Sterling Plumbing 100 User manual

Sterling Plumbing 100 User manual
Operation and Installation Manual
90,100, 150, 225 CFM Cabinet
Series Dehumidifying Dryers
Important! Read Carefully Before Attempting to Install or Operate
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A0534806
Part No: 882.00282.00
Cabinet Series Dehumidifying Dryer
Effective: 4/28/08
Chapter 1: Safety
Bulletin No: DH1-630.1
1
Performance figures stated in this manual are based on a standard atmosphere of 59°F (15°C)
at 29.92” Hg (1,014 millibars) at sea level, using 60 hz power. Altitude is an important
consideration when specifying drying and conveying systems. The manufacturer can advise you
on proper selection and sizing of systems for your operating environment.
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual
are subject to change without notice.
© Copyright 2008
All rights reserved.
Part No. 882.00282.00
Cabinet Series Dehumidifying Dryer
Effective 4/28/2008
Bulletin No. DH1-630.1
2
Table of Contents
CHAPTER 1: SAFETY……………………………………………...6
1-1
1-2
1-3
How to Use This Manual. ............................................................................................ 6
Safety Symbols Used in this Manual .....................................................................6
Warnings and Precautions .......................................................................................... 7
Responsibility .............................................................................................................. 8
General Responsibility ..........................................................................................8
Operator Responsibility .........................................................................................8
Maintenance Responsibility...................................................................................9
Reporting a Safety Defect ...................................................................................10
CHAPTER 2: GENERAL INFORMATION ............................... 11
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
Models Covered…………………………………………………………………………….11
Equipment Function .................................................................................................. 11
Necessary Documents .............................................................................................. 11
Standard Features..................................................................................................... 11
Options ...................................................................................................................... 11
The Closed Loop Drying System............................................................................... 12
What is Desiccant?.................................................................................................... 13
The Process/Regeneration Cycle.............................................................................. 13
Specifying a Drying/Conveying System .................................................................... 13
CHAPTER 3: INSTALLATION…………….………...…………...14
3-1
3-2
3-3
3-4
3-5
3-6
3-7
Positioning Your Dryer .............................................................................................. 14
Making Electrical Connections .................................................................................. 14
Connecting Compressed Air ..................................................................................... 14
Checking for Proper Blower Rotation ........................................................................ 14
Three Phase Models…..……………………………………………………………...14
Process Air Connections Between the Dryer and the Drying Hopper ....................... 15
Connecting Cooling Water to the Optional Aftercooler.............................................. 15
Installing Water Lines…………………………………………………………………15
Drying Hopper ........................................................................................................... 15
Removing the Rust Inhibitor ................................................................................15
Air Trap Considerations.......................................................................................15
CHAPTER 4: CONTROLS………………………………………..16
4-1
4-2
4-3
4-4
4-5
Control Panel Indicator Lights and Switches............................................................. 16
Rocker Switches..................................................................................................16
Indicating Lights ..................................................................................................16
Process Air Dew Point Display.................................................................................. 19
Process Air Temperature Controller.......................................................................... 19
Identifying Temperature Controller LED Indicators ................................................... 19
Identifying Temperature Controller Buttons............................................................... 20
E5CK Operating Parameters...............................................................................21
Available E5CK Modes........................................................................................21
Cabinet Series Dehumidifying Dryer
3
4-6
4-7
Setting the Process Air Temperature ........................................................................ 22
PLC Controller........................................................................................................... 22
PLC LED Indicators .............................................................................................23
Output LED Indicators .........................................................................................24
Status LED Indicators..........................................................................................24
4-8
Setting the Shift on Dew Point................................................................................... 28
4-9
Entering Operating Parameters to Select Modes...................................................... 28
4-10 Setting the High Dew Point Alarm ............................................................................. 28
4-11 Optional Seven-Day Timer ........................................................................................ 29
Programming the Optional Times........................................................................30
Checking the Set Time ........................................................................................31
Day Override .......................................................................................................32
Canceling the Settings ........................................................................................32
CHAPTER 5: OPERATION………………………………………..34
5-1
5-2
5-3
Pre-Startup Checks ................................................................................................... 34
Startup....................................................................................................................... 34
Shutdown .................................................................................................................. 34
CHAPTER 6: MAINTENANCE…………………………………...36
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
Work Rules................................................................................................................ 36
Servicing Process Air Filters ..................................................................................... 36
Recommendations for Cleaning and Replacing Filters .......................................37
Servicing the Dew Point Monitor ............................................................................... 39
Symptoms of Worn Desiccant ................................................................................... 39
Replacing Worn Desiccant ........................................................................................ 40
Replacing the Process Heater................................................................................... 41
Replacing the Regeneration Heater .......................................................................... 42
Changing the Controller Security Level ...............................................................42
Restoring Factory Defaults on the Process Temperature Controller...................42
Restoring Factory Defaults on the Dew Point Controller ....................................46
Restoring the E5CK Temperature Controller and Dew Point Meter to Factory Setup 47
CHAPTER 7: TROUBLESHOOTING…………………………….48
CHAPTER 8: APPENDIX………………………………………….52
8-1
8-2
Contact Information ................................................................................................... 52
Technical Specifications............................................................................................ 52
Cabinet Series Dehumidifying Dryer
4
Charts and Figures
1
2
3
4
5
6
7
8
9
Dryer Air Flow Diagram
12
Typical Dryer Interface Panel
18
Typical Dryer Temperature Controller
20
Display Readout for Mode Settings and Available Security Levels
22
Typical Subpanel Layout
25
Typical Cabinet Dryer Electrical Schematic, Drawings 1 and 2
26-27
Required Desiccant Amounts Per Bed
Setting List for Process Temperature Controller,
Part No. A0548565
41
Setting List for Dew Point Controller, Part No. A0548565
46
Cabinet Series Dehumidifying Dryer
43
5
Chapter 1: Safety
1-1
How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining the large
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 large 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! DANGER indicates an imminently hazardous situation that, if not
avoided, will result in death or serious injury.
WARNING!
WARNING indicates a potentially hazardous situation or practice
that, if not avoided, could result in death or serious injury.
Caution!
CAUTION indicates a potentially hazardous situation or practice
that, if not avoided, may result in minor or moderate injury or in
property damage.
Cabinet Series Dehumidifying Dryer
6
Dryer Safety Tags
Tag
Description
PE
1-2
Tag
Description
Read Operation
& Installation
Manual
High Voltage Inside
Enclosure
Hot!
Lifting Point
Protected Earth
Ground
Earth Ground
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.
Cabinet Series Dehumidifying Dryer
7
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.
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.
Cabinet Series Dehumidifying Dryer
8
„ 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.
„ 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.
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.
Cabinet Series Dehumidifying Dryer
9
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 environment.
Cabinet Series Dehumidifying Dryer
10
Chapter 2: General Information
2-1
Models Covered
This manual provides instructions for installing and operating 90, 100, 150, and 225 CFM
cabinet-style dehumidifying dryers.
2-2
Equipment Function
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.
2-3
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.
2-4
Standard Features
; Rugged compact frame with handle and sturdy 4” (10 cm) casters.
; Dual blower dryer with dual desiccant beds and 4-way compressed air operated valves.
; Up to 400ºF (204ºC) drying temperature range.
; Cartridge type (two stage) air filters for all blowers.
; Integral Control Center for dryer options.
; Electrical disconnect with all wiring to a common terminal point.
; PLC microprocessor control of the drying and conveying stations.
; Digital Dew Point monitor indicates dryer efficiency.
; Sequence shutdown of the dryer.
2-5
Options
Options can tailor your dehumidifying dryer system to meet the exact requirements of the drying
task being performed.
; 13X desiccant.
; Aftercoolers for high and low temperature applications.
; Seven-day timer to allow programmable dryer startup.
Cabinet Series Dehumidifying Dryer
11
; Audible/visual critical alarm.
; Fusing for blowers and heaters.
; Dirty Filter indicator for each individual blower.
2-6
The Closed Loop 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.
This system is a closed loop, because ambient (outside) air is never introduced into the process
air. See Figure 2. 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.
Figure 1-Dryer 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
Cabinet Series Dehumidifying Dryer
Process blower
12
2-7
What is Desiccant?
Desiccant is a material which attracts and holds (absorbs) water from the air. Our dehumidifying
dryers use a synthetic crystalline metal aluminosilicate desiccant blended with a clay binder and
formed beads.
Absorbed water is driven from saturated desiccant by heating it to a high temperature (reducing
desiccant capacity to hold water) and forcing air through it. This moisture removal process is
called regeneration.
2-8
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, indicates that the bed is
dry. At bed breakthrough, the bleed air temperature peaks between 350°F (176ºC) and 400°F
(204ºC).
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). This ultra-low humidity level is more than
adequate to dry plastics to as little as .003% moisture, depending on the process and material.
2-9
Specifying a Drying/Conveying System
Many variables were 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. If your operating environment
changes, the manufacturer can advise you on necessary equipment and process time and
temperature modifications required for your system.
Cabinet Series Dehumidifying Dryer
13
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,
two locking and two swivel.
Caution!
3-2
Use caution and observe safety rules when placing your dryer!
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.
WARNING!
3-3
Proper grounding of the main power line is critical!
Connecting Compressed Air
Connect compressed air to the dryer before operation.
Caution!
Excessive air pressure damages the neoprene components of the
air distribution valve.
Connect the air supply, using a ¼” NPT fitting, to a clean, dry, lightly lubricated source of 80 psi
(551 kPa/5.51 bars) compressed air. A pressure gauge and regulator are recommended
components of your plant air supply.
The compressed air indicator switch prevents the dryer from starting without an 80 psi (551
kPa/5.51 bars) air supply. If the air supply drops to below 60 psi (413 kPa/ 4.13bars) during
operation, the dryer shuts down until at least 80 psi (551 kPa/5.51 bars) is restored.
3-4
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.
Caution!
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.
Cabinet Series Dehumidifying Dryer
14
3-5
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.
3-6
Connecting Cooling Water to the Optional Aftercooler
High temperature applications (300°F to 400°F / 148°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. Aftercoolers are also required in extremely low temperature applications.
Installing Water Lines
3-7
•
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).
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.
Cabinet Series Dehumidifying Dryer
15
Chapter 4: Controls
4-1
Control Panel Indicator Lights and Switches
Rocker Switches
System ON/OFF Rocker Switch
Used to de-energize control power to the indicator panel, allowing separate control of the dryer
and conveying systems.
Dryer ON/Sequence Shutdown Rocker Switch
Used to start the dryer. Move this switch to the Sequence Shutdown position to turn off the
process heaters, finish the regeneration cycle and then turn off the dryer.
Optional Alarm Silence Rocker Switch
Press the Alarm Silence switch to silence the horn when a high temperature alarm activates.
The alarm repeats every five minutes until the problem causing the alarm condition is cleared.
Indicating Lights
Indicator
Name
Description
Regen Blower
On Light
The Regen Blower On indicator lights when the
regeneration blower energizes.
G
Left Bed In
Regen Light
The Left Bed In Regen LED lights when the left bed
is in regeneration.
G
Left Bed Heater
Light
The Left Bed Heater indicator lights when the left
bed regenerates and is in the heat-up portion of the
regeneration cycle.
G
Right Bed In
Regen Light
The Right Bed In Regen LED lights when the right
bed is in regeneration.
G
Right Bed Heater
Light
The Right Bed Heater indicator lights when the right
bed regenerates and is in the heat-up portion of the
regeneration cycle.
G
Process Blower
On Light
The Process Blower On indicator lights when the
process blower energizes.
G
Process Heater
On Light
The Process Heater On indicator lights when the
process air heater is energized.
R
Low Compressed
Air Light
The Low Compressed Air alarm indicator lights
when the dryer compressed air supply drops below
60 psi (413kPa/ 4.13 bars). Upon loss of
G
Cabinet Series Dehumidifying Dryer
16
Indicator
Name
Description
compressed air, the pressure switch opens and sends
a signal to the PLC controller to shut down dryer
operation. Dryer operation automatically resumes
when 80 psi (551 kPa/ 5.51 bars) air is restored.
High Temp
Process Air Light
R
The High Temp Process Air alarm indicator lights
when the temperature at the process air
thermocouple is above the high alarm set value.
Upon high temperature alarm condition the process
heaters turn off, the process blower remain on.
The alarm mode and value are factory-set to track
25º above the process set point. The alarm value is
an upper-limit deviation above the process set point.
When the temperature at the process thermocouple
returns to within the acceptable range, the alarm
output de-energizes and all heaters turn on again
automatically.
High Temp
Regen Air Light
The High Temperature Regen Air alarm indicator
lights when the thermostat above the regeneration
heater assembly senses an abnormally high
temperature.
The regeneration heaters shut down until the
temperature falls below the alarm point. The
regeneration blower continues to run for cooling the
heaters and desiccant bed. The alarm condition
clears when the temperature drops below the
thermostat setpoint. The heaters re-energize
automatically.
R
A
High Dew Point
Light
The High Dew Point alarm indicator lights when the
process air delivery dew point exceeds a dew point
of -10°F (-23°C).
G
Material Loading
Light
The Material Loading indicator lights when material
is being conveyed.
Optional Dirty
Filter Light
If installed, the Dirty Filter alarm indicator lights
when the pressure differential across the process,
regeneration and conveying air return filter exceeds
the pressure switch setting. Service the filter when
this indicator lights. The indicator and the alarm
condition clears after you service and reinstall the
filter.
A
Cabinet Series Dehumidifying Dryer
17
Figure 2-Typical Dyer Interface Panel
Cabinet Series Dehumidifying Dryer
18
4-2
Process Air Dew Point Display
The Dew Point display indicates the current process air delivery moisture content. The display
uses a microprocessor-based controller for reading dew point air temperature. The controller is a
modular, self-contained removable unit in the mounting housing. All parameters are factory-set
and adjusted; no field adjustment to the internal controls is necessary. The high dew point alarm
is also factory adjusted.
4-3
Process Air Temperature Controller
Our dehumidifying dryers use a microprocessor-based PID temperature controller for maintaining
process air temperature. The controller is a modular, self-contained unit you can remove from the
mounting housing. All parameters except for the process air set point is factory set and adjusted;
no field adjustment to the internal controls is necessary.
4-4
Identifying Temperature Controller LED Indicators
LED
Indicator
Description
Process Value
Numerical
LED
During normal operation, the process value (PV)
numeric LED indicator displays the process
temperature at the To Process thermocouple. It
also lists parameters during setup and error
messages if any errors occur.
Set Value
Numeric LED
During normal operation, the set value (SV)
numeric LED indicator displays the process set
point you selected for the dryer. The dryer then
maintains this set point temperature. This LED
indicator also displays parameter and pre-set
function values during setup.
OUT1
Lit when control output 1 turns on. The Out
indicator lights when the controller signals the
process heaters to be energized.
OUT2
Lit when control output 2 turns on. Not used in
this application.
MANU
Lit when the manual operation mode is being
used.
STOP
Lit when control operation has been stopped. Not
used in this application.
RMT
AT
SUB1
Lit during remote operation. Not used in this
application.
Flashes during auto-tuning.
Lit when the output function assigned to auxiliary
output 1 turns on.
Cabinet Series Dehumidifying Dryer
19
4-5
Identifying Temperature Controller Buttons
Display Button
This button shifts the display to the next set of parameters. Then, the menu screen displays.
Down Arrow Button
The Down Arrow button lets you lower the process air set point temperature. During setup, it lets
you decrease the value of the parameter displayed on the set point LED readout.
Up Arrow Button
The Up Arrow button lets you raise the process air set point temperature. During setup, it lets you
increase the value of the parameter displayed on the set point LED readout.
AT
Auto-Tune Button
Hold down for two seconds to initiate auto-tune. Repeat to cancel.
Figure 3:
Typical Dryer Temperature Controller
PV
SV
OUT1
OUT2 MANU STOP RMT
AT
SUB1
AT
E5CK
Cabinet Series Dehumidifying Dryer
20
E5CK Operating Parameters
The E5CK has several mode selections. Within each mode are numerous parameters that can be
set. The setting is different for the temperature control unit and the dew point display.
Before you can access the several modes of operating parameters, you must change the security
lock-out of the controller. The factory sets the security level to protect the parameters from being
accidentally changed. Below is an explanation of the operating modes, how to change out the
security level and the factory default settings.
Available E5CK Modes
Menu Display
Level 0 Mode
For normal operation. Execute AT auto-tuning, change to manual mode.
Level 1 Mode
For adjusting primary control parameters. Execute: Set alarm values; set the control period; set
PID parameters.
Level 2 Mode
For adjusting secondary control parameters. The dehumidifying dryer uses E5CK default settings.
Setup Mode
For setting the basic specifications. Set parameters for input type, scaling, output assignments and
direct/reverse operation.
Expansion Mode
For setting expanded functions. Set: ST (self-tuning), SP setting limiter. Select: advance PID or
ON/OFF control.
Option Mode
This mode is only accessible when and option board is installed.
Calibration Mode
For calibrating communication unit E53-CKF. Not used.
Manual Mode
Sets the controller to manual operation mode. Not used on dehumidifying dryers.
Cabinet Series Dehumidifying Dryer
21
Figure 4:
Display Readout for Mode Settings
PV
Menu display
SV
Level 0 mode
SV
Level 1 mode
SV
Level 2 mode
SV
Setup mode
SV
Expansion mode
SV
Option mode
SV
Calibration mode
4-6
Setting the Process Air Temperature
To change the process air temperature set point with the dryer running:
„ Press the Up Arrow button to increase the set point to the temperature you want.
„ Press the Down Arrow button to lower the set point to the temperature you want.
„ Press the Auto-tune button to initiate auto-tuning.
4-7
PLC Controller
The PLC controller uses an Allen-Bradley programmable logic controller (PLC). This “brick”type controller has 32 I/O points: twenty (20) inputs and twelve (12) outputs, all inputs and
outputs are 115 VAC.
All programming and logic is factory-installed on an EEPROM chip and cannot be modified. A
battery backup retains programming if power fails. Battery life is five (5) years at room
temperature.
If the alarm indicator blinks intermittently, replace the battery within one week.
Cabinet Series Dehumidifying Dryer
22
PLC LED Indicators
The following indicators are located inside the dryer cabinet. See Figures 5, 6, and 7.
Name
Description
System
Start/Sequence
Shutdown (I/0)
When ON, activates the operation of the dryer
portion.
Compressed Air
Input (I/1)
Process Blower
Enable (I/2)
When ON, confirms that compressed air is present.
Bed Switch Set
Point Input (I/4)
When ON, indicates that dewpoint is above bed
switching set point.
High Regen
Temp Alarm,
Right Bed (I/5)
When OFF, indicates a situation of a temperature
exceeding the set level in the right regen bed.
High Regen
Temp Alarm,
Left Bed (I/6)
When ON, Confirms the operation of the process
blower.
When OFF, indicates a situation of a temperature
exceeding the set level in the right regen bed.
Compressed Air
Alarm Input (I/7)
When ON, it indicates loss of compressed air.
High Process
Temp Alarm (I/8)
When ON, sends the information to the PLC to be
used later in forming alarm procedure.
Push To Silence
(I/9) (Optional)
When the existing rocker switch is pressed, the
audible horn will be silenced and flashing strobe
will be turned off. Also, it serves as an alarm
acknowledgment.
Cabinet Series Dehumidifying Dryer
23
Output LED Indicators
Name
Description
Blower On (O/0)
The Blower On indicator lights when the blower
energizes.
Process Heater
Enable (O/2)
The Process Heater Enable activates the process
heater. The indicator lights when the process heater
is energized. This condition occurs when no blower
failures or high temperature conditions exist.
Left/Right Regen
Heater Output
(O/3, O/4)
Right Bed
Regeneration
Output (O/5)
The Regen Heater Output indicator lights when the
indicated bed regeneration heater energizes.
High Regen
Temp Alarm
(O/6)
When ON, indicates a high regen temp condition in
either the left or right bed.
Alarm Horn
Output (O/7)
Optional
The Alarm Horn Strobe Output indicates a high
process temperature condition and optional critical
low level at the drying hopper.
The right Bed Regeneration Output activates the
right bed regeneration indicator lights when the
right bed regenerates. When this indicator is off, the
left bed is energized.
Status LED Indicators
Name
Description
Power
The Power indicator lights when the PLC receives
115V control power.
Run
The Run indicator lights when the PLC executes the
program in normal conditions.
Fault
The Fault indicator lights when the PLC program
has a problem or failure condition.
Force
The Force indicator is not used.
Cabinet Series Dehumidifying Dryer
24
Figure 5:
Typical Subpanel Layout
Cabinet Series Dehumidifying Dryer
25
Figure 6:
Typical Cabinet Dryer Electrical Schematic, Drawing 1
\
Cabinet Series Dehumidifying Dryer
26
Figure 6:
Typical Cabinet Dryer Electrical Schematic, Drawing 2
222
Cabinet Series Dehumidifying Dryer
27
4-8 Setting the Shift on Dew Point
Our dehumidifying dryers shift air flow from the on-line desiccant bed to the regenerated
desiccant bed, based on actual dew point demand, not fixed time cycles. After the off-line bed
regenerates, the PLC controller waits for a high dew point signal from the process air dew point
controller before switching beds. The PLC controller has a four (4) -hour timer override if it does
not receive a signal from the dew point control.
„ Set the shift on dew point set point to the highest process air moisture content you
want to allow before the dryer shifts air flow to the regenerated desiccant bed. The
dew point controller is set at the factory for -20ºF (-29ºC).
„ To change the dew point setting, press the Up Arrow and Down Arrow buttons to the
shift point you want.
4-9
Entering Operating Parameters to Select Modes
To enter the menu display:
1. Press the Display button for one second (keep the pressure on the button for about 1.5 to 2
seconds).
The screen displays
.
2. Press the Up Arrow button to toggle through the different modes.
The SV readout displays the mode you selected.
3. To switch parameters within a mode, press the Display button once more for about one and a half
to two (1.5 to 2) seconds.
The PV readout displays the different parameters within each mode.
4. Use short presses on the Display button to display each parameter within a mode.
The SV readout displays the different values for the parameter within a mode.
5. Press Up Arrow and Down Arrow buttons to set the higher or lower the values of a parameter.
6. Press Display button for about one and a half to two (1.5 to 2) seconds to move up a level back
into the different modes.
7. Press Down Arrow button until Level 0 displays. Press the Display button for about one to one
and a half (1 to 1.5) seconds to go to Operating mode.
4-10 Setting the High Dew Point Alarm
The high dew point alarm is factory set for -10ºF (-23ºC). The high dew point alarm will energize
the “High Dew Point” light. Entering the Level 1 operating parameter changes the high dew point
alarm setting. Use the following procedure to set the high dew point alarm:
1.
Press and hold the Display button to access Level 0. The controller displays Level 0.
2.
Press Up Arrow button to display Level 1. Lu-1 displays.
3.
Press the Display button to select Level 1.
4. Press the Display button until the controller displays AL-1.
Cabinet Series Dehumidifying Dryer
28
5. Use the Up and Down Arrow buttons to set the higher or lower value for the high dew point
alarm. Hold the Display button to save the value and return to Level One.
6. Press the Down Arrow button until the controller displays Level 0.
7. Press and hold the Display button to return to Operating mode.
Note: The E5CK controller has several levels of securities to lock out access to parameters and menu
settings. If the controller will not allow you to change settings, see Section 6-8 on Page 60 to
set the E5CK security to access the function you need.
4-11 Optional Seven Day Timer
The seven-day timer can be programmed for daily or weekly (over midnight) on/off operation.
An internal battery back up holds the settings in memory when the dryer is de-energized.
Timer
SUN
MON
TUE WED THU
FRI
SAT
(16) Timing chart display
DAY
SHIFT
SET/RESET
PM
h
(15) Output indicator
1
(5) CHECK key
1
AM
OUT
PM
1 OUT 2
PROG
CHECK
ON
AUTO
OFF
(12) OUT switch
m
WRITE
TIME ADJ
TIMER 1 2 MAN
MODE
BOOT
PULSE 1 2 AUTO
(13) TIMER/PULSE switch
CYCLE/PULSE
COPY
MON
Time adjustment
mode indicator
TUE WED THU
FRI
SAT
AM
PM
1
2
AM
PM
S
m
AM
PM
S
m
Timing chart display
Cabinet Series Dehumidifying Dryer
(3) h key
(4) m key
(6) WRITE key
(11) MODE switch
(7) TIME ADJ key
(10) CLR key
(9) COPY key
(8) CYCLE/PULSE key
(14) MAN/AUTO RESET switch
Power failure indicator
Output circuit indicator
(2) SET/RESET key
CLR
Display
SUN
P1
P2
RUN
(1) SHIFT key
1
2
Cursor
Day indicator
Main display
Pulse width indicator
Indicator for number
of remaining steps
Set circuit
number indicator
29
No.
1
2
3, 4
5
6
7
8
9
10
11
12
13
14
15
16
Function
Shifts the cursor (∇) specifying a day to the right.
Sets or cancels (reset) a specified day.
Sets a time or ON/OFF time width. (hours, minutes)
Monitors the parameters set for an operation during an operation.
Sets parameters. (Write)
Sets a time adjustment mode.
Specifies a cyclic operation, or sets a pulse width. (Not used)
Specifies a day substitution operation. (Copy)
Cancels the parameters set for each circuit, or a day substitution operation.
P1:
Circuit 1 programming mode.
P2:
Circuit 2 programming mode.
Run:
Run mode.
ON:
Turns on the output regardless of the program
AUTO: Executes according to the program.
OFF:
Turns off the output regardless of the program.
TIMER: Executes an ordinary timer or cyclic operation.
PULSE: Executes a pulse-output operation.
Specifies automatic or manual operation following a power failure.
The Output indicator will light when the timer output is energized. (Dryer On)
Displays the time at which the next operation will be preformed.
Note: For timer operation, the System Power rocker switch must be in the ON position and the
Dryer/on Sequence Shutdown rocker switch must be in the SEQUENCE SHUTDOWN
position.
•
The OUT switch (#12) should be set to AUTO.
•
The P1-P2 RUN mode switch (#11) should be set to RUN for normal 7-day timer operation, set to
P1 for changing times; P2 is not used. Open the front cover; the MODE switch (#13) must have
Mode 1 set to TIMER (up); 2 is not used, BOOT (#14) is set to AUTO (down).
•
Program 1 is operational; Program 2 is not used.
Note:
To bypass the 7-day timer operation, turn the 7-day timer OUT switch (#12) to off. Turn the
Dryer/On Sequence Shutdown rocker switch located on the dryer control panel to DRYER
ON.
Programming the Optional Timer
Setting the Current Day of the Week, Hour, and Minute
1. Apply main power to the dryer.
2. The 7-Day timer MODE selector switch (#11) should be in the RUN position.
3. Hold the TIME ADJ key (#7) for 1 second or longer.
4. Press the SHIFT key (#1) to move the cursor (∇) to the desired day position. Holding down this
key advances the day.
5. Press the SET key (#2). The bar mark will turn on under the chosen day.
6. Press the h key (#3) to adjust the hours. Holding the key will rapidly advance the hour.
7. Press the m key (#4) to adjust the minutes.
Cabinet Series Dehumidifying Dryer
30
8. Press the WRITE key (#6) to store the correct time.
9. The time and day can be adjusted or changed while the timer is operating.
Daily Timer Operation
Daily time is typically set to operate from 8:00 AM and to stop at 5:00 PM from Monday through Friday.
1. Set the MODE switch (#11) to P1.
2. Press the SHIFT key (#1) to move the cursor to the desired day of the week. Or select several
days at once by using the SHIFT (#1) and SET keys (#2). The bar mark will turn on under the
chosen days.
3. Press the SET key (#2).
4. Set the desired start time by pressing the h key (#3) to adjust the hour. Holding this key will
rapidly advance the hour.
5. Press the m key (#4) to adjust the minutes.
6. Press the WRITE key (#6) to store the start time in the timer memory.
7. Next, set the stop time by using the h and m keys, then press WRITE.
8. Turn the MODE switch (#11) to run.
Multiple-Day Operation
Multiple day operation will start the dryer on one day and run continuously for several days before
stopping the dryer.
1. Turn the MODE switch (#11) to P1.
2. Select the desired start day with the SHIFT (#1) and SET keys (#2).
3. Set the start time with the h and m keys.
4. Press the WRITE key (#6) to store the dryer startup hour in the timer memory.
5. Next cancel the day that was just set by using the RESET key (#2).
6. Now select the stop day by using the SHIFT (#1) and SET key (#2).
7. Set the stop time with the h and m keys.
8. Press the WRITE key (#6).
9. Turn the MODE switch (#11) to RUN.
Checking the Set Time
The set times can be checked in the sequence the timer is to operate.
1. Press the CHECK key (#5). Each time the key is pressed the operation schedule is displayed in
the time sequence.
2. If the time switch is left untouched for 20 seconds during check, the display automatically returns
to RUN mode.
If a holiday occurs during the weekly operation, the off time for Sunday can be executed for the holidays.
The override will execute for one week only, then the timer will automatically go back to the previous
program.
Cabinet Series Dehumidifying Dryer
31
1. Hold the COPY key (#9) for one (1) second or longer. Make sure that the mode selector switch
is in RUN mode.
2. Select the day(s) you want with the SHIFT (#1) and SET keys (#2). If a previous override had
been set, this will show up when you first hold the COPY key. To clear a previous override,
press the CLR key (#10).
3. Press the WRITE key (#6).
4. Select Sunday (or another shutdown day) with the SHIFT (#1) and SET keys (#2).
5. Press the WRITE key (#6).
Day Override
If a holiday occurs during the weekly operation, the off time for Sunday can be executed for the holidays.
The override will execute for one week only, then the timer will automatically go back to the previous
program.
1. Hold the COPY key (#9) for one (1) second or longer. Make sure that the mode selector switch
is in RUN mode.
2. Select the day(s) you want with the SHIFT (#1) and SET keys (#2). If a previous override had
been set, this will show up when you first hold the COPY key. To clear a previous override,
press the CLR key (#10).
3. Press the WRITE key (#6).
4. Select Sunday (or another shutdown day) with the SHIFT (#1) and SET keys (#2).
5. Press the WRITE key (#6).
Canceling the Settings
All the operations can be cancelled.
1. Set MODE selector switch (#11) to P1.
2. Press the CLR key (#10).
Note:
The 7-day timer cycle and pulse output are not used for dryer applications.
Cabinet Series Dehumidifying Dryer
32
- Notes -
Cabinet Series Dehumidifying Dryer
33
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, 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 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.
Important!
5-2
Clean the rust-preventing oil from inside the drying hopper.
Failure to clean the hopper fouls the desiccant and voids your
warranty!
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.
Note: To allow proper residence time during continuous processing, maintain the
material level in the hopper at the midpoint of the air trap assembly.
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
Cabinet Series Dehumidifying Dryer
34
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.
Cabinet Series Dehumidifying Dryer
35
Chapter 6: Maintenance
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
Important!
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.
Cabinet Series Dehumidifying Dryer
36
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.
Caution!
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.
Cabinet Series Dehumidifying Dryer
37
Preventative Maintenance Checklist
Dehumidifying Dryer Systems
System model #
Every week
Serial #
Date/
By
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.
Check air regulator
to make sure pressure is 60-80 psi
(413.7 to 551.6 kPa
/4.1 to 5.5 bars). (If
applicable)
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 -
Cabinet Series Dehumidifying Dryer
38
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.
Caution!
6-4
Do not attempt to check the continuity or resistance of the dew point
sensor. The sensor will be destroyed!
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.
WARNING!
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.
Cabinet Series Dehumidifying Dryer
39
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.
6-5
Replacing Worn Desiccant
Caution!
Make sure desiccant beds are sufficiently cool before replacing worn
desiccant.
1. Disconnect the electrical and compressed air supply.
2. Remove the rear and side shrouds to expose the desiccant beds.
3. Free the bed covers by removing the hex nuts on the retaining rods and remove the upper screens
from both beds.
4. Remove the desiccant in one of the following ways:
•
Vacuum out the desiccant.
•
Remove the entire bed from the frame and dump it out. To do this, remove the hose
connections, unclamp the beds, and unbolt from the regen heater assembly.
Make sure the bed interiors are clean.
Important!
You should properly dispose of any discarded desiccant.
Consult local disposal regulations for more information.
Before re-packing the beds, determine the proper amount of desiccant for the dryer being
serviced. See Figure 14 on the following page for more information. Pre-measured desiccant kits
are available from the manufacturer’s parts department.
Attach the beds to the frame for Steps 5 through 9.
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.
9. Re-install the rear and side shrouds. Re-connect the compressed air supply and electrical
power.
Cabinet Series Dehumidifying Dryer
40
Figure 7:
Required Desiccant Amounts per Bed; Type 4X Desiccant (2 beds per unit)
Dryer
CFM
90
100
150
225
Large bead (Type 4X)
Part no.
lbs.
Kg
3.0
1.362
3.0
1.362
W00000892
9.0
4.086
9.0
4.086
Small bead (Type 4X)
Part no.
lbs.
Kg
21.0
9.534
21.0
9.534
W00000893
30.0 13.620
30.0 13.620
Total per bed
lbs.
Kg
24.0
10.896
24.0
10.896
39.0
17.706
39.0
17.706
Type 13X Desiccant
Dryer
CFM
90
100
150
225
6-6
Large bead (Type 13X)
Part no.
lbs.
Kg
3.0
1.362
3.0
1.362
W00018050
9.0
4.086
9.0
4.086
Small bead (Type 13X)
Part no.
lbs.
Kg
21.0
9.534
21.0
9.534
W00018051
30.0 13.620
30.0 13.620
Total per bed
lbs.
Kg
24.0
10.896
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.
WARNING!
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.
6. Re-install the heater and heater plate assemblies in reverse order. Install new heater
gaskets and securely tighten all fasteners.
Caution!
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.
Cabinet Series Dehumidifying Dryer
41
6-7
Replacing the Regeneration Heater
The dehumidifying dryers use heater elements located below each desiccant bed.
WARNING!
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.
Caution!
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.
Changing the Controller Security Level
1. To access protect mode, press and hold the AT button and the Display button for more than one
and a half to two (1.5 to 2) seconds.
2. The display should read SECr for security mode. If you press the Display button for short
presses you will toggle between (SECr) and (KEYP) for AT protect.
3. With the display reading SECr, set the security levels by the arrow up and down keys. Change
the security level to 1 to make changes to the operating parameters. The temperature controller is
factory set to Security Level 5, the dew point indicator is factory set to Security Level 3.
Available Security Levels
Mode
Calibration
Option
Expansion
Setup
Level 2
Level 1
Level 0
0
X
X
X
X
X
X
X
1
X
X
X
X
X
X
Security level
2
3
4
X
X
X
X
X
X
5
6
X
Any mode marked with an X is displayed in the Security
Level indicated. To return to the main display (run mode),
press and hold the AT and display key for 1.5 to 2 seconds.
Restoring Factory Defaults on the Process Temperature Controller
1. Remove controller from housing and check for output board number E53-QR4R (Pulse
NPN/Relay).
Cabinet Series Dehumidifying Dryer
42
2. Make sure jumper setting for input type is set for thermocouple TC-PT, middle jumper.
3. Return controller to housing.
4. Press the Display button for one (1) second to enter Menu Display.
5. Press the Up Arrow button to get to Setup mode.
6. To switch parameters within Setup mode, press the Display button.
Figure 8:
Setting List for Process Temperature Controller, Part No. A0548565
Mode
Parameter
Protect SECr Security
Protect YEYP A/M Key Protect
Manual Manual MV
Mode
Parameter
Level 0
Level 0
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
SP Set Point
r-S Run/Stop
SP-0 Set Point 0
SP-1 Set Point 1
AL-1 Alarm Value 1
AL-2 Alarm Value 2
AL-3 Alarm Value 3
P Proportional Band
I Integral Time
d Derivative Timer
C-SC Cooling
Coefficient
C-db Dead Band
6F-r Manual Reset
Value
HYS Hysteresis (Heat)
CHYS Hysteresis (Cool)
CP Control Period
(Heat)
C-CP Control Period
(Cool)
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Mode
Level 0
Level 0
Level 1
Level 1
Level 1
Parameter
SP Set Point
r-S Run/Stop
SP-0 Set Point 0
SP-1 Set Point 1
AL-1 Alarm Value 1
Cabinet Series Dehumidifying Dryer
Setting range
0 to 6
ON/OFF
-5.0 to 105.0%
Setting range
Default
1
OFF
0.0
SP Lower Limit to Upper Limit EU
Run/Stop
SP Lower to Upper EU
SP Lower to Upper EU
-1999 to 9999 EU
-1999 to 9999 EU
-1999 to 9999 EU
0.1 to 999.9% FS
0 to 3999 SEC
0 to 3999 SEC
0.01 to 99.99
0
Run
0
0
0
0
0
10.0
233
40
1.00
Factory
setting
Default
Default
Default
Default
25.0
25.0
Default
4.4
84
13
Default
-19.99 to 99.99%FS
0.0 to 100.0%
0.00
50.0
Default
Default
0.01 to 99.99%FS
0.01 to 99.99%FS
1 to 99 SEC
0.10
0.10
20
Default
Default
Default
20
Default
Default
Factory
setting
Default
Default
Default
Default
25.0
1 to 99 SEC
Setting range
SP Lower Limit to Upper Limit EU
Run/Stop
SP Lower to Upper EU
SP Lower to Upper EU
-1999 to 9999 EU
Default
Factory
setting
5
ON
Default
0
Run
0
0
0
43
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Level 1
Mode
AL-2 Alarm Value 2
AL-3 Alarm Value 3
P Proportional Band
I Integral Time
d Derivative Timer
C-SC Cooling
Coefficient
C-db Dead Band
6F-r Manual Reset
Value
HYS Hysteresis (Heat)
CHYS Hysteresis (Cool)
CP Control Period
(Heat)
C-CP Control Period
(Cool)
-1999 to 9999 EU
-1999 to 9999 EU
0.1 to 999.9% FS
0 to 3999 SEC
0 to 3999 SEC
0.01 to 99.99
0
0
10.0
233
40
1.00
25.0
Default
4.4
84
13
Default
-19.99 to 99.99%FS
0.0 to 100.0%
0.00
50.0
Default
Default
0.01 to 99.99%FS
0.01 to 99.99%FS
1 to 99 SEC
0.10
0.10
20
Default
Default
Default
20
Default
Setting range
Default
RMT/LCL
M(Minutes)/H(Hours)
0 to 9999 EU
0 to 9999 SEC
-5.0 to 105.0%
-5.0 to 105.0%
MV Lower Limit +0.1 to 105.0%
-5.0 to MV Upper Limit –0.1%
0.0 to 100.0%/SEC
0 to 9999 SEC
0.01 to 99.99%
0.01 to 99.99%
0.01 to 99.99%
-199.9 to 999.9 °C
LCL
M
0
0
0.0
0.0
105.0
-5.0
0.0
0
0.02
0.02
0.02
0.0
Factory
setting
Default
Default
Default
Default
Default
Default
Default
Default
Default
Default
Default
Default
Default
Default
0.0
Default
1 to 99 SEC
Parameter
Level 2
Level 2
Level 2
Level 2
Level 2
Level 2
Level 2
Level 2
Level 2
Level 2
Level 2
Level 2
Level 2
Level 2
r-L Remote/Local
SPrU Sp Ramp Time Unit
SPrE Sp Ramp Set Value
LbA LBA Detection Time
Au-5 MV at Stop
Au-E MV at PV Error
6L-L MV Upper Limit
6L-L MV Lower Limit
6rL MV Change Rate Limit
CnF Input Digital Filter
ALH1 Alarm 1 Hysteresis
ALH2 Alarm 2 Hysteresis
ALH3 Alarm 3 Hysteresis
Cn5H Input Shift Upper
Limit
Level 2 Cn5L Input Shift Lower
Limit
Mode
Parameter
Setup
Cn-E Input Type
Cn-H Scaling Upper
Limit
Cn-L Scaling Lower
Limit
dP Decimal Point
d-U °C/F Selection
CnCE Parameter
Setup
Setup
Setup
Setup
Setup
Cabinet Series Dehumidifying Dryer
-999.9 to 999.9 °C
Setting range
0 to 21
Scaling Lower Limit +1 to 9999 EU
-1999 to SP Setting Upper Limit -0.1 EU
0 to 3
°C/F
Yes/No
2
Factory
setting
3
-100
Default
0
Default
0
°C
No
Default
°F
Default
Default
44
Setup
Setup
Setup
Setup
Setup
Setup
Setup
Setup
Setup
Setup
Initialize
6UE1 Control Output 1
Assignment
6UE2 Control Output 2
Assignment
Sub 1 Auxiliary Output
1 Assignment
ALE1 Alarm 1 Type
AL1n Alarm 1 open in
alarm
ALE2 Alarm 2 Type
AL2n Alarm 2 open in
alarm
ALE3 Alarm Type
AL3n Alarm 3 open in
alarm
6rEu Direct/Reverse
Operation
Mode
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Heat/Cool/Alarm 1/Alarm 2/Alarm 3/
LBA
Heat/Cool/Alarm 1/Alarm 2/Alarm 3/
LBA
Heat
Default
AL-1
Default
AL-1
Default
0 to 11
2
NO/NC
NO
Default
Default
0 to 11
2
Default
NO/NC
NO
Default
0 to 11
2
Default
NO/NC
NO
Default
OR-R
Default
Default
Factory
setting
1300
400.0
Alarm 1/Alm 2/Alm 3/LBA/S.ERR/E333
OR-R/OR-D
Parameter
SL-H Set Point Upper
Limit
SL-L Set Point Lower
Limit
CnEL PID/ON/OFF
SE ST Adaptive Tuning
(Fuzzy)
SE-b ST Stable Range
ALFA α
AE-G AT Calculated
Gain
rESE Standby
Sequence Reset
Setting Method
rEE Automatic Return
of Display Mode
AE-H AT Hysteresis
LbAb LBA Detection
Width
Setting range
SP Lower Limit +1 to Scaling Upper
Limit
Scaling Upper Limit to SP Lower Limit -200
0
PID/ON/OFF
PID
Default
OFF/ON
OFF
Default
0.1 to 999.9 °C/F
0.01 to 1.00
15
0.65
Default
Default
0.1 to 10.0
1.0
Default
Default
0/1
0
0 to 99 SEC
0
Default
0.1 to 9.9% FS
0.2
Default
0.0 to 999.9% FS
0.2
Default
Option Boards
Available Option Boards
Cabinet Series Dehumidifying Dryer
45
Option Type
Board Number
RE232C
E53-CK01
RS-485
E53-CK03
Mode
Parameter
Option
Option
Option
Option
Option
Option
Option
Option
Option
Option
Eu-A Multi-SP Function
Eu-1 Event Input Assign 1
SbCE Communication Stop Bit
Len Comm. Data Length
PrEY Commication Parity
6PS Comm. Baud Rate
U-n6 Comm. Unit No.
Er-E Transfer Output Type
Er-H Xfer Output Upper Limit
Er-L Xfer Output Lower Limit
Event Input
E53-CKB
Setting range
0/1
STOP/MAN
½ BITS
7/8 BITS
None/Even/Odd
1.2/2.4/4.8/9.6/19.2
0 to 99
SP/SP-M/PV/O/C-O
5
5
Transfer Output
E53-CKF
Default
0
STOP
2
7
Even
9.6 kbps
0
SP
5
5
Factory
setting
Default
Default
Default
Default
Default
Default
Default
Default
Default
Default
Restoring Factory Defaults on the Dew Point Controller
1. Make sure jumper setting for input type is set for Current Input (I), right jumper.
2. Return controller to housing.
3. Press the Display button for one (1) second to enter Menu Display.
4. Press the Arrow Up button to switch between menus.
5. To switch parameters within a menu, press Up Arrow button.
Figure 9
Setting List for Dew Point Controller, Part No. A0548567
Mode
Protect
Protect
Manual
Level 0
Level 0
Level 1
Level 1
Level 1
Level 1
Level 1
Level 2
Level 2
Level 2
Level 2
Level 2
Level 2
Parameter
Setting range
Default
SECr Security
YEYP A/M Key Protect
Manual MV
SP Set Point
r-S Run/Stop
AL-1 Alarm Value 1
AL-2 Alarm Value 2
C-db Dead Band
HYS Hysteresis (Heat)
CHYS Hysteresis (Cool)
SPrU Sp Ramp Time Unit
SPrt Sp Ramp Set Value
CnF Input Digital Filter
ALH1 Alarm 1 Hysteresis
ALH2 Alarm 2 Hysteresis
Cn5H input shift upper limit
0 to 6
ON/OFF
-5.0 to 105.0 %
SP lower limit to upper limit EU
Run/Stop
-1999 to 9999 EU
-1999 to 9999 EU
-19.99 to 99.99%FS
0.01 to 99.99% FS
0.01 to 99.99 FS
M(Minutes)/H(Hours)
0 to 9999 EU
0 to 9999 SEC
0.01 to 99.99%
0.01 to 99.99%
-199.9 to 999.9°C
1
OFF
0.0
0
Run
0
0
0.00
0.10
0.10
M
0
0
0.02
0.02
0.0
Cabinet Series Dehumidifying Dryer
Factory
setting
3
ON
Default
Default
Default
-10.0°F/-23°C
-10.0°F/-23°C
Default
Default
Default
Default
Default
Default
Default
Default
Default
46
Level 2 Cn5L input shift lower limit
Mode
Setup
Setup
Setup
Setup
Setup
Setup
Setup
SetUp
Setup
Setup
Setup
Setup
Setup
Expansion
Expansion
Expansion
Expansion
Expansion
6-8
Parameter
Cn-t Input Type
-999.9 to 999.9°C
Setting range
0 to 21
Scaling Lower Limit +1 to
Cn-H Scaling Upper Limit
9999 EU
-1999 to SP Setting Upper
Cn-L Scaling Lower Limit
Limit –0.1 EU
dP Decimal Point
0 to 3
CnCE Parameter Initialize
Yes/No
6Ut1 Control Output 1
Heat/Cool/Alarm 1/Alarm 2/
Assignment
Alarm 3/LBA
6Ut2 Control Output 2
Heat/Cool/Alarm 1/Alarm 2/
Assignment
Alarm 3/LBA
Sub 1 Auxiliary Output 1
Alarm 1/Alm 2/Alm 3/LBA/S.
Assignment
ERR/E333
ALt1 Alarm 1 Type
0 to 11
AL1n Alarm 1 open in alarm
NO/NC
ALt2 Alarm 2 Type
0 to 11
AL2n Alarm 2 open in alarm
NO/NC
6rEU Direct/Reverse
OR-R/OR-D
Operation
SP Lower Limit +1 to
SL-H Set Point Upper Limit
Scaling Upper Limit
Scaling Upper Limit to Sp
SL-L Set Point Lower Limit
Lower Limit
CntL PID/ON/OFF
PID/ON-OFF
rESt Standby Sequence
0/1
Reset Setting Method
rEt Automatic Return of
0 to 99 SEC
Display Mode
0.0
Default
Default
2
Factory
setting
17
-100
15°F/-9C
0
-40°F/-40C
0
No
Default
Default
Heat
COOL
AL-1
Default
AL-2
Default
2
NO
2
NO
8
Default
8
Default
OR-R
Default
1300
15°F/-9C
-200
-40°F/-40C
PID
ON-OFF
0
Default
0
Default
Restoring the E5CK Temperature Controller and Dew Point
Meter to Factory Setup
If preset parameters on the controller have been tampered with and it no longer properly controls
temperature and displays dew point, you can restore the controller to factory setup.
Cabinet Series Dehumidifying Dryer
47
- Notes -
Cabinet Series Dehumidifying Dryer
48
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.
Cabinet Series Dehumidifying Dryer
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.
49
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.
Cabinet Series Dehumidifying Dryer
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.
50
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.
Cabinet Series Dehumidifying Dryer
51
CHAPTER 8: APPENDIX
8-1
Contact Information
Parts Department
Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610; Fax [262] 641-8653
The Parts Department is ready to provide the parts to keep your systems up and running. DEM
replacement parts ensure operation at design specifications. Please have the model and serial
number of your equipment when you call. Consult the Customer Parts List included in your
information packet for replacement part numbers.
Service Department
Call toll-free 8am–5pm CST [800] 423-3183 or call [262] 641-8610
Emergencies after 5pm CST, call [847] 439-5655
We have a qualified service department ready to help. Service contracts are available for most our
products.
Sales Department
Call [262] 641-8610 Monday–Friday, 8am–5pm CST
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.
Contracting Department
Call [262] 641-8610 Monday—Friday, 8am—5pm CST
Let us install your system. The Contracting 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.
8-2
Technical Specifications
Process
air flow
cfm cmh
90 153
100 d170
150 255
225 382
Hose
conn.
dia.
in.
mm
2½”
2”
2½”
4”
63.5
50.8
63.5
101.6
Output
temperature
range c
ºF
ºC
140º-400º
185º-400º
160º-400º
160º-400º
60º-204º
85º-204º
71º-204º
71º-204º
Amps
460/3/60
(nameplate)
20
23
34
45
Process
blower
power
hp kW
1.00
4.00
4.00
5.00
0.75
3.00
3.00
3.75
Regen.
blower
hp kW
0.25
0.25
0.33
0.33
0.19
0.19
0.25
0.25
Dimensions
inches
cm
L W H L W H
Approx.
shipping
weight
lbs. Kg
27
27
37
37
440
475
750
850
27
27
37
37
68
68
79
87
69
69
94
94
69
69
94
94
173
173
239
239
c Aftercooler required above 250ºF (121ºC) operation.
d 100 CFM operation below 185ºF (85ºC) requires a precooler.
Cabinet Series Dehumidifying Dryer
52
200
216
341
386
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