver and no material has been loaded.
• Check to see if the material supply is adequate and all hoses
are in the correct location.
• To reset the alarm after fixing the problem, either satisfy the
proximity sensor or turn the main power off and back on“
“Repair Required” Indicates a failed heater or solid-state relay upon startup.
• Check all heaters and solid-state relays for proper operation
18
OPERATIONAL MENU SELECTION SUMMARY
You can access the menu screens directly by pressing the menu key:
Press MENU button and arrow down to access screens.
Press ENTER to access screens within a menu selection.
Main Menu
Set Process Temp
↑ or ↓ to Scroll
Main Menu
Hopper Control
↑ or ↓ to Scroll
Main Menu
Setback Setup
↑ or ↓ to Scroll
Main Setback Menu
Setback On Off
↑ or ↓ to Scroll
Select Hopper
1=hopper1 2=hopper 2
3=Hopper3 4=Hopper4
Select Hopper
1=hopper1 2=hopper 2
3=Hopper3 4=Hopper4
Process Temp =180
Key in new value
Enter key to accept
Or Clear to Exit
Hopper Air Control
Press 1 to turn ON
Press 2 to turn OFF
CLEAR to exit
Select Hopper
1=hopper1 2=hopper 2
3=Hopper3 4=Hopper4
Main Setback Menu
Press 1 to turn ON
Press 2 to turn OFF
Main Setback Menu
Setback Delta = 30
Setback Delta
Key in new value
↑ or ↓ to Scroll
Enter key to accept
Main Setback Menu
Setback Inhibit=120
19
Setback Inhibit
Key in new value
↑ or ↓ to Scroll
Enter key to accept
Main Menu
Seven Day Timer
THIS SCREEN IS NOT USED FOR
↑ or ↓ to Scroll
HOPPER BANKS
Main Menu
Alarm Setup
Select Hopper
1=hopper1 2=hopper 2
↑ or ↓ to Scroll
3=Hopper3 4=Hopper4
Hi-Alarm Delta =50
Key in new Value
Enter key to accept
Or CLEAR to Exit
Use Enter to Select
Main Menu
System Setup
↑ or ↓ to Scroll
Main System Menu
Degrees F or C
Use Enter to Select
↑ or ↓ to Scroll
Main System Menu
Select Hopper
Temp Calibration
1=hopper1 2=hopper 2
↑ or ↓ to Scroll
3=Hopper3 4=Hopper4
Select F or C
Press 1 for F
Press 2 for C
Set Temp Cal =1
↑ or ↓ to Change
Enter key to accept
20
Main System Menu
Loader ON Time=25
Loader On Time
Key in seconds
↑ or ↓ to Scroll
Enter key to accept
Use Enter to Accept
Main System Menu
Loader delay = 10
Loader Delay
Key in seconds
↑ or ↓ to Scroll
Enter key to accept
Main Menu
Factory Settings
↑ or ↓to Scroll
THIS SCREEN REQUIRES A
PASSWORD TO ACCESS AND
IS USED BY THE FACTORY ONLY.
Main Menu
Diagnostics
Main Diag Menu
View Event Log
↑ or ↓ to Scroll
↑ or ↓ to Scroll
Event Log
# 1= System Start
Thu 10:35
↑ or ↓ to Scroll
Main Diag Menu
View Temps
Temperatures
H1 Process = 180
↑ or ↓ to Scroll
↑ or ↓ to Scroll
21
TEMPERATURE SETBACK THEORY
The optional temperature setback feature for the ADC control
prevents over drying of the material due to excessive residence in a
drying hopper at the suggested drying temperatures. This is
especially true for Nylon, which can be over dried leading to
degradation of the resin resulting in molding problems and brittle
parts. It can also be useful in hopper bank applications to dry material
to specific moisture levels.
When the temperature setback is actuated, a timer is started allowing
the material to dry for a specified time. Once this time has expired,
the return temperature from the hopper is compared to the process
temperature using a thermocouple located in the return port of the
hopper. If the return temperature is within a specified delta from the
process temperature, the process temperature is reduced by the
programmed setback delta. This indicates that the material has been
dried and further drying is not required.
The process temperature is restored to the set temperature when the
return temperature reaches 100 degrees F indicating new material
has been added and needs drying. The process temperature will
remain at the set temperature until the return temperature again
reaches the delta from the setpoint. The process temperature will
then be setback by the setback delta.
22
DEFINITIONS:
Setback Delta
The Setback Delta setting is the amount below the setpoint that the
process temperature will be reduced by. If the process temperature is
set to 250 F and the setback delta is set at 30, the setback
temperature will be 220 F. Our experience has shown the factory
setting of 30 for the setback delta is ideal for most resins.
Caution: Do not enter a Setback Delta that will reduce the setback
temperature below 140 degrees F, as the dryer will not maintain temperatures
below 140F.
Setback Inhibit
The Setback Inhibit setting is the time in minutes to dry the material
before the setback can be initiated. The setting has a range of 10 to
360 minutes and is factory set for 120 minutes. The inhibit time is
started when the hopper is turned on, a new drying temperature is
entered, or the setback option has been selected.
Setback display:
Selection of the setback option is shown on the main screen by an
asterisk * prior to the hopper number.
Parenthesis around the setpoint temperature indicates the
temperature has been setback. The setback temperature is then
displayed.
23
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