WARNING - Reliance on this Manual Could Result in Severe...

WARNING - Reliance on this Manual Could Result in Severe...
WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death!
This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual
detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject
matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon.
Contact Conair at [email protected] or 1-800-654-6661 for more current information, warnings, and materials about
more recent product manuals containing warnings, information, precautions, and procedures that may be more adequate
than those contained in this out-of-date manual.
Please record your
equipment’s model and
serial number(s) and
the date you received it
in the spaces provided.
It’s a good idea to record the model and serial number(s) of
your equipment and the date you received it in the User
Guide. Our service department uses this information, along
with the manual number, to provide help for the specific
equipment you installed.
Please keep this User Guide and all manuals, engineering
prints and parts lists together for documentation of your
equipment.
Date:
Manual Number:
UGS001/0798
Serial number(s):
Model number(s):
DISCLAIMER: The Conair Group, Inc., shall not be liable for errors
contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this
information. Conair makes no warranty of any kind with regard to
this information, including, but not limited to the implied warranties
of merchantability and fitness for a particular purpose.
Copyright 1998
THE CONAIR GROUP, INC.
All rights reserved
INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1
Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2
Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . .1-2
ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3
How to use the lockout device . . . . . . . . . . . . . . . . . . . . . .1-4
TABLE OF
CONTENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1
What is the CDS? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical applications (basic) . . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical applications (advanced) . . . . . . . . . . . . . . . . . . . . .2-3
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
How it works (drying) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
How it works (conveying) . . . . . . . . . . . . . . . . . . . . . . . . .2-6
INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Unpacking the boxes (accessories) . . . . . . . . . . . . . . . . . . .3-4
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Installing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Installing the wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1
Testing the system installation . . . . . . . . . . . . . . . . . . . . . .4-2
Testing the pocket conveying valve . . . . . . . . . . . . . . . . . .4-3
To start drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
To stop drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1
Maintenance checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1
Before beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
When trouble occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Drying problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Moisture regain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
System problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Material problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
APPENDIX
Customer service information . . . . . . . . . . . . . . . . . . . . . .A-1
Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
UGS001/0798
Central Distribution System
i
INTRODUCTION
● Purpose of the User Guide . . . .1-1
● How the guide is organized . . . .1-2
● Your responsibilities as a user .1-2
● ATTENTION: Read this so
no one gets hurt . . . . . . . . . . . .1-3
● How to use the lockout device .1-5
UGS001/0798
Central Distribution System
1-1
PURPOSE OF
THE USER
GUIDE
This User Guide describes the CDS System and explains stepby-step how to install, operate, maintain and repair this equipment.
HOW THE
GUIDE IS
ORGANIZED
Symbols have been used to help organize the User Guide and
call your attention to important information regarding safe
installation and operation.
YOUR
RESPONSIBILITY
AS A USER
Before installing this product, please take a few moments to
read the User Guide and review the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system. This
review won’t take long, and it could save you valuable installation and operating time later.
Symbols within triangles warn of conditions that could
be hazardous to users or could damage equipment.
Read and take precautions before proceeding.
1
Numbers within shaded squares indicate tasks or steps
to be performed by the user.
◆
A diamond indicates the equipment’s response to an
action performed by the user.
❒
●
An open box marks items in a checklist.
A shaded circle marks items in a list.
You must be familiar with all safety procedures concerning
installation, operation and maintenance of this equipment.
Responsible safety procedures include:
● Thorough review of this User Guide, paying particular
attention to hazard warnings, appendices and related diagrams.
● Thorough review of the equipment itself, with careful
attention to voltage sources, intended use and warning
labels.
● Thorough review of instruction manuals for associated
equipment.
● Step-by-step adherence to instructions outlined in this
User Guide.
1-2
INTRODUCTION
Central Distribution System
UGS001/0798
We design equipment with the user’s safety in mind. You can
avoid the potential hazards identified on this equipment by
following the procedures outlined below and elsewhere in the
User Guides.
ATTENTION:
READ
THIS SO NO
ONE GETS HURT
WARNING: Improper installation, operation or servicing may
result in equipment damage or
personal injury.
This equipment should be installed,
adjusted, and serviced by qualified technical personnel who are familiar with the
construction, operation and potential
hazards of this type of machine.
All wiring, disconnects and fuses should
be installed by qualified electrical technicians in accordance with electrical
codes in your region. Always maintain a
safe ground. Do not operate the equipment at power levels other than what is
specified on the machine serial tag and
data plate.
WARNING: Pinch Point
Moving pieces on valves, slide gates
and other optional equipment included
with this system may cause personal
injury. Always disconnect compressed
air before performing any maintenance
or troubleshooting procedures.
CAUTION: Electrical Shock
Hazard
Always disconnect and lock out the main
power source before servicing. You are
responsible for developing a lockout procedure.
UGS001/0798
Central Distribution System
INTRODUCTION
1-3
ATTENTION:
READ
THIS SO NO
ONE GETS HURT
CAUTION: Hot Surfaces
Always allow the Heat Booster and drying
hopper to cool before performing repairs
or maintenance. Also, protect yourself
from hot exterior surfaces on the drying
hopper. Surface temperatures around
door frames of some hoppers and around
the return air hose can reach 180˚ to
200˚ F (82˚ to 93˚ C).
WARNING: Do not place aerosol,
compressed gas or flammable
materials on or near this equipment.
The hot temperatures associated with
the drying process may cause aerosols
or other flammable materials placed on
the dryer or hopper to explode.
WARNING: Hazardous substance
The electrical relays in the Heat Booster
have contactors that contain mercury,
which is considered a hazardous substance and must be dealt with accordingly. Material Safety Data Sheet (#7439-97)
has been included in your instruction
packet. This sheet explains the potential
hazards, how to avoid them and how to
clean up and dispose of the mercury if it
ever spills.
1-4
INTRODUCTION
Central Distribution System
UGS001/0798
CAUTION: Before performing maintenance
or repairs on this system, you should disconnect
and lock out electrical power sources to prevent
injury from unexpected energization or start-up. A
lockable device has been provided to isolate this
product from potentially hazardous electricity.
HOW TO USE
THE LOCKOUT
DEVICE
Lockout is the preferred method of isolating machines or
equipment from energy sources. Your Conair product is
equipped with the lockout device pictured below. To use the
lockout device:
1
2
Stop or turn off the equipment.
Isolate the equipment from
electrical power.
I
Turn the rotary disconnect
switch to Off, or O position.
3
Secure the device with an
assigned lock or tag.
O
4
The equipment is now locked out.
WARNING: Before removing lockout
devices and returning switches to the ON position,
make sure that all personnel are clear of the
machine, tools have been removed and all safety
guards reinstalled.
Central Distribution System
INTRODUCTION
1-5
DESCRIPTION
● What is the CDS? . . . . . . . . . . . .2-2
● Typical applications (basic) . . . .2-2
● Typical applications
(advanced) . . . . . . . . . . . . . . . . . . .2-3
● Typical applications . . . . . . . . . .2-4
● How it works (drying) . . . . . . . .2-5
● How it works (conveying) . . . . .2-6
UGS001/0798
Central Distribution System
2-1
WHAT IS
CDS?
THE
CDS stands for Central Distribution System. A Typical system consists of 2-6 individual drying stations, a central dehumidifying unit, supply and return manifold, and conveying
opportunities.
The CDS system can run high volume long runs or low volume short runs. You can configure a system that will go from
single or multi-source to single or multi-destination. The system provides isolation valves so that you can remove any station from the system to change materials, perform a cleanout
or only use as many stations as you need.
Modular components make the CDS system as automated or
basic as you need. The advanced system eliminates moisture
regain.
The CDS system will save money by preventing the need for
multiple dryers. This will cut the cost of your energy usage.
TYPICAL
APPLICATIONS
Here are some things to remember when considering the
possibilities:
● Each station can be different. One station may have a heat
booster,Drying Monitor, and single tube distribution box, and
the next may have only a pocket conveying valve.
● It is possible to use color, as long as the color can withstand
the temperature necessary to keep the rest of your material
dry.
● Pocket Conveying requires some type of control (SLC
deluxe for central system, Selectronic 4+ or 5 for individual
stations) and works best with a direct feed loader (K loader) at
the machine.
● A dry air generator may be necessary in a plant with high
humidity.
● If you are thinking about the possibilities of expanding
your CDS system in the future, plan up front. Larger systems
may require larger dryers.
● Uninsulated manifolds are supplied when the dryer is supplying only regeneration capabilities.
● The CDS can handle a wide range of material types and
Throughput types. Throughput can be up to 900 lb/hr (150
lb/hr per station), but will vary due to hopper size and material
used.
2-2
DESCRIPTION
Central Distribution System
UGS001/0798
A central dryer is used to provide dehumidified air. The heat
boosters provide the heat to the air entering the hoppers. The
hoppers are hand fed and emptied into buckets. The system
still has isolation valves and the bypass valve, allowing one or
more of the stations to be turned off during a process.
This application should only be used when the material being
handled does not regain moisture easily.
Shown below is the CDS system at the most “featured” state.
This CDS system begins with the core system and adds a
pump with dust collector for loading capabilities both on the
throat, and on the hoppers in the CDS.
This system uses a dry
air generator for dry air
conveying.
TYPICAL
APPLICATIONS
(BASIC)
TYPICAL
APPLICATIONS
(ADVANCED)
Each hopper has a
Drying Monitor
which will monitor
the exact conditions
of the material in
each hopper.
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The material is directed
into a fantail manifold,
where it can be sent to
many destinations from
a single source.
The pocket conveying
valve allows for purging.
UGS001/0798
Central Distribution System
DESCRIPTION
2-3
HOW IT WORKS
(DRYING)
2
1
Just before the air
enters the hoppers,
it passes through
the heat boosters.
The heat boosters
make sure that the
temperature is at
the set point
entered by the user.
Once the heated,
dehumidified air
passes through the
hopper, it exits to
the return air manifold and returns to
the dryer for processing again.
One central dryer
provides dehumidified air through a
supply manifold to
each hopper on the
system.
The isolation valves
are used to disconnect
any station from the
system for changing
material or cleanout
while the other stations
remain in use.
2-4
3
DESCRIPTION
A bypass valve between the
supply and return air manifolds
acts as a pressure relief valve
and allows excess air to pass
from the supply manifold to the
return manifold. The bypass
valve makes it possible to disconnect a station from the system without effecting the other
stations’ performance.
Optional add-ons will provide further monitoring of material
in the hopper, pocket conveying capabilities, dewpoint monitoring, open loop dehumidified conveying to the throat, and
multiple source-multiple destination material handling.
Central Distribution System
UGS001/0798
1
HOW IT WORKS
(CONVEYING)
Material is fed into
the hopper either by
hand or using a
loader.
2
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3
Material stays in the
hopper until it is
dried.
Once processed, the material passes
through the hopper one of three ways:
using the manual slide gate and emptying
into a bin, using a single-tube distribution
box, or using a pocket conveying valve
(shown).
4
UGS001/0798
A Peripheral Pump or other vacuum conveying equipment pulls the material from
the pocket conveying valve to the throat of
the machine.
Central Distribution System
DESCRIPTION
2-5
INSTALLATION
● Unpacking the boxes . . . . . . . . .3-2
● Unpacking the boxes
(accessories) . . . . . . . . . . . . . . . . .3-4
● Preparing for installation . . . . . .3-5
● Installing the system . . . . . . . . .3-6
● Installing the wiring . . . . . . . . . .3-7
Central Distribution System
UGS001/0798
3-1
UNPACKING
BOXES
THE
No matter what kind of a system you ordered, it is going to
require some assembly. Always read this manual completely
before assembling.
Depending on what you ordered, you will have a number of
different boxes and pieces.
For each station, this is what you should have: (your station
may not include a loader, and may have the optional remote
heat booster control. Each system includes one bypass valve
and 2 manifold adapters.)
heat booster
loader
hose clamps
manifold to dryer adapters
bypass valve
heat
booster
control/
enclosure
hopper
hose
air pressure
tap hose
NOTE: Manifold hose pieces
(number and size dependent
on what size system, and
how many stations)
isolation valves
RTD probe
floor stand
manifold “T”s
3-2
INSTALLATION
Central Distribution System
UGS001/0798
UNPACKING
BOXES
THE
loader
hose clamp
hopper
RTD probe
hose
heat booster
floor stand
isolation valve
air pressure
tap hose
Return (to dryer)
Supply (from dryer)
manifold “T”s
UGS001/0798
Document name
INSTALLATION
3-3
UNPACKING
BOXES
THE
Accessories and Options:
The Drying monitor will monitor the
material’s exact conditions inside the
hopper and alert you of any problems.
The Peripheral Pump is used to pull
material from the hopper (using a pocket conveying valve or a single tube distribution box) to the throat of the
machine.
The Dust Collector prevents material
and dirt from being pulled into the
conveying system’s vacuum pump
The Dry Air Generator is used to provide dry air to closed loop systems and
prevent moisture regain in conveying
lines.
The single tube distribution box is
one option for emptying your hopper
into a conveying line.
The pocket conveying valve is another
method of emptying material from the
hopper to the conveying lines. It also
allows for purging.
A direct feed vacuum receiver
mounted to the throat of a processing
machineworks well with the CDS system and prevents large amounts of
material from sitting on the throat of the
machine.
The fantail manifold is used to convey
from one material sources to multiple
destinations, or from multiple material
sources to multiple destinations.
3-4
INSTALLATION
Central Distribution System
UGS001/0798
The CDS system is easy to install, if you prepare the area
properly, and follow the installation procedure later in this
manual.
PREPARING FOR
INSTALLATION
1 Make sure the installation area provides:
❒ Grounded, disconnectable power sources supplying
the correct current for each piece of equipment in
your system. Check each piece of equipment’s serial
tag for the correct amps, voltage and cycles. Field
wiring should be completed by qualified personnel to
the planned location for the CDS system. All electrical
wiring should comply with your region’s electrical
codes.
NOTE : You are responsible
for providing any additional
electrical disconnects that
may be required.
❒ Enough room for the entire system to be together.
This system is designed so that all equipment can be
together in one location. Do not place pieces of equipment farther apart than intended.
❒ Material vacuum lines to the general area of the
system. It is best to make sure you know where the
material lines are going to be before you install your
system.
❒ Common compressed air line with regulator. The
Pocket Conveying valve uses a clean, non-lubricated
source of air at 60-80 psi. We recommend filters and
regulators on all compressed air lines.
❒ Minimum clearance for safe operation and maintenance. The CDS system should be placed in a location
where it has 30-36 inches (76-91 cm) clearance on all
sides.
2
Have a plan. Know where you are going to install each
3
Sort and begin to lay out the pieces. Refer to the
control box, all material lines, and all electrical lines.
illustrations earlier in this section, and begin laying out the
pieces for the manifold and each station. Remember to
match all sizes. The size of the heat booster inlet should
match the size of the hose, the isolation valves, and the
“T” on the manifold.
UGS001/0798
Central Distribution System
NOTE : Never bundle communication lines with high
power electrical lines, or conveying piping. Static electricity, and electric current will
affect communication lines.
INSTALLATION
3-5
INSTALLING
SYSTEM
WARNING: Do not stand on the
equipment
THE
Do not use the floorstands or any equipment as
a ladder or step. This equipment is not
designed to safely support a person.
NOTE : See the appropriate
equipment manual for more
information on proper installation.
1 Clean out the area for your CDS system.
2 Lay out all the pieces to your system. Make sure
NOTE : If you are using a
Drying Monitor, install the
DM-1 probe before mounting
the hopper.
3
that the “T” stub ends match the hopper outlet size.
Set the floorstands and the dryer. We recommend
that you bolt the floorstands to the floor.
4
Mount the hoppers to the floorstands. Place the
5
Mount the pocket conveying valve or distribution box. They may be oriented in which ever way is
largest hopper closest to the dryer, and the smallest hopper
farthest from the dryer. Mount the hopper drainport below
the floorstand. On the flat bottom hopper, it may be necessary to drill a clearance hole in the floorstand.
easiest to connect to the conveying system.
6
Mount the Heat Booster on the hopper. See the
Heat Booster User Guide for instructions
on installign the isolation valves, heater
box, control and RTD sensor.
7
Mount the mitered elbow and
bypass valve on the
last floorstand in the
system. Veriy that the
valve is
3-6
INSTALLATION
Central Distribution System
UGS001/0798
8 Install the manifold, manifold adapters, and
piping to the heat booster. Install the manifold beginning
with the end furthest from the dryer. Begin with the upper
level of the manifold (return air). Complete this return air
manifold to the last hopper and adaptors. Then beginning
at the lower end of the bypass valve, install the manifold
piping back the supply air line to the dryer. Make sure the
placement of the manifold does not obstruct the outlet of
the distribution box.
INSTALLING
SYSTEM
THE
NOTE : If you have insulated
hose, place it from the dryer
to the manifold on the supply
side .
9 Continue the piping for any takeaway conveying. If the piping and the heat booster enclosures are
going to be mounted on the same wall, make sure that
there is enough room for the enclosure.
10 If you are using an existing dryer for dehumidifying, disable the process heaters.
1
Plan where you are going to place each control.
(heat booster enclosure and control, Drying Monitor, SLC
or Selectronic controls)
2
INSTALLING
WIRING
THE
Connect the wiring from the heat booster to its
electrical enclosure.
3
Connect the heat booster control to its electrical enclosure.
4
Connect the RTD probe to the heat booster
control.
5
Connect the wiring from the isolation valves to
the heat booster electrical enclosure.
6
Connect the air tubing from the pressure tap to
the heat booster electrical enclosure.
7
Connect all other controls by following the instruc-
NOTE : Never bundle communication wires with electrical wires or conveying lines.
NOTE : If you are using a
pocket conveying valve and a
Selectronic control, you will
need to wire from the destination loader back to the
conveying valve.
tions in the appropriate manual.
UGS001/0798
Central Distribution System
INSTALLATION
3-7
OPERATION
● Testing the installation . . . . . . .4-2
● Testing the pocket conveying
valve . . . . . . . . . . . . . . . . . . . .4-3
● Starting up . . . . . . . . . . . . . . . .4-3
● Shutting down . . . . . . . . . . . . . .4-3
UGS001/0798
Central Distribution System
4-1
TESTING THE
SYSTEM
INSTALLATION
NOTE : The temperature
controller is factory-set for
degrees Fahrenheit.
1
Turn on the dryer. Set the drying temperature to the
2
Turn on the Heat Booster.
3
Enter a drying temperature for the material
you are using.
lowest possible temperature. On CS dryers, it is not possible to set the drying temperature.
◆ The POWER ON light is lit.
◆ The temperature controller displays
“standby”.
Use the ▲ or ▼ button to pick a set point.
Make sure, two seconds after you release the ▲ or ▼ button, that the display blinks to show the temperature controller has accepted the new set point.
4
5
Make sure that all isolation valves are open.
6
If everything is working properly:
Flip the heat booster START/STOP switch to
START.
◆ DRYING light comes on. Both alarm lights are off.
◆ Heater elements come on. (Verify this by feeling air
inside the hopper at the hopper inlet.)
7 Turn off the heat boosters, followed by the rest
of the equipment, and close all valves.
4-2
OPERATION
Central Distribution System
UGS001/0798
1
Program the loader control per instructions in
the appropriate manual.
2 Turn on the dry air generator.
◆ You should hear the motor turn on.
3 Turn the pump system on.
TESTING THE
POCKET
CONVEYING
VALVE
◆ Control should recognize demand at loader.
◆ Pump should turn on and pocket conveying valve
should open simultaneously.
◆ The pocket conveying valve should close.
◆ The pump should remain on.
4 Turn all equipment off.
1 Turn on power to all equipment.
2 Fill any or all hoppers (as needed).
3 Open the isolation valves.
4 Enter actual drying temperatures on the heat
TO START
DRYING
booster control. On systems with no heat booster, set the
drying temperature on the dryer.
5 Start the dryer.
6 Start the heat booster heating process.
1
Turn off the heat boosters, followed by the rest
of the equipment.
2
3
4
5
Close all valves.
Empty material from hopper.
Purge lines (if necessary).
Turn off the dryer.
UGS001/0798
Central Distribution System
TO STOP
DRYING
NOTE : See your control
manual for information on
starting and stopping conveying.
OPERATION
4-3
MAINTENANCE
● Maintenance checklist . . . . . . . .5-2
Central Distribution System
UGS001/0798
5-1
MAINTENANCE
CHECKLIST
NOTE : See your component manuals for more maintenance information.
CAUTION: Hot Surfaces
Always allow the Heat Booster and drying
hopper to cool before performing repairs
or maintenance. Also, protect yourself
from hot exterior surfaces on the drying
hopper. Surface temperatures around
door frames of some hoppers and around
the return air hose can reach 180˚ to
200˚ F (82˚ to 93˚ C).
The CDS requires little maintenance. We recommend the following maintenance schedule and tasks. We also recommend
following the maintenance schedules in each of the component manuals.
● Whenever you change material or process
❒ Change Heat Booster set point if necessary.
❒ Clean out the pocket conveying valve or distribution
box.
❒ Clean out the hoppers.
● Daily or weekly as needed
❒ Inspect all hoses. Tighten hose clamps if loose.
Replace hoses if worn or damaged.
❒ Inspect all gaskets. Replace any worn or damaged gaskets.
❒ Inspect all filters. Replace filters if dirty or damaged.
● Monthly or as often as needed
❒ Inspect main power wires, heater wires and conduit,
switch wires, and probe wires for damage and wear.
Replace any damaged or worn wire or conduit.
❒ Check for damage to the Heat Booster control panel,
especially to the display. Replace any damaged component.
❒ Check for damage to the heater box.
❒ Check for leaking around heater box outlet junction at
hopper inlet.
❒ Clean dirt from exterior surfaces with damp (not soaking) cloth dipped in water.
5-2
MAINTENANCE
Central Distribution System
UGS001/0798
TROUBLESHOOTING
● Before beginning . . . . . . . . . . . .6-2
● A few words of caution . . . . . . .6-2
● When trouble occurs . . . . . . . . .6-3
● Drying problems . . . . . . . . . . . .6-4
● Moisture regain . . . . . . . . . . . . .6-5
● System problems . . . . . . . . . . . .6-6
● Material problems . . . . . . . . . . .6-7
Central Distribution System
UGS001/0798
6-1
BEFORE
BEGINNING
You can avoid most problems by following the recommended installation and maintenance procedures outlined in this
User Guide. If you do have a problem, this section will help
you determine what caused it and how to fix it.
Before you start disassembling the Central Distribution
System:
❒ Diagnose causes from the Heat Booster control panel.
You can start diagnosing some problems by viewing
alarm signals (or lack of power) on the control panel.
❒ Find the wiring diagrams and component manuals
that were shipped with your equipment. These manuals are the best references for correcting a problem. The
diagrams also will note any custom features not covered
in this User Guide.
❒ Try resetting the equipment. Many times, you can clear
an alarm (and a false alarm condition) simply by turning
the ON/OFF switch off, then back on.
A FEW WORDS
OF CAUTION
The Central Distribution System is equipped with numerous
safety devices. Do not remove or disable them. Improper
corrective action can lead to hazardous conditions and
should never be attempted to sustain production
WARNING: Only qualified service
personnel should examine and correct
problems that require opening electrical
enclosures and testing electrical wires
with power on to diagnose a problem.
WARNING: High voltage.
Always stop the equipment, disconnect and
lock out the main power source before troubleshooting or performing repairs.
CAUTION: Hot surfaces.
Always protect yourself from hot surfaces
inside and outside of the Heat Booster, drying hopper, pocket conveying valve and
hose manifolds.
6-2
TROUBLESHOOTING
Central Distribution System
UGS001/0798
The Heat Booster control is your main indicator of any drying
problems with your CDS system.
WHEN TROUBLE
OCCURS
1 Turn off all equipment.
2 See the appropriate manual for any alarm indicators you see.
3
Refer to the troubleshooting charts. Identify
the alarm signal or symptom that you saw.
4
5
Perform applicable tasks in the chart.
If the problem remains, contact Conair.
UGS001/0798
Central Distribution System
TROUBLESHOOTING
6-3
DRYING
PROBLEMS
6-4
If you have poor product quality, it may be due to a drying
problem. Use the following chart to correct any problems you
may have. (It may be necessary to see the troubleshooting
section of your dryer or Heat Booster manual.)
Symptom
Possible cause
Solution
Little or no airflow
Are the isolation valves
fully open?
Make sure that the isolation
valves are completely open on
stations being used.
Has the hosing been
crimped or cut?
Inspect and repair any damaged hosing.
Are hopper doors shut
and sealed?
Make sure all hopper doors are
closed and sealed.
Is the bypass valve
installed correctly?
Disconnect and turn over the
bypass valve if necessary.
Is the Heat Booster
mounted correctly to the
inlet of the hopper?
Make sure that the Heat
Booster is mounted properly.
Directional arrow should point
up.
Are the return and supply lines of the manifold
connected to the correct
inlets and outlets?
Review the installation instructions in this manual to make
sure you have connected all
equipment correctly.
Are the dryer filters
clogged?
Replace dryer filters as
described in your dryer manual.
Is the blower running
correctly?
Make sure air is blowing in the
correct direction.
Are the hopper filters
clogged?
Clean out the inlet and outlet
of the hopper.
TROUBLESHOOTING
Central Distribution System
UGS001/0798
Product quality may also be effected by moisture regain in
your system. Use the following chart to diagnose the problem. If you can not identify/solve your problem using this
chart, refer to the component manuals.
MOISTURE
REGAIN
Symptom
Possible cause
Solution
Poor product quality
Are your temperature
settings correct on your
dryer and Heat Booster?
Check the recommended drying temperature for your material.
Is the dryer producing a
low enough dewpoint for
your process?
Refer to your dryer manual.
(product displays
bubbles, cracking,
weak areas)
Is there a temperature
Refer to the heat booster manalarm on your heat boost- ual.
er control panel?
Is your hopper too small,
not allowing enough drying time?
UGS001/0798
Make sure that your process is
allowing enough time for
material to dry in the hopper.
Central Distribution System
TROUBLESHOOTING
6-5
SYSTEM
PROBLEMS
Use the following chart to determine and correct any system
problems.
Symptom
Possible cause
Solution
Poor part quality
Are you using dry air
conveying?
If moisture regain is a problem, it may be necessary to
add a dry air generator to your
system.
Are any hose connections
loose, cut, or torn?
Are any gaskets worn or
damaged?
Is your pocket conveying
valve or distribution box
sealed properly?
Do you have a large
inventory of material sitting at the machine (cooling)?
Repair or replace any damaged
hose.
Replace any gaskets or O-rings
that are damaged or worn-out.
Check to make sure that the
pocket conveying valve or box
is bolted tightly, and that gaskets are in good condition.
Make sure that material
remains in the hoppers until it
is ready to be used.
Is the purge side of the
In some conditions, it may be
distribution box connectnecessary to use dry air coned to a dry air generator?
veying.
6-6
TROUBLESHOOTING
Is your dry air source
malfunctioning?
Refer to the manual.
Is the hopper or loader at
the machine throat properly sealed?
Make sure that all connections
are tight.
Central Distribution System
UGS001/0798
Use the following chart to determine and correct any problems
you may have.
MATERIAL
PROBLEMS
Symptom
Possible cause
Solution
No material getting
to the machine.
(no part)
Is the material getting to
the processing machine?
Make sure that you don’t have a
clog at the throat or in the conveying line.
Make sure the component Refer to the component manual.
mounted to the throat of
the machine is operating
properly?
UGS001/0798
Is your conveying pump
working properly?
Refer to the component manual.
Is the demand switch
working properly?
Refer to the control manual.
Is the filter clogged at the
loader or at the dust collector?
Make sure that all filters are
clean. Replace any worn filters.
Is the pocket conveying
valve opening?
Make sure the valve is connected to the control properly.
Refer to the control manual.
Is the manual slide gate
open?
Open the slide gate.
Is the air adjustment correct on the pocket conveying valve?
Experiment with the air intake
valve until you get the proper
mix of vacuum and air. (see
manual)
Is the line connected
properly to the fantail
manifold?
Refer to the fantail manual.
Is the drying hopper
empty?
Make sure there is material in
the hopper.
Is your system sized
properly?
Make sure there is enough
material to fulfill the needs of
all loaders in the system
Central Distribution System
TROUBLESHOOTING
6-7
Conair has made the largest investment in customer support in
the plastics industry. Our service experts are available to help
with any problem you might have installing and operating
your equipment. Your Conair sales representative also can
help analyze the nature of your problem, assuring that it did
not result from misapplication or improper use.
WE’RE HERE
TO HELP
To contact Customer Service personnel, call:
HOW TO
CONTACT
CUSTOMER
SERVICE
From outside the United States, call: 814-437-6861
You can commission Conair service personnel to provide onsite service by contacting the Customer Service Department.
Standard rates include an on-site hourly rate, with a one-day
minimum plus expenses.
If you do have a problem, please complete the
following checklist before calling Conair:
❒ Make sure you have all model, serial and parts list
numbers for your particular equipment. Service
personnel will need this information to assist you.
BEFORE YOU
CALL ...
❒ Make sure power is supplied to the equipment.
❒ Make sure that all connectors and wires within
and between control systems and related
components have been installed correctly.
❒ Check the troubleshooting guide of this manual
for a solution.
❒ Thoroughly examine the instruction manual(s)
for associated equipment, especially controls.
Each manual may have its own troubleshooting
guide to help you.
❒ Check that the equipment has been operated as
described in this manual.
❒ Check accompanying schematic drawings for
information on special considerations.
IMS0002/0296
SERVICE INFORMATION
Additional manuals and
prints for your Conair
equipment may be
ordered through the
Customer Service or
Parts Departments for
a nominal fee.
APPENDIX A-1
EQUIPMENT
GUARANTEE
PERFORMANCE
WARRANTY
Conair guarantees the machinery and equipment on this order,
for a period as defined in the quotation from date of shipment,
against defects in material and workmanship under the normal
use and service for which it was recommended (except for
parts that are typically replaced after normal usage, such as
filters, liner plates, etc.). Conair’s guarantee is limited to
replacing, at our option, the part or parts determined by us to
be defective after examination. The customer assumes the cost
of transportation of the part or parts to and from the factory.
Conair warrants that this equipment will perform at or above
the ratings stated in specific quotations covering the equipment or as detailed in engineering specifications, provided the
equipment is applied, installed, operated and maintained in the
recommended manner as outlined in our quotation or specifications.
Should performance not meet warranted levels, Conair at its
discretion will exercise one of the following options:
● Inspect the equipment and perform alterations or adjustments to satisfy performance claims. (Charges for such
inspections and corrections will be waived unless failure to
meet warranty is due to misapplication, improper installation,
poor maintenance practices or improper operation.)
● Replace the original equipment with other Conair equipment that will meet original performance claims at no extra
cost to the customer.
● Refund the invoiced cost to the customer. Credit is subject
to prior notice by the customer at which time a Return Goods
Authorization Number (RGA) will be issued by Conair’s
Service Department. Returned equipment must be well crated
and in proper operating condition, including all parts. Returns
must be prepaid.
Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is
being made.
WARRANTY
LIMITATIONS
APPENDIX A-2
Except for the Equipment Guarantee and Performance
Warranty stated above, Conair disclaims all other warranties
with respect to the equipment, express or implied, arising by
operation of law, course of dealing, usage of trade or otherwise, including but not limited to the implied warranties of merchantability and fitness for a particular purpose.
WARRANTY INFORMATION
IMS0003/0796
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