A18 ~ 100PDII, H18 ~ 100PDII, ARID-X 18 ~ 100PDII, ARID

A18 ~ 100PDII, H18 ~ 100PDII, ARID-X 18 ~ 100PDII, ARID
DRI-AIR INDUSTRIES, INC.
A-PDII & H-PDII
OPERATING MANUAL
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 1
DRI-AIR INDUSTRIES, INC.
DRI-AIR INDUSTRIES, INC.
16 THOMPSON ROAD
P.O. BOX 1020
EAST WINDSOR, CT 06088-1020
Tel. (860) 627-5110
FAX (860) 623-4477
Internet http://www.dri-air.com
e-mail: [email protected]
Page 2
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
CONTENTS
DRYER OPERATION/FEATURES --------------------------- 4
AIR FLOW SCHEMATIC FOR APD II DRYERS --------- 8
AIR FLOW SCHEMATIC FOR HPD II DRYERS --------- 9
DRYER CYCLE DIAGRAM ---------------------------------- 10
PLC STANDARD ELECTRICS ----------------------------- 11
INSTALLATION PROCEDURE ----------------------------Electrical Connection ------------------------------------Check for correct motor rotation ----------------------Compressed Air Connection ----------------------------
12
12
12
12
START-UP PROCEDURE ----------------------------------Standard Electrics ----------------------------------------Microprocessor Control ---------------------------------Operation ----------------------------------------------------
13
13
14
15
CLOSED LOOP LOADING SYSTEM --------------------Receiver Installation -------------------------------------Vacuum Check --------------------------------------------Adjustment of Sensors ----------------------------------Material Flow Adjustment --------------------------------
16
16
17
17
18
BASIC TROUBLE SHOOTING for
CLOSED LOOP LOADING SYSTEM --------------------- 19
Material will not feed. ------------------------------------- 19
CLL MAINTENANCE ------------------------------------------ 19
Daily Maintenance: ---------------------------------------- 19
Monthly Maintenance: ------------------------------------ 19
AUGER FEED MIXING SYSTEM -------------------------- 20
Auger Feed SETUP --------------------------------------- 20
Auger Feed Operation ------------------------------------ 21
Auger Feed Maintenance -------------------------------- 21
Mix System Sampler Option ---------------------------- 21
DRYER OPERATION-TROUBLE SHOOTING --------- 22
DRYER OPERATION-DETAILED DIAGNOSIS -------- 23
DRI-AIR ROTARY ZONE VALVE --------------------------- 24
PARTS LISTS
ARID-X 18 - 35 APD 1-4 and HPD 1-4 --------------- 25
ARID-X 50 - 100 APD 5-9 and HPD 5-9 ------------- 26
PROPORTIONAL MIX FORMULAS ---------------------- 27
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 3
DRI-AIR INDUSTRIES, INC.
DRYER OPERATION/
FEATURES
The PDII model dryer is a portable, dual hopper, self
contained resin drying system. The PDII dryer series was
developed to accommodate the customer who utilizes
multiple resins and wishes to minimize mold press downtime by drying the resin prior to the material change-over.
The PDII dryer can also be configured to allow the user to
simultaneously dry and feed virgin and regrind, or two
different resins.
Separate drying controls for each hopper give the operator
the flexibility to dry at two different temperatures or allow the
user to operate only one hopper to facilitate the cleaning
and filling of the other hopper. These controls automatically
divert air flow to and from each hopper and require no
operator intervention other than actuating the control switch
and setting the temperature.
Easy access to each hopper interior and takeoff box make
cleaning quick and simple.
Each dryer can be equipped with various material feed and
loading options which include:
Single and Dual Closed Loop Loaders that prevent
material contamination by utilizing desiccated air to
feed material to the receiver on the mold press.
Vacuum and DAC loaders that allow greater flexibility
when dealing with a large volume of material.
Fixed and Variable Speed Auger Mixing packages
that allow the user to blend virgin and regrind, and
typically outperform standard proportional mixing
systems that rely on vacuum and time for control.
Quick Disconnect material Feed Lines that allow for
easy swapping of material lines between hoppers.
These options are discussed in more detail later in this
manual.
Page 4
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
ARID-X Design
The ARID-X dryer series is a dual bed design that provides
a constant supply of dry air to the material hopper. While
one bed is removing moisture from the process air the
other is regenerating by heating the desiccant to a high
temperature. Once the regenerated bed cools down, the
Zone Valve switches the airflow, and the newly regenerated
bed is used to desiccate the process air stream. The
saturated bed is now regenerated in the same manner,
completing the regeneration cycle. The cycle is depicted
Page 10.
The airflow design of the ARID-X dryers makes the
regeneration cycle more efficient because we utilize a
small amount of the desiccated process air rather than
ambient air to regenerate the desiccant bed. This reduces
the impact of the high moisture content of the ambient air,
which would contaminate the desiccant bed, and allows the
dryer to attain a lower dew point. Please see the Air Flow
Schematic on Page 8.
HP4-X Design
Our patented HP4-X design incorporates 4 desiccant beds
where two are stacked, one over the other. This nearly
doubles the amount of desiccant available for drying the
process air stream, and because of the tower design, the
dryer is able to regenerate the desiccant in the same time
as our ARID-X series. This allows the dryer to operate in
very high humidity conditions without affecting the process
air dew point. In fact, this design produces dew point levels
of – 40’ to -80’ C for faster more complete drying of your
material. Please see the Air Flow Diagram on Page 9.
Hopper Design
Dri-Air’s ”all stainless” hopper design utilizes a stainless
steel inner shell surrounded by a stainless steel jacketed
insulation layer. The easily removable stainless steel
spreader cone promotes quick cleaning for material
changes as well as proper material flow to ensure that the
material is dried efficiently and no dried material is left at
the hopper bottom that needs to be fed out prior to
operating. You must ensure that your hoppers are
adequately sized for your usage rate and are kept filled, to
ensure that you have sufficient time to dry the material.
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 5
DRI-AIR INDUSTRIES, INC.
Closed Loop Loading System
Dri-Air’s closed loop loading system utilizes a dedicated
blower, small receiver, filtration system and desiccated air
to move the material from the dryer hopper to the molding
machine. This eliminates the possibility that your material
will be contaminated with moisture as with some other
material transfer systems, helping to eliminate defects
resulting from moisture contamination.
The PDII series dryers have an additional option of a Dual
Closed Loop Loading System. This allows the operator to
feed different materials from each hopper to two separate
presses or load the material hopper and molding press
receiver with the same blower. Please refer to the Closed
Loop Loader System section of this manual for proper
installation and maintenance.
Dryer Controls
The PDII series can be supplied with the standard PLC
Control or the advanced Microprocessor Control Modules.
PDII dryers supplied with the HP4-X option are only
available with the Microprocessor Control Module. Each
of these modules controls and monitors the dryer’s
regeneration cycle, operational hardware and their
associated alarms.
PLC Module
The PLC Control module includes a PLC control board,
display board and touch pad that is programmed for the
drying cycle described previously. The display board and
touch pad indicate the machine status and alarms. These
are explained in more detail later in this manual.
Microprocessor Module
The Microprocessor Control Module is one of the most
sophisticated yet operator friendly controls on the market.
It has many more features than the PLC control module
that provide the operator with more control and
operational flexibility with the dryer. These features and
the operating instructions are covered in detail in the
Microprocessor Control Instruction Manual included with
your dryer.
Process Air Controls
The process drying temperatures for each hopper are
controlled by a digital controller dedicated to that hopper.
Page 6
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
The digital controller is used to set, display and monitor the
process air temperature, as well as, actuate alarms if a
situation should arise.
To allow for greater flexibility, each hopper can run
independently. Each hopper can be set to a different
temperature while still using a common dry air source.
Airflow to the hoppers is controlled by pneumatic valves on
the air inlet lines to the process heaters and the hopper
return air lines. The valves are opened when the
corresponding toggle switch on the dryer control panel is
actuated.
Auger Feeding/Mixing
The Auger Feed System can be used to feed and blend
materials from each hopper. A fixed speed auger is used in
conjunction with a variable speed auger to accurately blend
materials at various rates and proportions. This feed
system can be utilized to blend materials at ratios ranging
from 5 to 75 percent with tolerances of +/- 2%. This auger
based system utilizes volumetric metering that offers
greater flexibility and accuracy than the standard
proportional systems that rely on vacuum efficiency and
time to properly proportion the materials and eliminate the
layering problems commonly associated with these
systems.
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 7
DRI-AIR INDUSTRIES, INC.
AIR FLOW SCHEMATIC
FOR A-18 to A-100PDII
DRYERS
VORTEX BLOWER
FILTER
4-WAY ZONE
VALVE
CONTROL
THERMOCOUPLE
H1
CONTROL
THERMOCOUPLE
H2
VENT
REGENERATION
AND PROCESS
HEATER
CONTROL
THERMOCOUPLE
L1
SAFETY THERMAL
CONTROL
THERMOCOUPLE
L2
SAFETY THERMAL
TO HOPPER
PROCESS AIR
FLOW VALVE
PROCESS HEATER
TO HOPPER
Page 8
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
AIR FLOW SCHEMATIC
FOR H-18 to H-100PDII
DRYERS
VORTEX BLOWER
FILTER
4-WAY ZONE
VALVE
CONTROL
THERMOCOUPLE
H1
CONTROL
THERMOCOUPLE
H2
VENT
CONTROL
THERMOCOUPLE
M1
SAFETY THERMAL
SECONDARY
REGENERATION
HEATER
CONTROL
THERMOCOUPLE
L1
CONTROL
THERMOCOUPLE
M2
CONTROL
THERMOCOUPLE
L2
SAFETY THERMAL
REGENERATION
AND PROCESS
HEATER
REGENERATION
AND PROCESS
HEATER
SAFETY THERMAL
TO HOPPER
PROCESS AIR
FLOW VALVE
PROCESS HEATER
TO HOPPER
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 9
Dryer Cycle
Diagram
Desicant Beds
DRI-AIR INDUSTRIES, INC.
Page 10
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
The control package includes a PLC controller which is
programmed for the drying cycle previously discussed. The
display board indicates the machine status, heater
operation and alarms. See section on start up for details.
PLC STANDARD
ELECTRICS
CR1
50
14
M2
AL1
T1
AL2
+
+
-
UNUSED
+
-
L1
+
-
L2
+
-
M1
+
-
M2
H1
+
-
-
H2
110 VAC
FROMXFORMER
SS2
SS1
SS5
SS4
SS3
Below are descriptions of the inputs and outputs of the
PLC which are used for trouble shooting. A lit LED indicates
the input or output is actuated. All inputs are 12 volts AC
and all outputs are 110 volts AC and 15 v DC to the heater
relays. Refer to the electrical schematic for more detail.
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 11
DRI-AIR INDUSTRIES, INC.
Electrical Connection:
INSTALLATION
PROCEDURE
Open electrical access door on the electrical panel
enclosure by turning the disconnect off and loosening the
bolt on each door clamp and sliding the clamp off the
retainer. Locate the disconnect by following the operating
handle down to the electrical panel.
Insert the incoming power cable or conduit through the
hole provided on the side of the machine.
« use approved wire and fastening means «
Wire incoming power to the top of the disconnect as shown
in the diagrams below.
NOTE:
When 3 wire supplies are used in place of 4 wire supplies,
a control transformer is required.
3 PHASE DRYER INSTALLATION
CHECK FOR CORRECT MOTOR ROTATION
BEFORE RUNNING DRYER
To check blower motor rotation.......
Connect compressed air and turn at least one hopper on.
The blower can be observed directly under the tower
cabinet. Turn on the power to the dryer and press the ON/
START touch pad and then immediately press the OFF/
STOP touch pad. Observe the cooling fan on the top of the
blower motor and verify the fan is turning clockwise. If the
motor is not turning clockwise, switch any two adjacent
supply wires.
Compressed Air Connection:
Compressed air is required to operate the airflow control
valves and the closed loop loader option. A minimum of 60
psi is required, maximum not to exceed 145 (1.0 mpa).
Thread connecting nipple and attach compressed air hose
to inlet located below Tower Cabinet. The compressed air
system includes a regulator that is factory set to the proper
pressure and an automatic drain water separator.
IMPORTANT - DRYER WILL NOT OPERATE UNLESS
COMPRESSED AIR IS CONNECTED.
The unit is now ready for operation.
Page 12
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
Standard Electrics Option- PLC Controlled Dryers
START-UP PROCEDURE
Std. Electrics - PLC
Depicted on the left is the Dryer Control Panel Touch Pad and
Display located on the front of the Electrical Panel Enclosure.
The control panel allows the operator to start the dryer and
observe the status of the regeneration cycle and alarm
conditions. To start the dryer, please do the following:
Ensure compressed air is connected.
Turn on the Hopper 1 or Hopper 2 process air controls by
actuating the appropriately labeled toggle switch located on
the front of the Electrical Panel Enclosure. IMPORTANT The dryer will not operate unless one of the above
mentioned switches are actuated.
Turn power on by actuating the main disconnect.
1. POWER light indicates power to the unit
is on.
Press ON button on key pad.
2. Illuminated BLOWER light indicates Blower is on
and system is ready.
3. Flashing ZONE light indicates which bed is in
Regeneration cycle.
4. Steady ZONE light means bed is in cooling cycle.
5. Illuminated HEATER lights indicate heater is on.
Alarm Conditions:
6. Flashing HIGH TEMP. ALARM indicates an over or
under temp alarm. Unit shuts down.
7. Steady HIGH TEMP. ALARM light indicates
thermocouple has failed. Further diagnostics are
required.
8. Flashing ALARM light indicates safety override
condition has occured. Dryer shuts down.
Depicted on the left is the display and touch pad associated
with the Digital Controllers used to monitor and control the
process air temperatures for each hopper. To set the
temperature, do the following:
Press SET button - temperature set point display (SV) will
flash.
Press up arrow to increase temperature and down arrow to
decrease temperature.
Press SET again to enter the new temperature setting.
If the upper “Temp. Readout Display” (PV) flashes, the
temperature is out of the control range.
If the display shows 0000 the thermocouple is not
connected or is faulty.
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 13
DRI-AIR INDUSTRIES, INC.
Microprocessor Option - Micro/Digital Controlled Dryers
START-UP PROCEDURE
Microprocessor Control
Depicted on the left is the Dryer Microprocessor Control
Display and Touch Pad located on the front of the Electrical
Panel Enclosure. The control panel allows the operator to
start the dryer and observe the status of the regeneration
cycle, process air dew point and alarm conditions. To start
the dryer, please do the following:
Turn power on to dryer by actuating the main disconnect.
The POWER light on the Dryer Display should illuminate
and the dryer will initialize.
Ensure compressed air is connected.
Turn on the Hopper 1 or Hopper 2 process air controls by
actuating the appropriately labeled toggle switch located on
the front of the Electrical Panel Enclosure. IMPORTANT The dryer will not operate unless one of the above
mentioned hopper switches are actuated.
After the dryer has initialized and dri Air is displayed, press
the START button located on the Dryer Control Touch Pad.
Observe the following:
1. Left display indicates actual temperature of process
air prior to Process Air Heater.
2. Right display reads Pd II or Process Air Dew Point.
To observe dew point, press TEMP D.POINT button
on Dryer Control Touch Pad.
3. Status block indicates heater on, heater fault and
regeneration status.
4. See Microprocessor manual for setting 7-day timer.
5. Configuration of the dryer parameters is done using
the SETUP button. See Microprocessor manual.
Depicted on the left is the display and touch pad associated
with the Digital Controllers used to monitor and control the
process air temperatures for each hopper. To set the
temperature, do the following:
Press SET button - temperature set point display (SV) will
flash.
Press up arrow to increase temperature and down arrow to
decrease temperature.
Press SET again to enter the new temperature setting.
If the upper “Temp. Readout Display” (PV) flashes, the
temperature is out of the control range.
If the display shows 0000 the thermocouple is not
connected or is faulty.
Page 14
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
After completing the dryer installation and start-up procedures,
the unit is ready for operation unless it has been equipped with
the options discussed below. Prior to beginning operation of
the dryer, you may need to install and set up the optional
components/systems that accompanied the unit. The Closed
Loop Loading and Auger Feed/Mixing Systems or the Vacuum
Loaders will require additional installation steps.
To install and operate the Vacuum Loaders, simply follow the
procedures detailed in the Instruction Manuals included with
loaders that were shipped with your dryer. These options will
require separate power and compressed air sources, and
operate independently of the dryer’s controls.
The Closed Loop Loading and/or Auger Feed/Mixing systems
require integration with the dryer controls and do not operate
independently of the dryer. The operating parameters for
these systems have been set at the factory and are suitable
for most applications. Each system is discussed in detail in the
following sections of this manual.
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 15
DRI-AIR INDUSTRIES, INC.
CLOSED LOOP LOADING
SYSTEM
(OPTIONAL)
The closed loop loading system uses a separate vortex
blower to provide the vacuum and “pressure assist”
necessary to move the dried resin from the hopper takeoff
box to the receiver mounted on the feed throat of the
molding machine.
At the start of the loading sequence, the lower proximity
switch on the receiver senses there is no material. The
blower starts, and the loader valve on the inlet line to the
blower is opened. Because the receiver is sealed to the feed
throat, a vacuum is created within the take off box, pulling
material from the hopper.
The outlet of the blower ( pressure side) blows air into the
take off box to help move the material to the receiver and
close the air loop. When the upper proximity switch on the
receiver senses material, the blower is stopped and the
loader valve is closed to prevent anymore material from
being conveyed and left in the hose to possibly be
contaminated with moisture.
To operate the system, complete the installation steps
detailed below and turn on the system by actuating the
toggle switch labeled LOADER on the front of the electrical
panel enclosure. If the Dual Closed Loop Loading option
has been installed, please consult the Dual Closed Loop
Loader Operating Manual enclosed with your dryer.
RECEIVER
INSTALLATION
Prior to installing the receiver, you must inspect the surface
of the molding press feed throat that the receiver is being
installed upon to ensure that it is clean and flush. Surface
irregularities must be removed, or a gasket installed, so that
there will be no vacuum leaks between the receiver and feed
throat after installation.
IMPORTANT
If the molding machine is equipped with a slide gate, swing
arm, starve feeder, additive feeder, or feed throat vent, you
must ensure these are sealed, as the system may not work
properly. If it is impractical, or impossible to seal off the
aforementioned equipment, Dri Air Industries has a Flap
Valve, available for purchase, that will enable the loading
system to function properly.
To install the receiver, simply drill holes in the bottom flange
of the receiver to match the hole pattern on the molding
press feed throat and affix the receiver with bolts sufficient to
accommodate the operating stresses. A silicone gasket is
provided with the receiver to ensure a tight seal between the
receiver bottom and the feed throat. Connect the plug for
the upper proximity switch into the line labeled H and
connect the lower proximity switch plug into the line labeled
L. Connect the material feed hose and vacuum hose as
Page 16
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
shown in drawing 82222 in the appendix to this manual.
VACUUM CHECK
Prior to production operation of the loading system, we
strongly recommend that you ensure the loading system is
properly sealed. To test the seal, follow the steps detailed
below.
While the loader is running, close the hopper slide
gate and remove the material wand and attached
hose from the takeoff box. Check the vacuum level
by placing your hand over the wand. Return the
wand to the takeoff box.
Remove the hose from the bottom port of the
blowback filter canister. Place your hand over the
filter canister port. Compare this vacuum level to
the level observed at the material wand. The two
vacuum levels should be the same.
Any difference between the vacuum levels is caused from
leaks in the loading system. Check for loose hoses,
missing gasket on the cyclone, or other possible sources of
leaks described below.
The most likely source is the seal between the feed throat
and receiver, or the configuration of the feed throat and
material feeder associated with the molding press. The
presence of vacuum leaks at these locations may exhibit
the following characteristics:
n
Material in the receiver may be seen to
bubble or move when loading, as a leak at the feed
throat causes air to be drawn in at the bottom of the
receiver rather than from the take off box.
n
Poor transfer of material from the takeoff box
to the receiver.
n
Large amounts of material or dust being
pulled into the blowback filter cannister.
If any of these occurrences are observed, the steps to
improve the vacuum seal detailed in the previous section on
Receiver Installation will be required.
PROXIMITY SENSOR
ADJUSTMENT
The proximity sensors supplied with the receiver may
require adjustment to operate properly. When positioning
the sensors, ensure that they are placed as close as
possible to the outer surface of the receiver as they operate
by sensing the density of the material in the receiver.
Vertically position the lower sensor to set the material level
at which the load cycle will initiate and the upper sensor to
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 17
DRI-AIR INDUSTRIES, INC.
set the material level at which the load cycle will stop.
CAUTION: Do not overfill the receiver as material may
be drawn back into the blowback filter canister.
To adjust the sensor’s sensitivity, turn the adjustment screw
on the back of the sensor. The adjustment screw turns a 20
turn potentiometer with a clutch to prevent over adjustment.
If you are unsure as to the current setting of the sensor, turn
the screw 20 turns counterclockwise. The LED should
light with no material in front of the sensor. Turn the screw
4-6 turns clockwise and proceed as directed below.
With no material in front of the sensor, the LED on the back
of the sensor should be lit. If not, turn the adjustment screw
located on the end of the sensor counterclockwise until the
LED turns on.
With material in front of the sensor, the LED on the back of
the sensor should be off. If not, turn the adjustment screw
clockwise, until it turns off.
MATERIAL FLOW
ADJUSTMENT
Material flow to the receiver should be continuous and
smooth. Irregularities in flow rate and volume can be
affected by the position of the material wand inserted into
the takeoff box or the density of the resin. To adjust the flow,
take the steps detailed below.
Upon initial operation of the loading system, push the wand
in until it stops. Then pull it out 1 to 2 inches and tighten the
set screw on the takeoff box material outlet. Operate the
loading system and observe how the material flows into the
receiver. If the flow rate is not as desired, the wand can be
adjusted out to reduce the flow of material conveyed, or in,
to increase the amount. Typically, loading times are 5-6
seconds for a 2” receiver and 15-20 seconds for the 4”
receiver.
If the material flow is irregular, with “slugs” of resin being
delivered to the receiver, the wand is most likely pushed too
far into the takeoff box. This “chokes” off the air flow
required to convey the material, causing the irregular flow.
To remedy this condition, pull the wand out slightly and the
material will flow more evenly and quickly.
If little or no material is conveyed and there are no
blockages in the takeoff box or material hose the wand may
be pulled too far out of the takeoff box. Push the wand in
until you get the desired flow rate.
Page 18
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
CLOSED LOOP LOADER
TROUBLESHOOTING
Material will not feed.
1. Ensure the proximity sensors are adjusted and
working properly. Both sensors LED’s should be lit
when the receiver is empty. Check that the sensors
are tightened on the bracket and the cable connectors
are tight and correct.
2. Check system for leaks. Tighten hose clamps. Check
seal at receiver/feed throat interface by comparing
vacuum levels as directed in previous section on
Receiver Installation.
3. Ensure the blower operates. Check the electrical
system to see if the relay is working and that the
blower overload is not tripped. Trip window will be
orange/yellow if tripped. Check to see that the blower
rotation is correct (clockwise).
4. Ensure that the compressed air is connected to the
system and the pressure regulator is set to 60 psi.
Does the air valve open when the system calls for
material? The air line to the valve can be easily
disconnected by pushing in on the plastic sleeve and
removing the hose. The air line should be pressurized
when the system is loading.
5. Ensure the drain valve at the bottom of the filter is
closed properly.
Daily Maintenance:
CLOSED LOOP LOADER
MAINTENANCE
CAUTION: Clean filter when loader is not working.
The filter is cleaned automatically with an air blast at the
start of each loading cycle. The canister needs to be drained
periodically by opening the valve at the bottom of the
canister. Gently bang on the side of the cannister with your
hand to loosen any fines and close the valve.
Monthly Maintenance:
Clean filter sock by removing the quick clamp on the filter
canister and removing cover. Remove the bag assembly
and blow off with compressed air. Reinstall bag assembly,
cover and quick clamp, checking that the seal is proper.
This maintenance may need to be performed more
frequently if your material is dusty.
Tighten all hoses and hose clamps and check for leaks.
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 19
DRI-AIR INDUSTRIES, INC.
AUGER FEED MIX
SYSTEM
(OPTIONAL)
AUGER FEED SETUP
The Auger Feed Mix System utilizes a fixed speed auger in
conjunction with a variable speed auger to blend materials
from each hopper to the user’s desired proportions. The
auger and motor assembly for each hopper is located directly
below the hopper, and feed a central takeoff box connected to
the mold press loading system. The controls for each auger
motor are in a control box located on the hopper support
frame. Each auger motor is actuated by a 3 position toggle
switch located on the front of the control box. The auger
situated below Hopper 1 (left side hopper) is operated by a
fixed speed AC motor, while the auger below Hopper 2 is
operated by a variable speed DC motor controlled by a 10-turn
potentiometer located on the Auger Feed Mix System Control
Box. The system allows the user to blend materials at ratios
ranging from 5 to 75 percent with accuracies in the range of
+/-2%.
To set up the Mix System, first remove all the shipping straps
attached to the system feed tubes and motor clamps. Ensure
that there is material in each hopper and the slide gates for
each hopper are open. Remove the V-Box Feed Tube
Assembly from the augers and follow the steps detailed below.
1. Actuate Auger 1 (fixed speed auger) by putting the toggle
switch in the TEST (down) position. This will operate the
auger for a 15 second interval. Allow the material to drop
into a container. Weigh the resin dispensed by the auger
(Do not include wt. of container). This will establish the
“Constant Portion” for your proportional mix formula (See
page 27 in this manual for formula). Repeat this several
times by returning the toggle switch to the OFF (Middle)
position and back to the TEST position so that you obtain
an average result which will be more reliable.
2. Return the toggle switch for Auger 1 to the OFF (middle)
position and put the toggle switch for Auger 2 in the TEST
(down) position. Auger 2 will operate for 15 seconds. If
the auger is not at the correct speed setting, turn the
potentiometer to the right to increase the motor speed or
to the left to decrease the speed. Allow the material to
drop into a container. Weigh the dispensed material and
compare it to the desired weight as determined by your
proportional mix formula.
3. Return toggle switch for Auger 2 to the OFF (middle)
position and repeat the previous step until you obtain the
desired weight. After obtaining your desired weight,
repeat the cycle several times to ensure that the auger is
feeding the correct amount of material. Record the
potentiometer setting and lock the potentiometer at the
desired setting by pushing the locking tab to the right.
Reinstall the V-Box Feed Tube Assembly and begin
operation.
Page 20
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
AUGER FEED
OPERATION
To operate the system, put the toggle switches for each
auger in the RUN (up) position. When the low material
sensor on the mold press receiver calls for material, the
loader blower will actuate and the augers will begin to feed
material two seconds after the blower starts. The augers
will continue to feed until the upper sensor is satisfied. The
blower will continue to operate for a factory set period of
time to clean out the material feed line and then shut down.
To prevent damage to the augers, the V-Box Feed Tubes
are equipped with material sensors that will shut the auger
motor off if the feed tube fills with material due to the loss
of vacuum in the loading system or material bridging. If
this occurs, clean out the feed tube and continue operation.
AUGER FEED SYSTEM
MAINTENANCE
The Auger Feed Mix System is designed for easy cleaning
and maintenance. Follow the steps detailed below to clean
the system.
V-Box Collection Tubes
Remove the V-Box Tube Assembly by loosening thumb
screws on inlet tubes, removing material hose and
detaching material sensor plugs. Loosen wing nuts
fastening plugs at top of tube and remove plugs. Clean
tubes with compressed air or wipe thoroughly.
Auger Tubes & Takeoff Box
After removing V-Box Assembly, unlatch clean-out cover
on bottom of auger assembly takeoff box. Remove motor
and auger assembly by loosening clamp on motor side of
auger assembly and detaching motor power cord. Pull
motor and auger assembly from feed tube and clean
takeoff box, tube and auger with compressed air or wipe
thoroughly. When reinstalling motor and auger assembly
be sure to place guide tab on auger tube in the up position
so that it fits into the notch on the takeoff box.
MATERIAL SAMPLER
(OPTIONAL)
Your dryer’s mixing system may be equipped with our
Material Sampler option. This allows you to operate each
auger individually to obtain a small amount of material for
moisture content or other testing.
To operate, remove the end cap on the top of the V-Box
Colection Tube and insert the Material Sampler Container
into the tube. Press the Sample Feed button located on
the Auger Feed System Control Box. The respective
auger will operate for as long as the button is depressed,
feeding material into the Sampler Container. Remove the
sampler, return the end cap to the tube and resume
operation.
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 21
DRI-AIR INDUSTRIES, INC.
DRYER OPERATION
TROUBLE SHOOTING
The new Dri-Air Standard PLC and MICROPROCESSOR
Electrics were designed for quick diagnosis of problems.
If a problem is encountered while operating the dryer
please follow the steps below before proceeding with other
diagnostic steps.
1. Check the Power Circuit:
a. Incoming power fuses or circuit breaker
b. All dryer fuses:
Each fuse, with the exception of the main fuses,
has a blown fuse indicator light that illuminates
when the fuse is blown.
c. Is power supplied to the unit?
d. Check heater continuity using a volt ohmmeter.
2. Compressed Air:
a. Is compressed air connected with at least 60 PSI.
b. Check water separator and drain if necessary.
c. Pressure gauge should read 60 PSI.
3. Air Flow Circuit:
a. Ensure Zone Valve position corresponds to the
regeneration cycle by comparing the Zone position
lights on the Zone Valve to the ZONE position lights
on the dryer panel.
b. Make sure that all hoses are connected, not crushed,
and free from obstructions.
c. Inspect filter and make sure cover is tight and the
filter is clean.
d. Is at least one hopper air control valve actuated. The
toggle switch(es) on panel door must be actuated.
4. Control Circuit:
a. Using the PLC/MICRO Display Panel ZONE indicator
lights as a guide for the dryer regeneration cycle,
check that all inputs/outputs are proper for the part of
the regeneration cycle that the machine is in.
b. Monitor the PLC output lights to ensure the
corresponding LED on the power board is illuminated
and there is an output voltage to the heater.
5. Operating Conditions:
a. Check the process temperature. It should not be set
below 140° F (60° C) because the unit will go into
high temp alarm.
Page 22
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
Machine will not start: Power light is not on.
DRYER OPERATION
DETAILED DIAGNOSIS
(PLC Controlled Dryer)
For Micro-Controlled dryers please see the
Microprocessor Control Instruction Manual
1. Check to ensure that at least one hopper process air
valve is actuated. Toggle switch(es) on panel door
should be on.
2. Check circuit breakers (CB1) or incoming fuses
inside control box to see if they are tripped or blown.
Reset circuit breakers by turning them off and then
on.
3. Check small fuses (FU1 & FU2) next to contactor.
The LED will be lit if they are blown. Replace if
necessary by opening the fuse holder and put new
fuse into holder.
4. Check that incoming power to the unit is proper.
5. Check safety snap discs.
Alarm light is flashing: Unit will not run.
Main contactor is not pulling in.
1. Check the motor overload OL1 located in the panel. If
it is tripped, the window will show as orange/yellow.
Reset overload by pushing in the reset button.
Machine will not run: High Temp Alarm Light flashing.
This indicates that the temperature has exceeded the high
limit programmed into the temperature control or the set
temperature can not be reached.
Press stop and restart machine holding in the start
button. Monitor the actual temperature to see if it exceeds
the set point or can not reach the set point. If it can not
reach set point, see section below.
Machine will not run: High Temperature Alarm Light on,
not flashing:
1. This indicates an “open” thermocouple or the
temperature in the desiccant tower exceeded 900° F.
Machine will not reach temperature:
1. If the process heater light is not lit.
A. Check output from temperature controller and
input to PLC.
B. Check the thermocouple. The tip should be in the
middle of the hose.
2. If the process heater light is lit.
A. Check fuses on power board
B. Check solid state relays on power board.
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 23
DRI-AIR INDUSTRIES, INC.
C. Check that the air flow is not obstructed.
D. Check blower rotation
E. Check heater for continuity.
Check the limit first by pressing the SET button on the
temperature control and holding until AL is displayed. The
setting shown indicated the amount over set point that the
alarm will be actuated. It is factory set to 50°F (30°C) and
should not be set below 30°F (16°C) or it will actuate too soon.
If the temp exceeds the set point check the following:
1. Remove the hose from the top of the hopper to check
air flow. There should be air flow out of the hopper
with a suction on the hose. If there is little or no flow,
check the inlet hose.
2. Inspect the filter to make sure that it is clean and not
affecting the air flow.
3. Check the power boards to see if one of the solid
state relays has failed on. Using an ammeter or
voltmeter on the output to the heater, see if there is
power when the LED is not lit which will indicate a
failed relay.
4. Check the valve position.
DRI-AIR ROTARY
ZONE VALVE
The Dri-Air rotary zone valve is designed to provide very little
flow restriction and no leakage. It incorporates high
temperature, self adjusting seals for years of trouble free
service. The electrical controls are built into the end of the
valve and include zone position lights.
Trouble shooting is easy. If the lights indicating position do not
match the zone displayed on the control panel, or there are no
lights, the valve is not working properly.
DO NOT PUT FINGERS INTO VALVE WITH POWER ON
If you are experiencing problems with the valve, check the
following:
1. Check to see if the cam is actuating a zone
position switch on the valve’s circuit board.
2. Check all electrical connections to make sure
they are tight.
3. Contact factory with the serial number of the
dryer for a replacement valve.
Page 24
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
A18-35PDII and H18-35PDII
GENERAL
CLOSED LOOP LOADER
ELECTRICAL
NOTE:
TO ORDER BLOWERS OR
OVERLOAD REFER TO
PART NUMBER ON ITEM.
*:
IEC CONTACTOR USED IN ALL
FM, PD & HM DRYERS AND CLL
POWER PACKS WITH SERIAL
NUMBERS GREATER THAN
D14650
HEATERS
DESCRIPTION
APDII
HPDII
Dryer Filter Element
Zone Valve
Thermocouple (Process)
Desiccant (Pounds) 80082
Tower Clamp
Tower Gasket
Pressure Switch
Regulator
SMC Valve
Caster (Swivel)
Caster (Fixed)
81055
83705
84054
8 lbs.
81172
81028
82813
80896
84221
81799
81798
81055
83705
84054
14 lbs.
81172
81028
82813
80896
84221
81799
81798
Filter Element
Blowback Valve
Proximity Switch (K10203 Std. El.)
Proximity Switch (K15208 Micro)
SMC Valve
82389
82695
81180
82298
84221
82389
82695
81180
82298
84221
Disconnect
Temperature Control (RKC CB-100)
Main Board
Display Board
Thermocouple Board
Transformer
Current Transformer
Main Contactor
Solid State Relay
IEC Contactor
IEC Contactor*
Power Board
Power Board (208 & 230 v Dryers)
Single Pole Relay
Double Pole Relay
Dual Solid State Board
Toggle Switch
Safety Thermal Switch (Tower)
Safety Thermal Switch (Process)
Thermocouple (Tower)
Transformer .050
TRI-Solid State Board
Dewpoint Sensor
Solid State Timer (Blowback)
Solid State Timer (Cleanout)
Solid State Timer (Auger Delay)
STD
MICRO
82308
84016
84100
83401
84049
83437
NR
82270
82302
80576
84860
83397
84080
82496
80587
NR
80466
80221
80551
82175
82245
NR
81908
83318
83527
83442
82308
84016
82071
82072
NR
82245
82246
82270
82302
80576
84860
83493
84080
82496
80587
82870
80466
80221
80551
82175
82245
83468
81908
83318
83527
83442
208V 230V 400V
Regeneration (Cone Style) 83342 83373 83982
HP Center (Flat Style)
82373 82373 83958
Process
82343 82343 84204
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
480V
83374
82505
82319
575V
84235
84260
84065
Page 25
DRI-AIR INDUSTRIES, INC.
A50-100PDII and H50-100PDII
DESCRIPTION
APDII
HPDII
Dryer Filter Element
Zone Valve
Thermocouple (Process)
Desiccant (Pounds) 80082
Tower Clamp
Tower Gasket
Pressure Switch
Regulator
SMC Valve
Caster (Swivel)
Caster (Fixed)
81331
83705
84054
30 lbs.
81172
82795
82813
80896
84221
81799
81798
81331
83705
84054
50 lbs.
81172
82795
82813
80896
84221
81799
81798
Filter Element
Blowback Valve
Proximity Switch (K10203 Std. El.)
Proximity Switch (K15208 Micro)
SMC Valve
82389
82695
81180
82298
84221
82389
82695
81180
82298
84221
GENERAL
CLOSED LOOP LOADER
ELECTRICAL
NOTE:
TO ORDER BLOWERS OR
OVERLOAD REFER TO
PART NUMBER ON ITEM.
*:
IEC CONTACTOR USED IN ALL
FM, PD & HM DRYERS AND CLL
POWER PACKS WITH SERIAL
NUMBERS GREATER THAN
D14650
Disconnect
Temperature Control (RKC CB-100)
Main Board
Display Board
Thermocouple Board
Transformer
Current Transformer
Main Contactor
Solid State Relay
IEC Contactor
IEC Contactor*
Power Board
Power Board (208 & 230 v Dryers)
Single Pole Relay
Double Pole Relay
Dual Solid State Board
Toggle Switch
Safety Thermal Switch (Tower)
Safety Thermal Switch (Process)
Thermocouple (Tower)
Transformer .050
TRI-Solid State Board
Dewpoint Sensor
Solid State Timer (Blowback)
Solid State Timer (Cleanout)
Solid State Timer (Auger Delay)
230V
HEATERS
Regeneration (Cone Style)
HP Center (Flat Style)
Process
Page 26
STD
MICRO
82308
84016
84100
83401
84049
83437
NR
82270
82302
80576
84860
83397
84080
82496
80587
NR
80466
80221
80551
82175
82245
NR
81908
83318
83527
83442
82308
84016
82071
82072
NR
82245
82246
82270
82302
80576
84860
83493
84080
82496
80587
82870
80466
80221
80551
82175
82245
83468
81908
83318
83527
83442
400V
480V
575V
81351 81766 81366 81432
82364 83934 82493 83372
82343 84204 82319 84065
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
PROPORTIONAL MIX
FORMULAS
The following formulas are to be utilized to determine the material
feed rates for the variable speed auger. Select the formula to be
used based on the proportional mix that the user specifies. If the
proportional mix is based on a proportion of the TOTAL output,
then you should use Formula 1. If the mix is based on the
proportion of “virgin” (fixed speed auger), then you should use
Formula 2.
FORMULA 1
This formula is to be used if the mix proportion is expressed as a
percent of the TOTAL mix. For example; 85% Virgin, 15%
regrind.
EXAMPLE 1
Fixed Auger % (FA) = 85
Variable Auger % (VA)= 15
Fixed Auger Output (FAO)= 1000g
Mix Ratio (MR) = FA%/VA%
Mix Ratio = 85/15
Mix Ratio = 5.667
DATA REQUIRED
FIXED AUGER % of TOTAL
_______
VARIABLE AUGER % of TOTAL
_______
FIXED AUGER OUTPUT (grams)
_______
COMPUTATION
Variable Auger Output = FAO/MR
Variable Auger Output = 1000g/5.667
Variable Auger Output = 176.5g
Divide Fixed Auger % of Total by Variable Auger % of Total to
obtain the MIX RATIO.
Divide Fixed Auger Output by MIX RATIO to obtain VARIABLE
AUGER OUTPUT (grams of material from Variable Speed
Auger).
FORMULA 2
EXAMPLE 2
Fixed Auger Output (FAO)= 1000g
Variable Auger % of Output (VAO)=
15
Decimal Equivalent (DE)= VAO/100
Decimal Equivalent = 15/100
Decimal Equivalent = .15
Variable Auger Output = FAO x DE
Variable Auger Output = 1000g x .15
Variable Auger Output = 150g
This formula is to be used when the mix proportion is expressed
a percent of virgin (Fixed Auger Output). For example; Regrind
output is to be equal to 15% of virgin.
DATA REQUIRED
FIXED AUGER OUTPUT (grams)
______
VARIABLE AUGER % of Fixed Auger Output
______
COMPUTATION
Divide Variable Auger % by 100 to obtain DECIMAL EQUIVALENT.
Multiply Fixed Auger Output by Variable Auger % DECIMAL
EQUIVALENT to obtain VARIABLE AUGER OUTPUT (grams of
material from Variable Speed Auger).
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 27
DRI-AIR INDUSTRIES, INC.
NOTES:
Page 28
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
NOTES:
OPERATING MANUAL - A-PD II & H-PDII DRYERS
Revision 10/8/02
Page 29
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