Installation manual | ACS 100 Clothes Dryer User Manual

MDB Series Dehumidifying Dryers
Operation and Installation Manual
50, 100, 150, 255 CMF (85, 170, 255, 380 M3/hr)
Part Number: 882.xxxxx.00
Bulletin Number: DRY1-685
Effective: September 1, 2012
Write Down Your Serial Numbers Here For Future Reference:
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2013
All rights reserved.
ii
Shipping Info
Unpacking and Inspection
You should inspect the large dehumidifying dryer for possible shipping damage.
Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the Shipper
ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the agent’s
report. A certified copy of our invoice is available upon request. The original Bill of Lading is
attached to our original invoice. If the shipment was prepaid, write us for a receipted
transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
 Large Dehumidifying Dryer
 Bill of lading
 Packing list
 Operating and Installation packet
 Electrical schematic and panel layout drawings
 Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately. For
immediate assistance, please contact the correct facility located in the technical assistance section
of this manual. Have the order number and item number available. Hold the items until you
receive shipping instructions.
iii
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
Credit Returns
Prior to the return of any material authorization must be given by the manufacturer. A RMA
number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00
minimum) restocking charge.
ALL returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
No credit will be issued for material that is not within the manufacturer’s warranty period and/or
in new and unused condition, suitable for resale.
Warranty Returns
Prior to the return of any material, authorization must be given by the manufacturer. A RMA
number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
All returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given, at the manufacturer’s
discretion. If the item is found to be defective in materials or workmanship, and it was
manufactured by our company, purchased components are covered under their specific warranty
terms.
iv
Table of Contents
CHAPTER 1: SAFETY .............................................................. VII
1-1
1-2
1-3
How to Use This Manual .......................................................................................... vii
Safety Symbols Used in this Manual .................................................................. vii
Warnings and Precautions ........................................................................................ ix
Responsibility ............................................................................................................ x
General Responsibility .........................................................................................x
Operator Responsibility ........................................................................................x
Maintenance Responsibility ................................................................................ xi
Reporting a Safety Defect .................................................................................. xii
CHAPTER 2: GENERAL INFORMATION ................................ 13
2-1
2-2
2-3
2-4
2-5
2-6
2-7
Models Covered in This Manual...............................................................................13
Necessary Documents .............................................................................................13
General Description .................................................................................................13
Specifying a Drying System ...............................................................................14
What is Desiccant? ............................................................................................14
The Process/Regeneration Cycle.......................................................................15
Aftercoolers, Pre-Coolers, and Plasticizing Traps ..............................................15
Closed Loop and Heat Recovery Option ............................................................16
Process Heat Recovery Option ..........................................................................16
Modular Convey Options....................................................................................16
Material Overdrying Protection ...........................................................................16
Safety Devices and Interlocks ............................................................................17
Standard Features ...................................................................................................18
Mechanical Features..........................................................................................18
Electrical Features .............................................................................................18
Options ....................................................................................................................19
Dimensions and Specifications ................................................................................20
..........................................................................................................................20
Silo Dehumidification System ..................................................................................21
CHAPTER 3: INSTALLATION .................................................. 22
3-1
3-2
3-3
Positioning Your Dryer .............................................................................................22
Making Electrical Connections .................................................................................22
Checking for Proper Blower Rotation .......................................................................22
Three-Phase Models ..........................................................................................22
3-4 Process Air Connections Between the Dryer and Drying Hopper ............................. 24
3-5 Connecting Cooling Water to the Optional Aftercooler/Precooler and Closed Loop
Regeneration .....................................................................................................................24
Installing Water Lines ...........................................................................................24
3-6 Drying Hopper .........................................................................................................25
Removing the Rust Inhibitor ..................................................................................25
Air Trap Considerations ........................................................................................25
3-7 Positioning Your Dryer .............................................................................................25
v
CHAPTER 4: CONTROLS ........................................................ 26
4-1
4-2
4-3
4-4
4-5
4-6
Controller Descriptions ............................................................................................26
Operating the Dryer .................................................................................................26
DryPro Data Entry....................................................................................................28
Single Hopper Dryer Setup ......................................................................................28
Single Hopper Dryer Operation ................................................................................35
Program Upgrade Procedures .................................................................................41
PLC Program Upgrade .........................................................................................41
Dryer & Drying Hopper Faults ..............................................................................................43
Alarm List ...........................................................................................................44
4-7 Multi-Hopper Dryer Control Operation......................................................................45
CHAPTER 5: OPERATION ....................................................... 47
5-1
5-2
5-3
Pre-Startup Checks .................................................................................................47
Startup .....................................................................................................................47
Shutdown ................................................................................................................48
CHAPTER 6: OPERATION ....................................................... 49
6-1
6-2
6-3
6-4
6-5
6-6
6-7
Work Rules ..............................................................................................................49
Servicing Process Air Filters ....................................................................................49
Servicing the Dew Point Monitor ..............................................................................52
Symptoms of Worn Desiccant ..................................................................................52
Replacing Worn Desiccant.......................................................................................53
Replacing the Process Heater .................................................................................55
Replacing the Regeneration Heater .........................................................................56
CHAPTER 7: TROUBLESHOOTING........................................ 57
Determining Temperature Controller Errors or Sensor Errors...................................59
CHAPTER 8: APPENDIX .......................................................... 60
8-1
8-2
8-3
Technical Assistance ...............................................................................................60
Parts and Service Department ...........................................................................60
Sales and Contracting Department ....................................................................60
Annex B Information ................................................................................................60
Parts Diagrams ........................................................................................................62
vi
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining the mid-sized
dehumidifying dryer. The purpose is to assist you in applying efficient, proven techniques that
enhance equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be undertaken
without first contacting a service engineer.
The General Information section outlines models covered, standard features, and safety features.
Additional sections within the manual provide instructions for installation, pre-operational
procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup of
the mid-sized dehumidifying dryer. We can also provide the assistance of a factory-trained
technician to help train your operator(s) for a nominal charge. This section includes instructions,
checks, and adjustments that should be followed before commencing with operation of the dryer.
These instructions are intended to supplement standard shop procedures performed at shift, daily,
and weekly intervals.
The Controls and Operations chapters include a description of electrical and mechanical controls,
in addition to information for operating the dryer safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly
instructions for those areas of the equipment requiring service. Preventive maintenance sections
are included to ensure that the dehumidifying dryer provides excellent, long service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and available
options. A spare parts list with part numbers specific to your machine is provided with your
shipping paperwork package. Refer to this section for a listing of spare parts for purchase. Have
your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER indicates an imminently hazardous situation that, if not avoided, will result
in death or serious injury.
WARNING indicates a potentially hazardous situation or practice that, if not avoided,
could result in death or serious injury.
CAUTION indicates a potentially hazardous situation or practice that, if not avoided,
may result in minor or moderate injury or in property damage.
vii
Dryer Safety Tags
Hazard Alert Symbol
Mandatory Symbol
Description/Explanation
Preventative Maintenance
High Voltage Hazard. The
electrical enclosure is supplied
with 3-phase electrical power.
Use caution when using or
maintaining this product.
Every six months inspect all
electrical connections for
secure attachment. For
further information see the
Maintenance Chapter in this
manual.
Auto start Hazard.
Equipment may start at any
time. Lock out/tag out
before servicing the
machine.
Every month inspect all
electrical connections for
secure attachment and that all
warning labels are in place.
For further information see
the Maintenance Chapter in
this manual.
Hot Surface Hazard.
When the unit operates
above 212F (100C) the
surface of the unit may
reach excessive
temperatures. Use caution
when using or maintaining
this product.
Every month check heater
elements for continuity using
an ohmmeter. For further
information see the
Maintenance Chapter in this
manual.
Description/Explanation
Read Operators Manual. This equipment must be operated and
maintained by properly trained personnel. The information
contained within this manual must be read and understood prior to
operating this equipment.
Lock Out. This equipment is operated with 3-phase electrical
power. Therefore, when performing any maintenance operations
we recommend following the local standards for performing a
lock-out/tag-out procedure.
viii
1-2 Warnings and Precautions
Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes. This may include, but is
not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations.
To avoid possible personal injury or equipment damage when installing, operating, or maintaining
this equipment, use good judgment and follow these safe practices:
 Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.
 Follow all SAFETY CODES.
 Wear SAFETY GLASSES and WORK GLOVES.
 Work only with approved tools and devices.
 Disconnect and/or lock out power before servicing or maintaining the equipment.
 Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
 Operate this equipment within design specifications.
 OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
 Make sure the equipment and components are properly GROUNDED before you
switch on power.
 When welding or brazing in or around this equipment, make sure VENTILATION is
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with
sheet metal. An approved FIRE EXTINGUISHER should be nearby and ready for
use if needed.
 Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
 Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide by the
foregoing recommendations in order to make operator safety a reality.
ix
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard operating
conditions and when recommended instructions are followed in the maintenance and operation of
the machine.
All personnel engaged in the use of the machines should become familiar with their operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its vicinity.
Each individual must take responsibility for observing the prescribed safety rules as outlined. All
warning and danger signs must be observed and obeyed. All actual or potential danger areas must
be reported to your immediate supervisor.
General Responsibility
No matter who you are, safety is important. Owners, operators and maintenance personnel must
realize that every day, safety is a vital part of their jobs.
If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can affect
your production:
• Loss of a skilled operator (temporarily or permanently)
• Breakdown of shop morale
• Costly damage to equipment
• Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group from the
management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.
Hold daily equipment inspections in addition to regular maintenance checks. You will keep your
equipment safe for production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.
Operator Responsibility
The operator’s responsibility does not end with efficient production. The operator usually has the
most daily contact with the equipment and intimately knows its capabilities and limitations.
Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or through
a casual attitude toward machinery formed over a period of months or years. Your employer
probably has established a set of safety rules in your workplace. Those rules, this manual, or any
other safety information will not keep you from being injured while operating your equipment.
Learn and always use safe operation. Cooperate with co-workers to promote safe practices.
Immediately report any potentially dangerous situation to your supervisor.
 NEVER place your hands or any part of your body in any dangerous location.
 NEVER operate, service, or adjust the dryer without appropriate training and
first reading and understanding this manual.
x
 NEVER try to pull material out of the dryer with your hands while it is
running!
 Before you start the dehumidifying dryer, check the following:
• Remove all tools from the dryer;
• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the
area;
 If your dryer has been inoperative or unattended, check all settings before
starting.
 At the beginning of your shift and after breaks, verify that the controls and
other auxiliary equipment are functioning properly.
 Keep all safety guards in place and in good repair. NEVER attempt to
bypass, modify, or remove safety guards. Such alteration is not only unsafe,
but will void the warranty on your equipment.
 When changing control settings to perform a different mode of operation, be
sure selector switches are correctly positioned. Locking selector switches
should only be adjusted by authorized personnel and the keys removed after
setting.
 Report the following occurrences IMMEDIATELY:
• unsafe operation or condition
• unusual dryer action
• leakage
• improper maintenance
• NEVER stand or sit where you could slip or stumble into the
dehumidifying dryer while working on it.
 DO NOT wear loose clothing or jewelry, which can be caught while working
on the dryer. In addition, cover or tie back long hair.
 Clean the dehumidifying dryer and surrounding area DAILY, and inspect the
machine for loose, missing or broken parts.
 Shut off power to the dryer when it is not in use. Turn the switch to the OFF
position, or unplug it from the power source.
Maintenance Responsibility
Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety
a priority to effectively repair and maintain equipment.
Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric
supplies and all accessory equipment at the machine, and disconnect and lockout electrical and
pneumatic power. Attach warning tags to the disconnect switch and air shutoff valve.
xi
When you need to perform maintenance or repair work on a dehumidifying dryer above floor
level, use a solid platform or a hydraulic elevator. If there is a permanently installed catwalk on
your dryer, use it. The work platform should have secure footing and a place for tools and parts.
DO NOT climb on the dehumidifying dryer, machines, or work from ladders.
If you need to repair a large component, use appropriate handling equipment. Before you use
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes) be
sure the load does not exceed the capacity of the handling equipment or cause it to become
unstable.
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using them to
lift a load.
Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.
When you have completed the repair or maintenance procedure, check your work and remove
your tools, rigging, and handling equipment.
Do not restore power to the dehumidifying dryer until all persons are clear of the area. DO NOT
start and run the dryer until you are sure all parts are functioning correctly.
BEFORE you turn the dehumidifying dryer over to the operator for production, verify all
enclosure panels, guards and safety devices are in place and functioning properly.
Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should immediately
discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working
xii
Chapter 2: General Information
2-1
Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for 50, 100, 150 and
225 cfm Dehumidifying Dryers with DryPro control. Model numbers are listed on the serial tag.
Make sure you know the model and serial number of your equipment before contacting the
manufacturer for parts or service.
Our dehumidifying dryers are designed to generate heated, dehumidified air at carefully
controlled temperatures for use in closed-loop plastic drying systems. Moisture removal from
hygroscopic (moisture attracting) plastic pellets is an essential step in the manufacture of highquality plastic products. Our dehumidifying dryers are used to generate very low dew point air
heated to a controlled temperature for drying plastic pellets and regrind.
2-2
Necessary Documents
The documents listed below are necessary for the operation, installation, and maintenance of
Cabinet Series dehumidifying dryers. You can obtain additional copies from the manufacturer.
Make sure that the appropriate personnel are familiar with these documents:
 This manual.
 The schematic and assembly drawings included in the customer information packet.
 The Customer Parts List included in the information packet.
 Operation and installation manuals for any optional controls or auxiliary equipment in the
drying system.
2-3
General Description
Moisture removal from hygroscopic (moisture attracting) plastic pellets is an essential step in the
manufacture of high-quality plastic products.
Our Dehumidifying Dryers are used by the plastics industry to generate very low dewpoint air
that is heated to a controlled temperature for drying plastic pellets and regrind.
The drying system consists of a dry air source and drying hoppers with process heating controls.
The dry air source controls two primary sub-systems, the process air and the regeneration circuit.
Each dryer has a left and a right desiccant bed so that one bed can regenerate while the other is in
use.
The drying system can be configured for one drying hopper or for as many as 3 hoppers. The
process air heater can be located on the dryer (single hopper only) or on each individual drying
hopper. Heaters that are located on the drying hoppers have their own independent controls.
The Drying System
Dehumidifying dryers force hot, dry air through the resin in the drying hopper where the air picks
up moisture from the material and is drawn back to the dryer.
In the dryer, a desiccant bed strips moisture from the air. The dryer then re-heats dried process
air, and sends it back into the drying hopper to dry material again.
Large Dehumidifying Dryers
General Information
13
This system is a closed loop, because ambient (outside) air is never introduced into the process
air. See Figure 1. Our dehumidifying dryers use the closed loop system, because the process air
is typically much drier than ambient air, even after carrying moisture out of the plastic resin.
Recycling process air maintains drying efficiency at a consistently high level. (see
Figure 1).
Figure 1: Air Flow Diagram.
From
drying hopper
Ambient
Regen
filter
Process air
heater
Regen
bleed
Process
filter
To drying
hopper
Upper valve
Desiccant
beds
Desiccant
beds
Regen heater
Regen heater
Lower valve
Regen blower
Process blower
Specifying a Drying System
There were many variables considered in the selection of your drying system, including: type of
materials, residence time, throughput of the extruder or injection molding machine, ambient air
moisture and temperature, and the altitude at the processing site. Should your operating
environment change, we can advise you on necessary equipment, process time and temperature
modifications.
What is Desiccant?
Desiccant is a material that attracts and holds (absorbs) water from the air. The desiccant our
dryers use is a synthetic crystalline metal aluminosilicate that is blended with a clay binder and
formed into beads.
General Information
14
Absorbed water is driven from saturated desiccant by heating it to a high temperature (reducing
the desiccant's capacity to hold water) and forcing air through it. This moisture removal process is
called "regeneration".
The Process/Regeneration Cycle
Our dehumidifying dryers have two desiccant beds. While one bed is on-line in the process air
loop, the other is off-line being regenerated.
When a desiccant bed is on-line, it absorbs moisture from the process air. In time, the bed
becomes saturated with moisture and needs to be regenerated. The dryer automatically redirects
the process airflow to the second bed and starts the regeneration cycle on the first bed.
During regeneration, the dryer heats air to over 500°F (260ºC) and forces it through the desiccant
bed. Moisture driven off the bed bleeds to the atmosphere.
If you measure the temperature of the air bled to the atmosphere (bleed temperature), you should
observe a rise after a period of time. This condition, bed breakthrough or bed break, indicates that
the bed is dry. At bed breakthrough, the bleed air temperature peaks between 350°F (176ºC) and
400°F (204ºC). After bed breakthrough the desiccant is hot and needs to be cooled down to avoid
a temperature spike when the beds are switched.
The Dew Point meter measures the dew point of the process air. A properly regenerated bed
produces process air dew point of -40°F (-40ºC) or lower. This ultra-low humidity level is more
than adequate to dry plastics to as little as .003% moisture, depending on the process, material,
and ambient conditions.
Aftercoolers, Pre-Coolers, and Plasticizing Traps
These dehumidifying dryers force hot, dry air through the resin in the drying hopper, where the
High temperature applications (250°F to 400°F / 121°C to 204°C) require aftercoolers to cool
moist air returning to the dryer from the drying hopper. An aftercooler cools the return air by
100°F (38°C); this maintains dryer efficiency and condenses unwanted plasticizers from the airstream. Heat Exchangers are also required (called pre-coolers) when processing materials that
have low drying temperatures (typically 120 F to 150 F / 49 C to 66 C). Check your specific
dryer model technical specifications for actual requirements. Some models have a minimum low
end temperature range that will determine actual requirements.
Optional Plasticizer Trap:
• Plasticizer traps should be used when resins are processed in the family of
acetates, butyrates and/or propionates. They should also be used when any
resin (when dried) is known to produce residue, contaminates or volatiles. This
contaminate is trapped in the air stream and is carried back from the drying
process as the air leaves the drying hopper.
• The plasticizer trap will condense the contaminate that is in the air stream and
remove it before it enters the dryer unit. If this contaminant is not removed, it
can foul the desiccant beds and damage mechanical components in the dryer
and in the drying process
• Review your process and confirm with your resin supplier if this will be an
issue. If it is, a Plasticizer trap must be used or it will void the warranty on the
dryer.
General Information
15
Closed Loop and Heat Recovery Option
After bed breakthrough (see Process/Regeneration Cycle) the desiccant is hot and needs to be
cooled down to avoid a temperature spike when the beds are switched. Instead of using ambient
air to cool down the desiccant, the closed loop option recirculates a portion of the dry air from the
desiccant bed currently on-line for the process. This approach avoids introducing moisture from
the ambient air normally used to cool down the desiccant, also referred to as “pre-loading”. This
option may be required for high humidity environments.
The closed loop option may use an air to air or a water to air heat exchanger to cool the air before
it passes through the desiccant. If a water to air heat exchanger is used then a water source is
required (see section 3-5)
The heat recovery option utilizes an air to air heat exchanger to pull heat from the exhaust of the
regeneration cycle that would otherwise have been wasted. The recovered heat is then used to
pre-heat the air in the regeneration cycle before it reaches the regeneration heaters reducing the
amount of energy required to heat the air which translates to higher efficiency and lower
operating costs.
Process Heat Recovery Option
In high temperature applications the air returning from the drying hopper is at an elevated
temperature that requires cooling before it returns to the dryer. The process heat recovery option
uses an air to air heat exchanger to pull heat from the air returning from the drying hopper and
then the recovered heat is used to pre-heat the process air before it reached the process heaters.
This reduces the amount of energy required to heat the process air which increases efficiency and
decreases operating costs. This option is deal for high temperature applications.
Modular Convey Options
The midsized dryer line are designed to easily add a full range of convey options all of which are
controlled from the dryers touch screen. There are many variables to consider when adding a
convey system including dry air convey, proportioning, hopper and machine convey, among
others. For this reason consult sales who can advise you on necessary equipment.
Material Overdrying Protection
Material Overdrying Protection is an automatic system used to reduce the chance of over-drying,
and possibly melting, the resin in the drying hopper. Material Overdrying Protection activates
when the return temperature is above a set value, indicating that all the resin in the hopper is dry.
The control system monitors the return air temperature and automatically changes the process air
setpoint to the SET BACK SETPOINT value when the return air temperature rises above the set
back temperature. The process air setpoint returns to normal when the return air temperature falls
below the SETUP TEMPERATURE value. The target values for changing the process air
setpoint can be adjusted on the Mat Protect screen.
Recommended Temperature Settings
Drying Temperature (ºF)
160 180 200 220 240 260 280 300 320 340 360
Set Back Setpoint
130 145 160 175 190 210 225 240 170 260 290
General Information
16
Safety Devices and Interlocks
This section includes information on safety devices and procedures that are inherent to the large
dehumidifying dryer. This manual is not intended to supersede or alter safety standards
established by the user of this equipment. Instead, the material contained in this section is
recommended to supplement these procedures in order to provide a safer working environment.
At the completion of this section, the operator and maintenance personnel will be able to do the
following:
•
Identify and locate specific safety devices.
•
Understand the proper use of the safety devices provided.
•
Describe the function of the safety device.
Safety Circuit Standards
Safety circuits used in industrial systems protect the operator and maintenance personnel from
dangerous energy. They also provide a means of locking out or isolating the energy for servicing
equipment.
Various agencies have contributed to the establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the organizations
that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the large
dehumidifying dryer; however, it is the responsibility of the personnel operating and maintaining
the equipment to familiarize themselves with the safety procedures and the proper use of any
safety devices.
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a “Safe”
condition. As an example, a safety switch must be a normally open switch. The switch must be
held closed with the device it is to protect. If the switch fails, it will go to the open condition,
tripping out the safety circuit.
At no time should the safety device fail and allow the operation to continue. For example, if a
safety switch is guarding a motor, and the safety switch fails, the motor should not be able to run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are used
on the large dehumidifying dryer are primarily concerned with electrical power disconnection and
the disabling of moving parts that may need to be accessed during the normal operation of the
machines.
Some of the safety devices utilize a manual activator. This is the method of initiating the safety
lock out. This may be in the form of a plug, lever or a handle. Within this lockable handle, there
may be a location for a padlock. Personnel servicing the equipment should place a padlock in the
lockout handle.
General Information
17
In addition to the safety devices listed above, these dehumidifying dryers are equipped with a line
cord plug. This allows the operator or maintenance personnel to unplug the system from its
power source and tag it out. The plug can then be tagged with any number of approved electrical
lockout tags available at most electrical supply stores.
Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning the dehumidifying dryer. Failure to do so may result
in serious injury. No one but the person who installed the lockout may remove it.
2-4
Standard Features
Mechanical Features
 Rugged compact frame with sturdy 4” (10cm) casters
 Dual blower dryer with dual desiccant beds and electrically actuated valves
 180ºF – 300ºF (150ºC) standard drying temperature range
 High regeneration temperature control safeties
 13X desiccant (molecular sieve)
 Easy to access process, regeneration, and combustion air filters
 High pressure centrifugal blower
 Dew point +55º F to –90º F (13º C to -68º C)
Electrical Features
 Electrically-actuated air valves
 NFPA79, UL & CUL machinery electrical standards (Electric Dryers) includes:
NEMA 12 controls, components & enclosure
Non-fused electrical disconnect
Solid state relays for process heater control
Branch fusing
Lockable power disconnects
Color touch screen control
Password protection
Temperature display in C or F
Graphical temperature monitor
Data logging option available
Process & Regeneration PID temperature control with auto tune
Dewpoint extend
General Information
18
Material saver with temperature setback
Process recipes (200 max, over 50 pre-loaded)
Drying temperature
Residence time
Regrind percent
Density
Setback temperature
Throughput calculation
Alphanumeric hopper / process ID
Hour & KWH meters (total & resettable service)
Audible & visible alarm
7 day timer
Sequence shutdown
 Available supply voltages of 208, 230, 460, 575/3/60 and 220, 400/3/50
2-5
Options
Options can tailor your dehumidifying dryer system to meet the exact requirements of the drying
task being performed.
 Aftercoolers for high and low temperature applications.
 Audible/visual critical alarm.
 Dirty Filter indicator for each individual blower.
 Modular hopper stands, hopper banks, and convey systems.
 Closed loop regeneration and heat recovery system
 Process air heat recovery system
 Insulated dryer hose
General Information
19
2-6
Dimensions and Specifications
General Information
20
2-7
Silo Dehumidification System
Airflow range – Mid- Size 50-225 cfm
(In most cases, a 50 cfm dryer may not be adequate).
Metal silos are affected by the weather conditions surrounding them. They can become damp
internally from sweat on their sidewalls caused by changes in humidity and temperature and this
moisture can be transferred to the material stored in the silo. Silo dehumidifiers are not intended
to dry the material stored inside the silo.
Silo dehumidifiers operate on the simple principle of providing a blanket of dry air in the space
above the material to keep the material from picking up additional moisture while in storage.
Silo dehumidifiers are usually installed in the base of a silo. One dehumidifier may serve more
than one silo (if sized properly depending on the location and climate conditions).
The process heater is usually removed from the desiccant dryer (not required).
The process delivery air is driven to the top of the silo up the bulk material air delivery tube.
There is usual an air feeder tap line with a shut off valve (special tube assembly kit) sold with
the dryer to be installed in the truck fill line.
Never run the silo dehumidification system when you are filling material with the bulk truck fill
line. Isolate the dryer line with shut off valve and turn the dryer off line.
Run a return line back to the dryer to close loop the dryer and complete the loop to the dryer.
This silo dehumidified air blanketing system will blanket the silo with dehumidified air under
positive pressure. It will minimize moisture contamination of the resin.
The number of air exchanges and integrity of the blanket will depend on the size of the desiccant
system, the blower pressure and silo dome seals.
Review the silo deck for leaks prior to installation and install a PRV dome lid to prevent air from
leaking. Make sure the dome lid has pressure relief to allow for excess pressure build up.
Contact our factor application engineering for expert design and installation support.
General Information
21
Chapter 3: Installation
3-1
Positioning Your Dryer
The dehumidifying dryer system was designed to be wheeled into place. The entire assembly is
mounted on a rugged, compact frame and is equipped with sturdy, 4” (10 cm) heavy-duty casters.
It is important to leave room to access the dryer from the front, rear, and at least one side, for
repair and regular maintenance.
Use caution and observe safety rules when placing your dryer!
3-2
Making Electrical Connections
 Fulfill all national, state, and local safety and electrical code requirements.
 Connections should be made by a qualified electrician.
 Make sure all electrical connections are tight.
 Connect main power to the dryer at the disconnect or terminals in the upper right corner
of the control enclosure.
 Install a fused disconnect with a lockout feature in the power main leading to the dryer.
 The power drop must include a ground wire.
Proper grounding of the main power line is critical!
3-3
Checking for Proper Blower Rotation
Three-Phase Models
The blower rotates properly when air flows from the delivery outlet and a vacuum is felt on the
blower inlet.
In three-phase models, incorrect phasing of power leads can cause backward
rotation of blower motors and CONTAMINATION OF THE DESICCANT!
Always check blower rotation before putting material in the drying hopper!
If the three-phase blower rotates improperly, reverse any two wires at the fused disconnect
outside the dryer or at the disconnect/terminal in the control enclosure. This assures that the
blower rotates in the proper direction.
Installation
22
Process Blower
The air connection
marked “Delivery”
should be blowing air
while the “Return”
connection has suction.
Delivery port
Return port
Note: The return port is hosed to the process filter inlet.
Regeneration Blower
Regeneration filter
The regeneration filter
inlet shown should be
sucking air in for the
regeneration cycle.
Installation
23
3-4
Process Air Connections Between the Dryer and Drying Hopper
 Remove the cap plugs from the inlet, discharge and bleed tubes before operation.
 Use high-temperature flexible dryer hose to connect the dryer to the drying hopper.
 Keep the delivery hose as short as possible to minimize heat loss. Insulated dryer hose is
available for maximum energy savings.
 Do not shorten the return hose.
 Make sure the hoses are not kinked.
 Drying hopper air inlet and outlet locations vary from one drying hopper model to
another, but always connect the hoses so the dry process air from the dryer enters the
bottom of the drying hopper and flows out the top to return to the dryer inlet.
3-5
Connecting Cooling Water to the Optional Aftercooler/Precooler
and Closed Loop Regeneration
High temperature applications (250°F to 400°F / 121°C to 204°C) require aftercoolers to cool
moist air returning to the dryer from the drying hopper. An aftercooler cools the return air by
100°F (38°C); this maintains dryer efficiency and condenses unwanted plasticizers from the airstream. Heat Exchangers are also required (called pre-coolers) when processing materials that
have extremely low drying temperatures (typically 120 F to 150 F / 49 C to 66 C). Check your
specific dryer model technical specifications for actual requirements. Some models have a
minimum low end temperature range that will determine actual requirements.
Installing Water Lines
•
Use the ½” (about 13 mm) brass pipe nipples for water line connections.
Inlet and outlet line positions do not matter.
•
Make sure you grip the nipple tightly when attaching a fitting. Doing so
prevents damage to the soft copper coils. You should make connections
with flexible hose to allow removing the coil assembly for cleaning.
•
The aftercooler is designed to utilize either tower or city water as warm as
85ºF (29ºC). Recommended flow rate is one to three (1 to 3) gallons per
minute (4 to 11 liters per minute).
OPTIONAL PLASTICIZER TRAP –
•
Plasticizer traps should be used when resins are processed in the family of acetates, butyrates and/or
propionates. They should also be used when any resin (when dried) is known to produce residue,
contaminates or volatiles. This contaminate is trapped in the air stream and is carried back from the
drying process as the air leaves the drying hopper.
•
The plasticizer trap will condense the contaminate that is in the air stream and remove it before it
enters the dryer unit. If this contaminant is not removed, it can foul the desiccant beds and damage
mechanical components in the dryer and in the drying process
•
Review your process and confirm with your resin supplier if this will be an issue. If it is, a Plasticizer
trap must be used or it will void the warranty on the dryer.
Installation
24
3-6
Drying Hopper
Removing the Rust Inhibitor
Rust preventative has been applied to internal unfinished surfaces. Remove rust inhibitor before
using the drying hopper.
Using a non-water based degreasing agent, clean all inside surfaces of the drying hopper. Allow
components to dry thoroughly.
Inspect the inside of the drying hopper for loose connections, foreign objects, or a blocked
diffuser.
Air Trap Considerations
The air trap assembly in the top of the drying hopper prevents ambient air from contaminating the
material being dried.
 Keep the material level at the mid point of the air trap for maximum efficiency.
 Use a hopper loader or vacuum conveying system to maintain the proper material level.
3-7
Positioning Your Dryer
For the dryer work function properly it is critical to place the process air thermocouples on the
drying hopper inlet and outlet. These devices accurately monitor the air temperature entering and
leaving the drying hopper, the value of which is used by the control to maintain the process
temperature set point. Compression fittings are required to hold the thermocouple in place so that
the tip is approximately in the center of the tube as shown.
Air Inlet
Air Return
This photo demonstrates the proper
location of the thermocouple inside
the air inlet and return tubes.
The locations of
the inlet and
return will vary
on different
drying hoppers.
Compression fitting
Adapter (if required)
1/8” NPT to BSPT 1/8”
Installation
Thermocouple
25
Chapter 4: Controls
4-1
Controller Descriptions
The DryPro dryer control system is designed to control all ACS cabinet, medium and large
dryers. These dryers have separate Process and regeneration blowers and up to four desiccant
beds.
The DryPro control system includes the following features:
•
•
•
•
•
Customer configurable drying hopper identification.
Enhanced diagnostics for quick troubleshooting.
Support for up to 3 drying hoppers.
Support for Compact Flash memory cards.
o Save & restore dryer configurations easily.
o Save and recall material process recipes.
o Automatic Program upgrades with.
o Optional data logging.
Ethernet monitoring.
The dryer is available in two basic configurations—local I/O and remote I/O.
•
•
4-2
Local I/O where the Process heater controls are integral to the dry air source.
o Used for single drying hopper configurations.
o All controls are mounted on the dryer.
Remote I/O, for Central drying applications, where the Process heaters are separate
from the dry air source.
o Used on systems with from 2 or 3 drying hoppers.
o Drying hopper I/O is connected to the dryer controls using high speed
communications.
Operating the Dryer
To operate the dryer, access the Dryer Status screen and press the “Start” button.
The main air valves will find home position.
•
If the left bed finished regeneration then the right bed will be placed into
regeneration and the left bed will be placed into Process.
•
If the left bed did not finish regeneration then the left bed will be placed into
regeneration and the right bed will be placed into Process.
The Process blower(s) will start. 1
1
•
When air flow is verified, all enabled drying hoppers heaters will begin
heating the process supply air to their respective set points.
•
There is an adjustable time delay between the Process blowers starting and
the drying hoppers Process supply air heaters starting to allow the Process
supply air header to come up to operating pressure.
The Process and regeneration systems start operation in parallel and run independently.
Controls
26
The drying hoppers can be started in a staggered manner where the control waits an adjustable
time between starting each drying hopper.
ACS recommends that the customer execute an auto-tune cycle on the regeneration beds and
drying hoppers when the dryer is placed into service for the first time.
The regeneration blower starts. 2
•
When air flow is verified, the bed in regeneration is brought to the pre-set
regeneration temperature.
•
The bed remains at the regeneration temperature until either a pre-set time
has expired or the beds outlet air temperature rises above the “Bed Break”
target value at which point the regeneration heaters are turned off and the bed
is allowed to cool for either a pre-set time period or until the bed outlet
temperature reaches the “Cool Down” target value. If the closed loop
regeneration option was purchased, then the closed loop valve will place the
cooling bed into closed loop cooling, as opposed to ambient cooling, when
the bed outlet temperature reaches the “Closed Loop” target value.
A customer adjustable option allows the beds to switch either when the regeneration cycle
completes (“Switch on Time”) or if the dew point rises above a pre-set limit (“Switch on Dew
Point”). The “Switch on Dew Point” option will also cause the beds to switch if a side has been
on-line for an adjustable amount of time.
ACS recommends that the customer execute an auto-tune cycle on the regeneration beds and
drying hoppers when the dryer is placed into service for the first time.
The pattern continues until the dryer is shut down by pressing the “Stop” button on the Dryer
Status screen or the auto start feature reaches a preprogrammed stop event time. However it is
stopped, the DryPro control puts the dryer into a sequenced shutdown.
•
The drying hoppers process supply air heaters shut down and then the Process air
blower(s) shutdown after an adjustable delay and below an adjustable temperature.
•
Any running regeneration cycle is allowed to finish and then the regeneration blower
is shutdown.
•
The dryer can be re-started by pressing the “Restart” button on the Dryer Status
screen.
The Process and regeneration systems run in parallel and independently of each other with the
following exceptions.
2
The Process and regeneration systems start operation in parallel and run independently.
Controls
27
4-3
DryPro Data Entry
Values and text are changed using on-screen keypads. The screen will display either a numeric or
alphanumeric keypad, depending on the type of data entry.
The appropriate keypad appears when a changeable value is pressed.
Minimum & maximum values are indicated for each numeric value. Values outside of these
limits are rejected.
Passwords. All functions except starting and stopping the dryer require a password. Operator and
supervisor access require the entry of a valid user name and the associated passwords. Valid user
names are:
Oper1
Oper2
Super1
Super2
Oper1 & Super1 passwords can be changed. Passwords are provided in a separate document.
4-4
Single Hopper Dryer Setup
The customer can fine-tune the dryer by changing values and turning options on or off. All setup
screens are accessed from the setup menu:
Access to setup functions require supervisor password.
Controls
28
System Setup.
Use the “System Setup” display to
• Select whether temperatures are displayed in Fahrenheit or Celsius.
• Select metric or standard measure for volume & density.
• Set the alarm silence duration
The following are set at the factory and should only be accessed to commission a new
display when the configuration can not be restored from compact flash.
• Select the appropriate thermocouple type.
• Set the dryer size.
1
Hopper Setup
3
2
5
4
Use the Hopper Setup screen to:
Controls
29
1.
Set the normal process temperature setpoint. The material saver setpoints are
set on the Overdry Protect Setup screen.
2.
Set the deviation limits for process temperature alarms. Also set the standby
time to allow the drying temperature to rise to the set value at system startup.
3.
Set the process ID for the hopper. This can be a press ID, product name, or
any other value that makes sense. Also, the hopper volume and heater KW are
set. These values are used in throughput and KWH calculations.
4.
Press the material name to call up the Material Select screen described below.
Selecting a new material / recipe when the system is idle will automatically
change the drying temperature, setback temperature, residence time, and
density. If the dryer process is running, selecting a new material has no effect
on current settings.
5.
Press the Autotune button to call up the Process Autotune screen described
below.
Material Select Screen
Use the Material Select screen to recall the material / recipe to use. Pressing the “Load” button
will make the highlighted recipe current and return to the Hopper Setup screen. Pressing the
“Setup” button will call up the Material Setup screen described below.
Controls
30
Process Autotune Screen
Use the Process Autotune screen to start or stop autotune for the process heater. Also, values
can be manually entered, although this is generally discouraged. Autotune should be performed
on initial startup after installation, and any time a process change occurs that affects air flow
through the hopper. The values will change after a successful autotune. When autotune is in
progress, the banner message is displayed on this screen and “AT” indicators are displayed on
status screens.
Material Setup Screen
Use the material setup screen to make changes to the current material (recipe). Changing the
regrind percent will recalculate density, although density can also be manually entered. Press
the “Save” button to make changes permanent, otherwise changes will be lost when a new
recipe is selected or the dryer power is shut off. Press the “Copy” button to create a new recipe
using the current recipe as a template. Press the “New” button to create a new blank recipe.
Pressing the “New” or “Copy” button calls up the New Material Setup screen:
Controls
31
Use this screen for entering data for new recipes. Pressing the “Save” button will write the new
recipe to Compact Flash and return to the Material Setup screen. Pressing “Cancel” will return
to the Material Setup screen without making a new recipe.
Regen Setup screen
Use this screen to control the regen process. Bed switch on dewpoint can be set up here as well
as on the Dewpoint Setup screen. Regen heat time can be based on time only or on bed break
with an override time. The closed loop cooling option can also be enabled, although this
requires that the closed loop components are installed on the dryer.
Controls
32
Dewpoint Setup screen
Use this screen to set up switch on dewpoint parameters, as well as the high dewpoint alarm
value.
Overdry Protect Setup screen
Use this screen to configure overdry protection for your material. Setback setpoint is the
secondary drying temperature to use. Setback @ is the hopper exit temperature that will cause
the secondary setpoint to be activated. Setback Delay is how long the exit temperature must be
above the Setback @ setting before setback is activated. Setup @ is the hopper exit temperature
that will cause the drying temperature to be returned to the normal setpoint. Additionally,
material setback can be activated based on convey activity from the hopper. If selected, a lack
of convey activity for the set by Convey Delay will trigger setback, but only after residence
time has been satisfied.
Controls
33
Hour Meters Setup screens
Use these screens to view and / or reset the various hour meters associated with the dryer. To
reset a meter, press the “R” button for 3 seconds. Note that only the “Since Service” values are
resettable. Additionally, hour meters can be viewed via the Main Menu screen, but not reset.
Controls
34
4-5
Single Hopper Dryer Operation
Main Menu screen
9
8
1
2
3
7
6
4
5
The Main Menu is the main navigational screen for the DryPro control system.
No password is required to access :
1) Dryer Status
3) Regen Status
6) Alarms
7) Hour Meters
9) Splash screen
Operator or above password is required for 2) Hopper status.
Controls
35
Supervisor or above password is required for:
4) Setup Menu
5) Auto Start Timers
Service password access is required for Service screens (ACS qualified personnel only).
No password is required to access 8) Users screen, however functionality depends on current
password access.
E
F
D
1) Dryer Status screen
I
G
B
C
A
H
A) Dryer Start / Stop / Restart button
B) Dryer Status message
C) Auto Start Timer Active indicator.
D) Process temperature, setpoint, dewpoint, and exit temperature.
E) Hopper Status indicator / Button. Hopper color indicates status. Touching hopper
graphic calls up Hopper Status screen.
F) Auto Tune / Setback Active indicators. Displayed only when auto tune (“AT”) is in
progress or setback (“SB”) is active.
G) Regen Status Indicators / Button. Regen bed and heater icons indicate status. Touching
any graphic of the regen system (heaters, beds, blower) calls up the Regen Status screen.
Controls
36
H) Regen Heater Temperature. This appears adjacent to the bed currently in the regeration
cycle. Each Regen heater also may indicate “AT” when autotune is in progress for a
regen heater.
I) Regen Exit Temperature.
Touching any current temperature value will display the associated graphical trend screen.
2) Hopper Status screen
This screen displays the current values for the drying hopper as well as allowing for changing
the drying temperature. Operator or above password access is required. As with the Dryer
Status screen, touching any current temperature value will display the associated graphical
trend screen.
Controls
37
3) Regen Status screen
This screen displays all current status values for the regen subsystem. As with the Dryer Status
screen, touching any current temperature value will display the associated graphical trend
screen.
4) Setup Menu screen
See section 4-4.
5) Auto Start Timer screen
Controls
38
This screen is used to control the auto start functionality of the dryer. AutoStart must be
enabled for entered times to take effect. A value of 12:00 AM is considered a non-value and has
no effect. This screen requires supervisor password access.
6) Alarm History screen.
This screen displays a list of alarms that have occurred with descriptions and time
stamps.
7) Hour Meter Display screens
These screens are used to view current hour meter and KWH meter values. Note that meters
can only be reset via the Setup menu Hour Meter screens (see section 4-4).
Controls
39
8) Users screen
This screen is used to change passwords for User1 or Super1. That user must be logged
on to be able to change the password. User2 & Super2 passwords cannot be changed.
1) Splash screen
This screen is used to view the current PLC and HMI software versions.
Graphical Trend screens.
Controls
40
These screens are used to graphically track all dryer temperatures:
Process inlet (shown above)
Process exit
Regen heater
Regen exit
Dew point
4-6
Program Upgrade Procedures
The DryPro PLC and touch screen use either a EEPROM module or compact flash memory card
for program upgrades. Occasionally, a program upgrade will become available from ACS for the
DryPro PLC, touch screen or both. Follow the instructions in this document to upgrade the
specific component.
PLC Program Upgrade
Dry-Pro PLC field upgrade instructions
-
Record current dryer settings.
Turn off power.
Remove memory cassette cover.
Insert Memory cassette.
Controls
41
-
Turn dip switch 2 on (slide to right side).
-
Turn on Power.
Wait for “Backup” indicator to turn off.
Turn off power.
Remove memory cassette.
Replace cover.
Turn off dip switch 2.
Resume normal operation.
Restore settings that have changed.
Return upgrade kit to ACS for credit.
Power up the dryer, inspect and verify the new version number(s)
Start the dryer as required.
Dry-Pro HMI field upgrade instructions
-
Turn off power.
Remove existing compact flash – note orientation.
Retain existing compact flash for re-installation.
Insert upgrade compact flash.
Turn on power.
HMI will transfer upgrade database from compact flash.
HMI will return to normal operation.
Turn off power.
Remove upgrade compact flash.
Re-install existing compact flash.
HMI is ready for normal operation.
Return field upgrade kit to ACS for credit
Controls
42
Dryer & Drying Hopper Faults
Faults fall into two broad categories.
• Critical Faults – Shuts down equipment.
• Non-Critical Faults – Does not shut down equipment.
Critical faults are assigned to conditions that could cause damage to either the dryer
components or the material in the drying hopper while non-critical faults are assigned to
conditions that would allow an undesirable or inefficient Process condition to exist.
Because the Process and regeneration systems of the dryer operate independently, it is possible
that a condition exists in the regeneration system that prevents it from operating while the
Process system continues to operate without error.
Controls
43
When a fault condition occurs, the screen displays an “Alarm Banner” showing the time, date
and a brief description of the alarm. Optionally, the control will sound a klaxon and turn on an
alarm lamp. The alarm banner, klaxon and lamp do not distinguish between critical and noncritical alarms. The klaxon can be silenced and the alarm lamp turned off by pressing the “Push
to Silence” button on either the alarm banner or alarm history display. However, depending on
the customer’s setup, the klaxon and lamp may repeat after a pre-set time if the alarm condition
still exists.
If a dryer critical fault occurs then either a “Process Fault Push to Reset” or a “Regen Fault
Push to Reset” button appears on the overview displays. Press the button to restart the failed
system once the nature of the alarm is understood and corrected.
If a drying hopper critical fault occurs then disable and re-enable the drying hopper once the
fault has been corrected.
Alarms generally take the following forms:
• If something should be “ON” and it’s “OFF” or vice versa.
o Blower Motor Overloads should always be “ON”.
o Heater isolation contactors should be “ON” when the heaters are in use and OFF
otherwise.
• If a value is less than a pre-set limit.
o Process supply air temperature low deviation alarm.
• If a value is greater than a pre-set limit.
o Dryer high dew point alarm.
Alarm List
The following list describes all the alarms the control can detect. In general, those described as
faults are critical and will shut down the process, regen, or both subsystems. Alarms and alerts are
non-critical
Closed Loop Valve Position Alarm
Dewpoint Senser Error Alarm
High Dewpoint Alarm
Main Air Valve Position Fault
Process Air Blower Safety Fault
Process Air Dirty Filter Alert
Process Heater Temp Safety Fault
Process Heat High Temp Safety Fault
Process Heat High Deviation Fault
Process Inlet Sensor Error Fault
Process Outlet Sensor Error Alert
Process Low Deviation Alarm
Right Regen Heater Temp Safety Fault
Right Regen Heat High Deviation Fault
Right Regen Heat Low Deviation Fault
Left Regen Heater Temp Safety Fault
Left Regen Heat High Deviation Fault
Left Regen Heat Low Deviation Fault
Left Regen Heat Sensor Error Fault
Regen Air Blower Safety Fault
Controls
44
Regen Air Blower Safety Fault
Regen Air Dirty Filter Alert
Regen Exhaust Sensor Error Alert
Temperature Alarms
The control checks for high low and fail to change (loop break) alarm conditions on the
regeneration inlet temperature and the drying hopper process supply air temperature. It also
checks for high temperature on the dryer exit and the pre-cooler (or after-cooler) if the option is
installed.
A high temperature alarm is generated when the actual temperature rises above a pre-set limit, or
when the difference between the actual temperature and a controlling set point (if one exists) is
greater than a calculated limit. High temperature alarms are always treated as critical alarms.
A low temperature alarm is generated when the actual temperature falls below a pre-set limit, or
when the difference between the actual temperature and a controlling set point (if one exists) is
less than a calculated limit. Low temperature alarms are always treated as non-critical alarms.
A loop break alarm is generated when a controlled temperature fails to rise by X degrees every Y
seconds while its heaters are consuming power. The setting values associated with loop break
alarms are automatically calculated following the completion of an auto-tune. Loop break alarms
are always treated as critical alarms.
4-7
Multi-Hopper Dryer Control Operation
The DryPro Control for a dryer with more than one hopper is very similar to the standard
single hopper version. However, there a few differences that need to be noted.
You will notice the addition of the black and white arrow on several setup screens. This
allows for a convenient transition from one hopper or dryer setup screen to the next. The
single hopper control did not require this arrow.
Controls
45
The other key difference is the addition of the new pushbutton on the Drying Hopper screens.
For example, the green “Enable” icon on this screen is new. There may be other text that is
shown in the box. Pressing the box will perform a specific function depending on the text shown:
1
2
3
4
ENABLE
DISABLE
START
STOP
(Dryer is off and hopper is currently disabled)
(Dryer is off and hopper is currently enabled)
(Dryer is on and hopper is currently off)
(Dryer is on and hopper is currently running)
Controls
46
Chapter 5: Operation
5-1
Pre-Startup Checks
1.
Verify that the drying hopper is clean of rust-prohibitive oil or any foreign objects.
2.
Verify that process and return hose connections are tight.
3.
If your dryer has a water-cooled aftercooler/Precooler or closed loop cooler, make sure
that sufficient cooling water flows properly through the coil and that you have bled any
trapped air from the system. Make sure that the aftercooler/Precooler or closed loop
cooler has the proper supply water temperature.
4.
Check all companion equipment, such as the sight glass loader and drying hopper loader;
verify that all convey tubing is in place and the loading system is ready for operation.
5.
Verify that all electrical connection are tight and the unit is properly grounded.
6.
With main power on, turn the dryer on until the process blower starts, verify blower
rotation. (see section 3-3)
Clean the rust-preventing oil from inside the drying hopper.
Failure to clean the hopper fouls the desiccant and voids your warranty!
5-2
Startup
1.
Turn on (energize) the disconnect switch in your power drop.
2.
Turn the system ON/OFF switch to ON to energize the display panel.
3.
Close the slidegate at the bottom of the drying hopper.
4.
On three-phase models, make sure that the blowers turn in the right direction.
5.
Fill the drying hopper with material.
6.
Turn the DRYER ON/SEQUENCE SHUTDOWN switch to ON to start the dryer.
7.
The process blower will start.
8.
Set the process set point on the temperature controller to the recommend drying
temperature provided by the resin manufacturer. Press and hold the Auto-Tune key on the
process temperature controller for two (2) seconds to initiate the auto-tune function.
9.
After the proper pre-drying time for the initial hopper fill has elapsed, fully open the
drying hopper slide gate.
To allow proper residence time during continuous processing, maintain
the material level in the hopper at the midpoint of the air trap assembly.
Operation
47
5-3
Shutdown
1. Turn off the conveying system supplying the drying hopper.
2.
When processing is complete, close the hopper slide gate and shut down any in-line
companion equipment, such as the aftercooler.
3. Turn the dryer ON/OFF selector switch to the SEQUENCE SHUTDOWN position. The
sequence shutdown operation turns off process heaters and keeps the process blower on
for twenty minutes to cool down the process. The regeneration cycle of the off-line bed
completes the cycle before the dryer shuts down completely.
4.
To override the sequence shutdown turn the system ON/OFF switch to OFF.
5.
To completely shut off the unit after sequence shutdown has completed, turn the system
ON/OFF switch to OFF.
6.
If needed, empty the drying hopper.
7.
For maintenance or a long term shutdown, open (de-energize) the electrical disconnects
at the dryer and at the power drop.
Operation
48
Chapter 6: Operation
6-1
Work Rules
The installation, operation, and maintenance of this equipment is to be conducted in accordance
with all applicable work and safety codes for the installation location. This may include, but is not
limited to, OSHA, NEC, CSA, and any other local, national, and international regulations.
In addition, you must observe the following specific work rules:
 Keep these operating instructions on hand and follow them when installing, operating, or
maintaining your dryer.
 If these instructions become damaged or unreadable, you can obtain additional copies
from the manufacturer.
 Only qualified personnel familiar with this equipment should work on or with this unit.
 Work only with approved tools and devices.
Disconnect power before servicing your dryer. If the disconnect switch you installed has a
lockout, lock it in the OFF position before you perform any maintenance or service.
6-2
Servicing Process Air Filters
Operating the dryer without the process air filter installed voids your
warranty! Filter cleaning is an important part of your dryer
maintenance program.
Our dehumidifying dryers have a single cartridge canister-type filter in the process and conveying
air loop. The process filter is mounted above the process blower on the rear of the dryer. The
conveying filters are located under the drying hopper next to the conveying blowers. These filters
protect the blowers from plastic fines drawn in from the drying hopper. Regular filter cleaning is
essential to keep your dryer operating at peak efficiency.
You can wash or blow out the filters, but remember, you reduce dirt holding capacity with each
washing. The risk of dirt reaching the clean side of the filter during cleaning, plus possible filter
damage from high pressure washing or blowing, makes washing a gamble.
You can carefully clean or wash the filter when airflow becomes restricted. Do not wash filters
more than six (6) times or use them for more than a year, whichever comes first.
Use a detergent that won’t damage filter media. Such a detergent permits easy removal of dirt
particles through flushing and rinsing. An effective detergent removes the fine particles from the
pores of the filter media.
The filter manufacturer recommends FM 1400 washing compound. It is formulated specifically
for air filter element cleaning. It is non-sudsing and works in hot or cold water. FM 1400 contains
biodegradable synthetic detergents and is non-phosphate, non-NTA. For more information,
contact Filter Service Corporation, 2603 A West Main, Farmington, NM, 1-505-326-1127.
Operation
49
Recommendations for Cleaning and Replacing Filters
•
Turn off and/or lock out electrical power to the dryer.
•
Remove the threaded fastener securing the filter access cover, and then
remove the cover.
•
Remove the nut on the center retaining rod to remove the filter cartridge.
Vacuuming
Try vacuum-cleaning a soiled filter first. Vacuuming removes most large particles and surface
contaminants, and may suffice for the first time you clean a filter. Use a commercial-duty (recommended)
or household vacuum cleaner. Vacuum the filter from the air intake (dirty) side only.
Cleaning with Compressed Air
Blow clean, dry compressed air up and down the pleats, blowing out the filter from the clean
side. Remove loose dirt from the filter with compressed air or a water hose. Compressed air
should be less than 100 psi (689.5 kPa/6.89 bars). Use a 1/8”
(3 mm) dia. nozzle at least 2” (5 cm) away from the filter. Don’t shoot the air in a crisscross motion
against the grain of the pleats—you may damage it.
Washing
As a last resort, wash the filter. However, do so only if the pressure drop is too high
from fine dirt embedded in the filter, or if oily mist is present near the intake air
location. Soak in a solution of FM 1400 or comparable detergent and warm water from
five to ten minutes, then gently agitate for several minutes.
Rinse thoroughly with clean water to remove all detergent.
Let the filter dry completely before returning it to service! A damp filter can
contaminate the closed loop system of the dryer.
Do not use a light bulb to dry the filter. You should get satisfactory filtration after second or third
washings; however, dirt-holding capacity of the filter decreases after each washing.
After each cleaning:
•
Inspect the filter element. Briefly hold a light bulb behind the element and look for
any fatigued paper or residual dirt. Inspect for holes and tears by looking though the
filter toward a bright light. Check for damaged gaskets or dented metal parts. Do not
re-use a damaged filter!
•
Inspect the end plates. Any damage here can allow air to bypass the filter.
•
Look for rust on the end plates and metal core. Rust particles can flake off and
contaminate the dryer and resin.
•
Check the gasket for damage. A damaged gasket allows contaminants into the process.
Replace as needed.
•
Allow the filter to dry before re-using. Circulate warm air at less than 160ºF (71ºC). Do not use a
light bulb to dry the filter
Operation
50
Preventative Maintenance Checklist
Dehumidifying Dryer Systems
System model #
Serial #
Date/
By
Every week
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Nov
Dec
Inspect all filters for
wear, replace/clean
if dirty or worn.
Every month
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Lock out electrical
power and inspect
electrical wiring for
integrity.
Lock out electrical
power and check
heater elements for
continuity using an
ohmmeter.
Check dew point
and temperature
tracking with an
external dew point
monitor and
pyrometer.
Visually inspect the
shifting of the airflow
valve during one
cycle.
Every year
Next scheduled
inspection
Actual inspection
Date/By
Next scheduled
inspection
Actual inspection
Date/By
Scheduled
replacement date
Actual replacement
Date/Work done by
Scheduled
replacement date
Actual replacement
Date/Work done by
Inspect desiccant. Replace
if brown or broken.
Every two years
Replace desiccant.
-
Photocopy this page for your maintenance records –
Operation
51
6-3
Servicing the Dew Point Monitor
The accuracy of the dew point monitor on dehumidifying dryer systems depends on proper
operation of the dew point sensor and the control board. The dew point sensor is in the process air
stream and is therefore susceptible to contamination.
Dew point sensor life depends on:
Air temperature and flow passing over the sensor.
The amount of fines (dust) in the process air.
The amount of plasticizer vapor in the process air.
The dryer operator should monitor the initial dew point sensor readings and establish a periodic
replacement schedule as needed.
Do not attempt to check the continuity or resistance of the dew point sensor.
The sensor will be destroyed!
6-4
Symptoms of Worn Desiccant
The moisture absorption capacity of the desiccant used in your dehumidifying dryer degrades
after an indefinite period of time. Useful life depends on variables such as material moisture
content, plasticizer vapors in the return air, and number of regeneration cycles.
Your dehumidifying dryer may need new desiccant if it exhibits any of the following symptoms:
•
Plastic material is not being dried sufficiently (high scrap/reject rate).
•
Air temperature at the top of the regenerating desiccant bed rapidly climbs to
350°F (177ºC) or more shortly after the start of regeneration, even though a
saturated bed has just started heating.
•
The process air dew point measured with a portable dew point monitor is
higher than -10°F (-23ºC) throughout the process drying cycle.
•
Smoke or dust blows out of the process air outlet.
•
Noticeable amounts of desiccant in the beds is a medium-brown color or
darker.
If you notice any of these signs, replace the desiccant in the desiccant beds. Desiccant
replacement kits are available from the manufacturer’s parts department. If you want, a service
technician can repack desiccant beds at your site.
Desiccant material causes eye irritation! Breathing may be harmful and may
cause skin irritation!
• Do not get in eyes.
• Avoid prolonged contact with skin.
• Use with adequate ventilation.
• Wash thoroughly after handling.
First Aid:
In case of eye contact, immediately flush eyes with plenty of water for at least 15 minutes.
If irritation persists, see a physician.
Operation
52
6-5
Replacing Worn Desiccant
Make sure desiccant beds are sufficiently cool before replacing worn
desiccant.
1. Disconnect the electrical supply.
2. Remove the rear panels to expose the desiccant beds.
3. Access the desiccant cans in one of the following ways:
•
Remove the entire bed from the frame.
•
Remove the hoses located at the top of the beds.
•
Remove the thermocouple and fittings. Make a note of the correct location for each.
•
loosen the 4 knurled nuts below the desiccant can.
•
Loosen the couplers below the desiccant can by turning the “T” handle.
•
twist the desiccant can clockwise and lift to remove.
•
Remove only the top cover then remove the screen inside by removing the single nut
at the center of the can.
4. Replace the desiccant in one of the following ways:
• Replace the entire desiccant can with a pre-packed desiccant can assembly available
from parts and service.(see “Contact Information”, Can Assembly Part # 892.04505.00)
Drop in the new cans, tighten the knurled nuts, and replace the thermocouple and
fittings.
• Vacuum out the desiccant from the can and proceed to step 5.
The desiccant levels for each unit are etched inside the cans for reference.
Make sure the bed interiors are clean.
You should properly dispose of any discarded desiccant.
Consult local disposal regulations for more information.
Operation
53
Thermocouple
and fittings
Desiccant cans
Knurled Nut
Couplers with
“T” handles
Can Assembly Part #
892.04505.00
The pre-packed can assembly
is available from parts and
service. See “Contact
Information”
Before re-packing the beds, determine the proper amount of desiccant for the dryer being
serviced. See Figure 7 on the following page for more information. Desiccant can assemblies prepacked from the manufacturer are available and simply drop into the frame. Pre measures
desiccant kits are also available from the manufacturer.
5. Carefully place half of the large bead in the bottom of the beds, in an even layer, on the
bottom screen. Place the small bead on top of it, in an even layer. Carefully place an
even layer of the remaining large beads over the small beads.
6. Install the top screen, making sure that the edge is in contact with the sides of the bed all
the way around. Install the washers and nuts and tighten down. Gently tap the around the
sides of the desiccant canister with a rubber mallet to settle the desiccant. As settling
occurs, re-tighten the nuts. Repeat the tapping and tightening process until little
additional settling occurs.
7. Install the covers and gaskets on the beds, making sure they are tight and sealed. Replace
desiccant bed gasket if necessary.
8. Re-connect any hoses that were disconnected.
Operation
54
9. Re-install the rear and side shrouds. Re-connect the compressed air supply and electrical
power.
Figure 7:
Required Desiccant Amounts per Bed; Type 4X Desiccant (2 beds per unit)
Dryer
CFM
50
100
150
225
Large bead (Type 4X)
Part no.
lbs.
Kg
1.5
0.68
3.0
1.362
W00000892
9.0
4.086
9.0
4.086
Small bead (Type 4X)
Part no.
lbs.
Kg
10.5
4.75
21.0
9.534
W00000893
30.0 13.620
30.0 13.620
Total per bed
lbs.
Kg
12
5.44
24.0
10.896
39.0
17.706
39.0
17.706
Type 13X Desiccant
Dryer
CFM
50
100
150
225
6-6
Large bead (Type 13X)
Part no.
lbs.
Kg
1.5
0.68
3.0
1.362
W00018050
9.0
4.086
9.0
4.086
Small bead (Type 13X)
Part no.
lbs.
Kg
10.5
4.75
21.0
9.534
W00018051
30.0 13.620
30.0 13.620
Total per bed
lbs.
Kg
12
5.44
24.0
10.896
39.0
17.706
39.0
17.706
Replacing the Process Heater
Our dehumidifying dryers use Calrod-type heater elements mounted in a heater tube located in the
top rear of the cabinet. The wattage of the heater varies with model, voltage, temperature range,
etc., but the replacement procedure is the same.
If the process heater is mounted to the hopper, contact the manufacturer for the appropriate
replacement procedure.
Disconnect and lock out power before you replace heater elements!
Use the following procedure to replace the process heater:
1. Remove the bolts securing the process heater access cover.
2. Sketch the heater wiring configuration so you can properly re-wire the heater.
3. Remove the wires to the heater plate assembly being removed or replaced.
4. Remove the bolts securing the heater plate assembly, and slide out the assembly.
5. Remove the heater from the mounting plate by removing the large brass nuts and
washers.
Operation
55
6. Re-install the heater and heater plate assemblies in reverse order. Install new heater
gaskets and securely tighten all fasteners.
Heater loops should not touch each other. “Hot Spots” lead to
premature heater failure!
7. Reinstall the wires based on the sketch you made earlier.
8. Secure the heater access cover.
6-7
Replacing the Regeneration Heater
The dehumidifying dryers use heater elements located below each desiccant bed.
Disconnect and lock out power before you replace heater elements!
1. Remove the cover plate secured by bolts.
2. Sketch the heater wiring configuration so you can properly re-assemble the heaters.
3. Remove the wiring for the heater being removed or replaced.
4. Remove the bolts securing each heater mounting plate. Slide out the heater.
5. Re-install the new heaters in reverse order. Install new heater gaskets and securely
tighten all fasteners.
Heater loops should not touch each other. “Hot Spots” lead to premature
heater failure!
6. Re-install the wiring based on the sketch you made earlier.
7. Secure the heater access cover.
Operation
56
Chapter 7: Troubleshooting
Problem
Little or no air coming from
the process delivery tube.
Possible cause
Dirty filter.
Desiccant beds are
contaminated by material or
plasticizer leaking into the
system.
Blower overload has tripped.
Blower fins filled with dust or
contaminants.
Suction in delivery tube,
pressure from the return
tube.
Phase is reversed on power
drop coming into the dryer.
Process heaters are faulty.
Loss or reduction of process
air temperature.
Solid-state temperature
controller faulty.
Process temperature was
adjusted in error by plant
personnel.
Process heaters are faulty.
Desiccant beds are
contaminated.
Loss or reduction in drying
capacity.
Material being dried differs
from material specified at the
time of purchase.
Break in flex hose to/from
drying hopper.
Troubleshooting
Corrective action
Clean or replace filter.
Replace desiccant.
Fix the problem and reset the
overload.
Remove blower side plate,
clean baffles, replace.
Stop the dryer.
If the dryer was connected to
the drying hopper, check to
see if the desiccant and
process air heater has been
contaminated with resin.
If so, replace the desiccant
and remove any resin carryover. Otherwise, change the
phase of two legs of the
three-phase power drop.
Check for open heaters.
Replace if required.
Replace.
Make sure that plant
personnel are aware of the
proper temperature set point.
A sign posted next to the
controller is helpful.
Replace.
Replace desiccant.
Drying systems are designed
for the material which was
originally specified. Different
materials may need a longer
residence time or different
drying temperature.
Inspect for air leaks; replace
if necessary.
57
Problem
Loss or reduction in drying
capacity. (Cont’d.)
PLC Regeneration Bed LED
indicators both off.
Possible cause
Airflow valve sticking or
failing to shift.
Blower fins filled with dust or
contaminants.
Insufficient power to PLC
(Power LED is off).
Faulty PLC (PLC Power light
is on, Run light is off, and/or
Error light is on).
Regenerating bed cool down.
Blower Input indicator is off.
PLC Regeneration Heater
Left/Right output indicators
both off.
Process air in hightemperature condition.
Insufficient power to PLC
(Power light is off).
Faulty PLC (PLC Power light
is on, Run light is off, and/or
Error light is on).
Process temperature set too
high due to operator error.
Material in drying hopper
cakes, or meltdown occurs.
Poor dew point performance.
High temperature alarm not
set properly.
Process set point is out of
acceptable range.
Function set for degrees
Celsius (ºC), set point at
degrees Fahrenheit (ºF).
Burned out regeneration
heater.
Contaminated or worn out
desiccant.
Leaking process air hoses.
Dryer operates beyond its
capacity.
Bad dew point sensor.
Fouled dew point sensor
manifold.
Troubleshooting
Corrective action
Check for proper operation of
valve actuators. Repair or
replace if necessary.
Remove blower side plate,
clean baffles, replace.
Replace filter elements.
Check power supply and
power wiring to PLC.
Replace PLC.
None.
Verify that blower contactor is
on. Check input wiring to
PLC.
None.
Check power supply and
power wiring to PLC.
Replace PLC.
Check resin manufacturer’s
data sheet for proper drying
temperature. Make sure plant
personnel are aware of the
correct process temperature
set point.
Reset high temperature
alarm.
Restore temperature
controller to factory pre-sets.
Verify correct Celsius or
Fahrenheit settings.
Repair or replace.
Replace.
Repair or replace.
Check dryer and drying
hopper sizing.
Replace.
Clear obstruction. Air should
flow freely through sensor.
58
Problem
Nothing displays when the
controller is turned on.
Possible cause
The internal mechanism is
not inserted properly into the
housing.
The power supply is not
connected to its terminals
properly.
No power is supplied, or the
supplied power is not within
the specified range.
Disconnect switch or Control
Power switch not set to ON.
Control Power fuse blown.
Input polarity on thermocouple is wrong or
connection is wrong.
No compensating lead wires
used for extension of the
thermocouple.
Process value is abnormal or
not obtained.
Corrective action
Properly insert the internal
mechanism into the housing.
Properly connect the power
supply to the power supply
terminals.
Supply a voltage of 85 to 125
VAC to the power supply
terminals of the controller.
Check control power fuse for
continuity. Turn disconnect
switch and control power
switch ON.
Properly wire the terminals.
Use proper compensating
lead wires and terminals.
Thermocouple and controller
are connected by wires other
than proper lead wires.
Use a dedicated thermocouple connector. If a
connector is a metal different
from the thermocouple and
controller, a temperature
error may result.
Sensor is broken or shortcircuited.
Replace with a good sensor.
The controller is influenced
by noise or other induction.
Celsius temperatures used
instead of Fahrenheit or vice
versa.
Separate input wires as far
as possible from the origin of
the noise.
Setup mode level 2 display
d-U. S-V display shows
setting.
Determining Temperature Controller Errors or Sensor Errors
Using a Thermocouple
If the controller displays a temperature that is close to room temperature (70ºF/21ºC) when you shortcircuit controller input terminals, the controller is normal and the sensor is probably broken, shortcircuited, or incorrectly wired.
Using a Platinum Resistance Thermometer
If the controller displays a temperature of about 0.0°C (32ºF) when you insert a 100-ohm resistor between
terminals A and –B of the controller, and you short-circuit controller terminals +B and
–B, the controller is normal and the sensor is probably broken, short-circuited, or incorrectly wired.
Troubleshooting
59
Chapter 8: Appendix
8-1 Technical Assistance
Parts and Service Department
The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to
engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in
expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A
customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your
parts needs and is dedicated to providing excellent customer service.
For immediate assistance, please contact:
• North, Central and South America, 8am – 5pm CST +1 (800) 483-3919 for drying, conveying, heating and
cooling and automation. For size reduction: +1 (800) 229-2919.
North America, emergencies after 5pm CST (847) 439-5855
North America email: acsuscanadacustserv@corpemail.com
•
Mexico, Central & South America
Email: acslatinamericacustserv@corpemail.com
•
Europe, Middle East & Africa +48 22 390 9720
Email: acseuropecustserv@corpemail.com
•
India +91 21 35329112
Email: acsindiacustserv@corpemail.com
•
Asia/Australia +86 512 8717 1919
Email: acsasiacustserv@corpemail.com
Sales and Contracting Department
Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for
the name of the sales representative nearest you.
Let us install your system. The Contract Department offers any or all of these services: project planning; system
packages including drawings; equipment, labor, and construction materials; and union or non-union installations.
For assistance with your sales or system contracting needs please Call:
North, Central and South America +1 (262) 641-8600 or +1 (847) 273-7700
Monday–Friday, 8am–5pm CST
•
Europe/Middle East/Africa +48 22 390 9720
•
India +91 21 35329112
•
Asia/Australia +86 512 8717 1919
Facilities:
ACS offers facilities around the world to service you no matter where you are located. For more information, please visit
us at www.acscorporate.com
8-2
United States:
Asia/Australia:
India
ACS Schaumburg
1100 E. Woodfield Road
Suite 588
Schaumburg, IL 60173
Phone: + 1 847 273 7700
Fax: + 1 847 273 7804
ACS Suzhou
109 Xingpu Road SIP
Suzhou, China 215126
Phone: + 86 8717 1919
Fax: +86 512 8717 1916
ACS India
Gat No. 191/1, Sandbhor Complex
Mhalunge, Chakan, Tal Khed,
Dist. Pune 410501, India
Phone: +91 21 35329112
Fax: + 91 20 40147576
ACS New Berlin
Annex
BthInformation
Street
2900 S. 160
New Berlin, WI 53151
Phone : +1 262 641 8600
Fax: + 1 262 641 8653
Europe/Middle East/Africa:
ACS Warsaw
Ul. Działkowa 115
02-234 Warszawa
Phone: + 48 22 390 9720
Fax: +48 22 390 9724
Appendix
60
The following design information is provided for your reference:
1. No modifications are allowed to this equipment that could alter the CE compliance
2. Ambient temperature:
0 degrees Celsius – Maximum (104 degrees Fahrenheit)
3. Humidity range:
50% relative humidity
4. Altitude:
Sea level
5. Environment:
Clean and non-explosive
6. Radiation:
None
7. Vibration:
Minimal, i.e. machine mounting
8. Allowable voltage fluctuation:
+/- 10%
9. Allowable frequency fluctuation:
Continuous
+/- 1%
Intermittent
+/- 2%
10. Nominal supply voltage:
460/3/60 (Verify on serial number tag)
11. Earth ground type: TN (system has one point directly earthed through a protective
conductor)
12. Power supply should include a ground connection.
13. Over-current protection is supplied in the dryer, but additional protection should be
supplied by the user.
14. The door-mounted disconnect serves as the electrical disconnect device.
15. Dryer is not equipped with local lighting.
16. Functional identification
17. Dryer is equipped with a CE mark
18. Dryer is supplied with an operating manual in the language of the destination
country.
19. Cable support may be required for power cord, depending on final installation.
20. No one is required to be in the interior of the electrical enclosure during the normal
operation of the unit. Only skilled electricians should be inside the enclosure for
maintenance.
21. Doors can be opened with a screwdriver, but no keys are required.
22. Two-hand control is not required or provided.
23. All dryers should be moved around and set in a place with a lift truck or equivalent.
24. There are no frequent repetitive cycles that require manual controlrepetitive
functions are automatic while the dryer is operating.
25. An inspection report detailing the functional test is included with the dryer.
26. The machine is not equipped with cableless controls.
27. Color-coded (harmonized) power cord is sufficient for proper installation.
Appendix
61
8-3 Parts Diagrams
Valve Assemblies – MDB 85 & 170
Appendix
62
Notes
Appendix
63
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