Sterling | DH1-610-2 | User's Manual | Sterling DH1-610-2 User's Manual

Sterling DH1-610-2 User's Manual
SDAA 25-100 Small Dryer
With AP-1 Controls
Part Number: 882.00294.00
Bulletin Number: DH1-610-2
Effective: 05/15/06
Write Down Your Serial Numbers Here For Future Reference:
_________________________
_________________________
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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 2006
All rights reserved.
Shipping Information
Unpacking and Inspection
You should inspect your portable drying/conveying system 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 it. You should have:
; Portable drying/conveying system
; 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
shipments in the United States and Canada, call 1 (800) 233-4819; for all other countries, call
our international desk at (630) 475-7491. Have the order number and item number available.
Hold the items until you receive shipping instructions.
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
Portable Drying/Conveying Systems
2
Table of Contents
CHAPTER 1: SAFETY ................................................................ 6
1-1
1-2
1-3
1-4
How to Use This Manual ............................................................................................. 6
Safety Symbols Used in this Manual .....................................................................6
Safety Tag Information ................................................................................................ 7
Dryer Safety Tags .................................................................................................7
Warnings and Precautions .......................................................................................... 7
Responsibility .............................................................................................................. 8
General Responsibility...........................................................................................8
Operator Responsibility .........................................................................................9
Maintenance Responsibility.................................................................................10
Reporting a Safety Defect ...................................................................................10
CHAPTER 2: FUNCTIONAL DESCRIPTION............................ 11
2-1
2-2
2-3
2-4
2-5
Models Covered in This Manual................................................................................ 11
General Description................................................................................................... 11
The Drying System ..............................................................................................11
What is Desiccant................................................................................................11
The Process/Regeneration Cycle........................................................................11
Standard Features..................................................................................................... 12
Mechanical Features ...........................................................................................12
Electrical Features...............................................................................................12
Controller Features..............................................................................................12
Options ...................................................................................................................... 13
Safety Devices and Interlocks ................................................................................... 13
Safety Circuit Standards......................................................................................13
Fail Safe Operation .............................................................................................14
Safety Device Lock-Outs .....................................................................................14
CHAPTER 3: INSTALLATION .................................................. 15
3-1
3-2
3-3
3-4
3-5
Uncrating the Equipment........................................................................................... 15
Rigging and Placing the Dryer................................................................................... 15
Electrical Connections............................................................................................... 17
Setup Procedures...................................................................................................... 18
Checking for Proper Blower Rotation ..................................................................18
Drying Hopper Air Trap Considerations (If Equipped) .........................................18
Installing the Optional Aftercooler........................................................................18
Initial Start-up ............................................................................................................ 19
Pre-Startup Checks .............................................................................................19
Starting Up the Dryer...........................................................................................19
Auto-Tuning the Dryer .........................................................................................19
Shutting Down the Dryer .....................................................................................20
CHAPTER 4: OPERATION ....................................................... 21
4-1
Controller Description and Operation ........................................................................ 21
Identifying Control Panel Components for the AP-1 Controller ...........................21
Portable Drying/Conveying Systems
3
4-2
4-3
Disconnect Switch ......................................................................................21
Control Power Switch .................................................................................21
Touch Screen .............................................................................................21
Alarm Horn & Light .....................................................................................21
Process Air Temperature Controller ....................................................................22
Startup Screen ....................................................................................................22
Main Menu Screen ..............................................................................................23
Dryer Status Screen ............................................................................................23
Start Button .........................................................................................................24
Dryer Menu Screen .............................................................................................25
Dryer Status ........................................................................................................25
Dryer Setup ........................................................................................................25
Dryer Setup (Screen 1 of 3) Process Temperature High&Low ALarm ........25
Dryer Setup (Screen 2 of 3) Choosing Degree F or Degree C....................26
Dryer Setup (Screen 3 of 3) Process return air temperature …………….. 26
Overdry Protection Setup ....................................................................................26
Screen 1 of 2 (Enable or Disable the feature) .............................................26
Screen 2 of 2 (Overdry Protection Parameter Settings) ..............................27
Alarms .................................................................................................................28
Auto Tune............................................................................................................28
Dew Pt Setup ......................................................................................................29
Auto Start ............................................................................................................29
Main Menu...........................................................................................................30
Help Menu ...........................................................................................................30
System Menu ......................................................................................................31
System Setup ......................................................................................................31
Set Clock .............................................................................................................32
Set Auto Start Clock ...................................................................................32
Set Alarm Clock..........................................................................................33
Hour Meters.........................................................................................................33
Input Status .........................................................................................................34
Output Status ......................................................................................................34
System Setting ……………………………………………………………………….. 34
Service Menu ......................................................................................................35
Alarm Screens .....................................................................................................35
Redundant Safety Controller Display ..................................................................36
Setting the Redundant Safety Controller .............................................................36
Restoring the WATLOW Redundant Safety Controller to Factory Setup ............37
System Operation Procedures .................................................................................. 38
Shutting Down the Dryer ........................................................................................... 39
CHAPTER 5: MAINTENANCE .................................................. 40
5-1
5-2
5-3
Preventative Maintenance Schedule......................................................................... 40
Preventative Maintenance......................................................................................... 41
Servicing Process Air Filters................................................................................41
Servicing the Dew Point Monitor .........................................................................42
Corrective Maintenance ............................................................................................ 43
Symptoms of Worn Desiccant .............................................................................43
Replacing Worn Desiccant ..................................................................................43
Replacing the Regeneration Heater ....................................................................45
Portable Drying/Conveying Systems
4
Replacing the Process Heater.............................................................................45
Replacing/Cleaning the Cooling Coils .................................................................46
CHAPTER 6: TROUBLESHOOTING ........................................ 48
6-1
6-2
Introduction................................................................................................................ 48
Determining Temperature Controller Errors or Sensor Errors................................... 54
Using a Thermocouple ........................................................................................54
CHAPTER 7: APPENDIX .......................................................... 55
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
Warranty.................................................................................................................... 55
Warranty Specifications.......................................................................................55
Warranty Restrictions ..........................................................................................55
Warranty Liabilities ..............................................................................................55
Customer Responsibilities ...................................................................................56
Optional Components................................................................................................ 56
Technical Specifications............................................................................................ 56
Annex B Information ............................................................................................56
Aftercooler Design Specifications........................................................................57
Drawings and Diagrams ............................................................................................ 57
Spare Parts List......................................................................................................... 60
Returned Material Policy ........................................................................................... 62
Credit Returns .....................................................................................................62
Warranty Returns ................................................................................................62
Dryer Identification (Serial Number) Tag................................................................... 62
Technical Assistance................................................................................................. 63
Parts Department ................................................................................................63
Service Department.............................................................................................63
Sales Department................................................................................................63
Contract Department ...........................................................................................63
Portable Drying/Conveying Systems
5
Chapter 1: Safety
1-1
How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
drying system. 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 Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, preoperational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the drying system. 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 drying
system. These instructions are intended to supplement standard shop procedures performed
at shift, daily, and weekly intervals.
The Operation chapter includes 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 your drying system 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.
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Chapter 1: Safety
6 of 63
1-2
Safety Tag Information
Dryer Safety Tags
Hot!
Read Operation
and Installation
Manual
High Voltage
Earth Ground
Inside Enclosure
PE
Lifting Point
1-3
Protected 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.
; Use EXTEREME CAUTION when working with dryer. HIGH HEAT can be
dangerous. Keep body parts, tools, clothing, and debris away from dryer.
Portable Drying/Conveying Systems
Chapter 1: Safety
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; 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 close at hand 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.
1-4
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 machine should become familiar with its 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 mater 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.
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Chapter 1: Safety
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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 or appropriate
person.
REMEMBER:
• NEVER place your hands or any part of your body in any dangerous location.
• NEVER operate, service, or adjust the equipment without appropriate training and first
reading and understanding this manual.
• NEVER try to pull material out of the equipment with your hands while it is running!
• Before you start the portable drying/conveying system check the following:
•
•
Remove all tools from the equipment;
Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the
hopper area;
• If your portable drying/conveying system has been inoperative or unattended, check all
settings before starting the unit.
• 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/conveying system action
•
leakage
•
improper maintenance
Portable Drying/Conveying Systems
Chapter 1: Safety
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•
NEVER stand or sit where you could slip or stumble into the
equipment while working on it.
• DO NOT wear loose clothing or jewelry, which can be caught while working on the
equipment. In addition, cover or tie back long hair.
• Clean the equipment and surrounding area DAILY, and inspect the machine for loose,
missing or broken parts.
• Shut off power to the equipment 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
power. Attach warning tags to the disconnect switch.
When you need to perform maintenance or repair work on equipment above floor level, use a
solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your
equipment, use it. The work platform should have secure footing and a place for tools and
parts. DO NOT climb on 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 equipment until all persons are clear of the area. DO NOT start
and run the machine until you are sure all parts are functioning correctly.
BEFORE you turn the machine to the operator for production, verify all equipment
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/tag out), or failure to maintain a clean and safe working environment.
Portable Drying/Conveying Systems
Chapter 1: Safety
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Chapter 2: Functional Description
2-1
Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for 15, 30 or 60
cfm dehumidifying dryers. 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 mini dryers are designed to generate heated dehumidified air (at a very
low dew point) at carefully controlled temperatures for use in plastic drying systems. The
dryer circulates hot dehumidified air through a column of plastic resin in the large drying
hopper. The resin in the hopper is discharged through a slide gate in a “first in, first out”
manner.
2-2
General Description
The Drying System
Dehumidifying dryers are used to generate very low dew point air heated to a controlled
temperature for drying plastic pellets and regrind.
Our dryers force hot, dry air through resin in a drying hopper, where air picks up moisture
from the material and draws it back to the dryer. In the dryer, a desiccant bed strips moisture
from the air. The dried process air is then re-heated and delivered back into the drying
hopper for more moisture removal.
Portion of the low dew point process air is directed to the desiccant tank that is off process.
This air is heated to approximately 450°F (232°C) before entering the bed that is in
regeneration. The moisture is then forced from the desiccant before being exhausted into the
atmosphere. A small amount of ambient air is introduced into the process return air filter to
make up for the air lost during the bed regeneration. To compensate for the humidity content
in the air, this dryer is supplied with the proper amount of desiccant.
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 blended with a clay binder and
formed into beads.
The Process/Regeneration Cycle
Our 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 system heats the very low dew point air and forces it through
the desiccant bed. The moisture driven off the bed bleeds to the atmosphere.
Portable Drying/Conveying Systems Chapter 2: Functional Description
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2-3
Standard Features
Mechanical Features
• Rugged compact cart with handles and sturdy 4” (10 cm) casters.
• Dual desiccant beds
• Electrically-motorized air valve
• 13X Molecular Sieve
• Single regenerative process blower
• Drying temperature range of 180ºF to 250ºF (82ºC to 121ºC)
• 2.5” hose connections
Electrical Features
• Process thermocouple to be connected to drying hopper air inlet.
• Nema 12 control enclosure
• NFPA79 machinery electrical standards
•
Non-fused electrical disconnect
•
Branch fusing
•
Solid State process heater contactor
•
Regeneration temperature control
•
Process high temperature alarm light
•
Dirty filter indicator
•
Process/regeneration heater box
•
Dew Point Monitor.
•
Material saver/over dry protection
•
High temperature safety system (Process/Regeneration)
•
7 day timer/auto start
Controller Features
• Mitsubishi programmable relay controller
• Display of process temperature set point and actual settings
• Display of process air dew point
Portable Drying/Conveying Systems
Chapter 2: Functional Description
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2-4
Options
Options marked with “*” indicate options that can be factory installed or retrofitted in the
field.
• * Process temperature up to 400ºF (204º C), including aftercooler with dryer and
silicone insulated delivery hose.
Note: For below 180°F (82ºC), cooler needs to cool the air coming
out of the desiccant tank prior to entering the process heater
box.
• * If the dryer is a central dry air generator, it will not have a process heater box.
• * Plasticizer trap (with cooling coil) in lieu of standard aftercooler (mounts outside on
back of dryer).
• * Drawer magnet, stainless steel construction.
• * Casters, two (2) fixed and two (2) swivels.
• * Machine mount adapter to accommodate a dryer and corresponding hopper.
• * Low temperature operation below 180ºF (82ºC), includes an internal cooler.
• * Redundant high temperature safety circuit.
• * Cart with caster with hopper mounting place.
• * Low level indicator(s).
• * Insulated air hose for air delivery.
• * RPV for drying hopper
2-5
Safety Devices and Interlocks
This section includes information on safety devices and procedures that are inherent to the
drying system. 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.
Portable Drying/Conveying Systems Chapter 2: Functional Description
13 of 63
Every effort has been made to incorporate these standards into the design of the drying
system; 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 this equipment 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
machine.
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.
In addition to the safety devices listed above, these dryers are equipped with a line cord plug.
This allows the operator or maintenance personnel to unplug the dryer 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.
WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning this equipment. Failure to do so may result in
serious injury. No one but the person who installed the lockout may remove it.
Portable Drying/Conveying Systems
Chapter 2: Functional Description
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Chapter 3: Installation
3-1
Uncrating the Equipment
Portable Drying/Conveying Systems are shipped mounted on a skid, enclosed in a plastic
wrapper, and contained in a cardboard box.
1. Pry the crating away from the skid.
Note: Remove the nails holding the box to the skid and lift the box
off carefully; avoiding staples in the 1’ x 4’ wood supports.
Cut the steel banding.
2. Use a pry bar to remove the blocks securing the unit to the skid.
3. Lift unit from sides. Use a pry bar if necessary to carefully remove the
skid from the unit.
4. Lower slowly.
3-2
Rigging and Placing the Dryer
Take care when rigging and placing the drying and conveying system. Figure 1 below shows
a suggested safe rigging diagram. It lets you lift the dryer/hopper unit vertically using a fork
truck.
Caution!
If you are mounting a machine-mount dryer with a magnet or transition adaptor on the
machine throat, you must provide additional support to hold the dryer securely on the
machine.
Be aware that off-center static and dynamic hopper loading can occur with machine
vibration. Again, provide additional support to hold the dryer securely on the machine.
For 60 cfm dryer units, you must provide additional support to stabilize these units and
to protect personnel when installing on machine throats.
Use caution and observe safety rules when lifting and placing your dryer!
Portable Drying/Conveying Systems
Chapter 3: Installation
15 of 63
Figure 1: Suggested Lift Rigging for Cart Mount Dryers
DO NOT
USE
DEW POINT
ALARM HORN
ALARM
ALARM Silencer
OFF
ON
PROCESS
TEMPERATURE
CONTROL POWER
ON
OFF
USE
FORK
LIFT
TRUCK
Caution!
Do not use a hoist to move or rig your Drying/Conveying System when it is
mounted on a cart! Moving the unit with a hoist will cause it to become
unstable and may cause damage to the equipment and/or injury to
personnel!
Figure 2: Suggested Lift Rigging for Cart Mounted Dryers
Note: Floor Mounted Dryers can be lifted by hoist or fork lift.
USE
Overhead
Crane
Portable Drying/Conveying Systems
DEW POINT
CONTROL POWER
ON
OFF
ALARM HORN
ALARM
ALARM Silencer
OFF
ON
PROCESS
TEMPERATURE
USE
FORK
LIFT
TRUCK
Chapter 3: Installation
16 of 63
Figure 3: Suggested Lift Rigging for Cart Mounted Dryers
Mounting flange
E
E
Diameter hole:
F
ON
DEW POINT
CONTROL POWER
ON
OFF
ALARM HORN
ALARM
ALARM Silencer
Notes: Hopper mounting flanges on 0.75 and
and 1.5 cu. ft. (20 & 40 liter) hoppers
are supplied blank so the customer
can drill to match existing machine throat.
OFF
PROCESS
TEMPERATURE
3.0 cu. ft. (80 liter) hoppers and larger
are not supplied with a cast flange
(as shown).
Caution!
3-3
When using a hoist to move a machine mounted dryer, ALWAYS attach
chains to the three (3) locations/lifting points on the unit! Moving the
Dryer without the chains attached to all of the lifting points will cause the
unit to become unstable and may cause damage to the Dryer and/or injury
to personnel!
Electrical Connections
When making electrical connections to your unit, ensure that you take into consideration and
make arrangements for the following:
• A qualified electrician should make all electrical connections.
• Fulfill all national, state, and local safety and electrical code requirements.
• The serial tag lists voltage, phase, and amp draw information:
•
Line voltage must be within plus or minus ten percent (±10%) of the
voltage listed on the serial tag, or damage may occur. Phase imbalance
must be less than two percent (2%).
• 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.
• Make sure all electrical connections are tight.
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3-4
Setup Procedures
This section provides the procedures necessary for configuring your portable
drying/conveying system.
Configuration of your unit includes checking for proper blower rotation and installing the
optional aftercooler (on 60 cfm models). We recommend that you carry out these procedures
in the order given here.
Note: Before carrying out these procedures, install all equipment
as described in this section.
Checking for Proper Blower Rotation
Three-Phase Models
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!
The blower is rotating properly when air flows from the delivery outlet.
Note: Holding your hand in front of the air return will also
indicate if the blower rotates in the proper direction (by
feeling suction).
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.
Drying Hopper Air Trap Considerations (If Equipped)
Our exclusive air trap assembly on the top of the drying hopper prevents ambient air from
contaminating the material being dried. To ensure that your unit will operate at peak
efficiency, do the following:
• Keep the material level at the mid point of the air trap
This can be achieved by utilizing a hopper loader or vacuum conveying system to
supply material to the drying system.
Installing the Optional Aftercooler
Water-cooled 15/30/60 cfm models use a water-to-air heat exchanger as an aftercooler.
Cooling water is required for this design (3 gpm at 85°F or lower). Return air from the
hopper passes through the air filter to trap fines and dust before entering the heat exchanger.
Installing Water Lines
(Hose and Hose Clamp)
When installing the water lines, ensure that the aftercooler utilizes either tower, chilled or city
water as warm as 85°F (29°C). Recommended flow rate is three (3 gpm) gallons per minute
(11 liters per minute).
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NOTE: If the Aftercooler is used as a plasticizer trap, the water temperature of 50°F or lower
is recommended.
3-5
Initial Start-up
Pre-Startup Checks
; Check the process and return hoses for tight connections.
; Check all companion equipment, such as the drying hopper; verify that the loading
system is ready for operation.
; Verify that all dryer electrical connections are tight.
; Verify that the thermocouple is properly installed at the hopper inlet.
Starting Up the Dryer
1. Turn on (energize) the disconnect switch in your power drop, then turn on the
disconnect switch on the dryer.
2. Turn the system ON/OFF switch to ON to energize the display panel.
3. Check the display for the proper temperature scale (ºF or ºC).
4. Close the slide gate at the bottom of the drying hopper.
Make sure that the blowers turn in the right direction.
5. Fill the drying hopper with material.
6. Press the START button on the Touch Screen to start the dryer.
The process blower starts.
7. If your dryer has a water-cooled aftercooler, make sure that sufficient cooling water
(3gpm at 85°F or lower) flows properly through the coil and that you have bled any
trapped air from the system.
8. Set the process set point on the touch screen.
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.
Auto-Tuning the Dryer (Requires Supervisory Password)
From the “Dryer Status” screen, press “D-Menu” and select Auto Tune to gain access to this
screen.
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Figure 2: Process Autotune Screen
1. The autotune feature can be enabled by pressing the START/STOP button located in
the center of the screen.
2. AUTOTUNE IN PROGRESS or PROCESS NOT ACTIVE will inform the
operator of the current status of this feature.
3. At this point the operator can return back to the DRYER MENU or MAIN MENU by
touching the appropriate button on the screen.
Shutting Down the Dryer
1. Turn off the conveying system supplying the drying hopper and/or machine. Press
the shutdown button for the dryer to complete its cycle.
2. When processing is complete, close the hopper slide gate and shut down any in-line
companion equipment, such as the aftercooler.
3. If the dryer is shut down using the shutdown button on the dryer status screen, the
process heater will shut off and the bed regeneration process will be completed.
When the dryer is started at a later date the process air will be directed through the
bed that was regenerated last.
4. If the dryer control switch is turned off without using the dryer shutdown feature, the
dryer will stop immediately. When the dryer is started at a later date, the process
air will be directed through the last bed that was being used when the dryer control
switch was turned off. If a bed was being regenerated when the dryer control switch
was turned off, the regeneration process would begin over again on that same bed.
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Chapter 4: Operation
4-1
Controller Description and Operation
Identifying Control Panel Components for the AP-1 Controller
Disconnect Switch
The Disconnect Switch is located in the front upper right hand corner of the control
enclosure. It allows the user to disconnect power to the dryer for emergency shutdown,
service or long periods of inactivity.
Control Power Switch
The Control Power Switch is located on the front of the control enclosure below the touch
screen. The switch energizes the control circuit (PLC, touch screen, relays, etc.) within the
control enclosure.
Touch Screen
The Touch Screen is located in the center of the control enclosure. Once the disconnect is
on and the control circuit is energized, the machine can be started and parameters can be
adjusted through the touch screen.
Alarm Horn & Light
The Alarm Horn is located in the center of the control enclosure, next to the Control Power
Switch. The Alarm Light is located on the top of the enclosure. These devices give an
audible and visual indication that there is a malfunction with the system.
Figure 3: Typical Control Panel
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Process Air Temperature Controller
Control package use a PLC with a touch screen interface to control the operation of the dryer
and the optional conveying system. This section of the manual will address those parameters
that allow the user to optimize the drying/conveying system for specific applications.
Figure 4: Dryer Status Screen on Touch Screen Controller
Startup Screen
The screen shown above provides the operator with the following information:
• Dryer Model Number
• Temperature view (In Celsius or Fahrenheit)
• Copyright Information
• PLC Version
• Display Version
After approximately 10-12 seconds the controller will flash to the Dryer Status Screen shown
in Figure 10 above.
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Main Menu Screen
The MAIN MENU provides information on the following drying/conveying system
parameters:
•
DRYER MENU (some submenus are password protected)
•
ALARM HISTORY
•
HELP MENU
•
SYSTEM MENU
•
NO USERS LOGGED ON
This section of the manual will focus on the dryer features portion of the controller at this
time.
Press the DRYER MENU button to return to the next section of dryer functions.
Dryer Status Screen
(Shown at Controller Power Up)
Note: Looking at the screen from Left to Right
Dryer Process
The SETPOINT button allows the operator to set the process air temperature. The ACTUAL
button will give you a reading of what the actual process air temperature is entering the
drying hopper.
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Machine Status
The area in the lower left portion of the touch screen conveys two lines of information
relating to the overall operation of the dryer. The following is a list of typical machine/dryer
summary status line text messages:
1. Left Bed In Process
8.
Left Bed Heat
2. Right Bed In Process
9.
Left Bed Cool
3. Process Offline
10. Left Bed Ready
4. Valve Changing Position
11. Right Bed Heat
5. Auto start Timer Enabled
12. Right Bed Cool
6. Autotune in Progress
13. Right Bed Ready
7.
14. Over-dry Protect Active
Dryer Offline
Start Button
The START BUTTON allows the user to stop and start the dryer manually. When the start
button is pressed, the dryer begins to operate. The text in the button will change from
START to SHUTDOWN. The next time the button is pressed, the dryer will go into a
sequence shutdown and the button text will change to RESTART. The process heater will
shut off, the current bed regeneration will be completed and then the blower will stop. If
sequence shutdown is not desired, turning the POWER SWITCH off will turn off all
components of the dryer immediately and the optional conveying system will be turned off
also.
Setting Values
By pressing and holding the numbers in the SETPOINT button, the following screen will be
displayed:
Enter the values you would like to set in the screen by pressing the number keys. Press ENT
(Enter) when you are finished to set the new values or CLR (Clear) to erase the current
values and reenter new ones. To set the values in the next field, press ENT (Enter) to close
the screen shown above. Then select the next number field to enter new values.
Dryer Menu
Pressing this button will take the user to another screen where more machine parameters can
be viewed and adjusted.
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Dryer Menu Screen
The screen shown above will allow the operator to set/review operating parameters for the
following:
•
DRYER STATUS
•
DRYER SETUP (requires supervisory password)
•
OVERDRY PROTECT (requires supervisory password)
•
ALARMS
•
AUTO TUNE (requires supervisory password)
•
DEW PT SETUP (Dew Point Setup)
•
AUTO START (requires supervisory password)
•
MAIN MENU
DRYER STATUS
Pressing the STATUS button will take the operator back to the original status screen shown
on page 27. Pressing MENU will return you back to the menu screen.
DRYER SETUP
By pressing the LOW or HIGH alarm buttons, the operator can enter the desired values to
enable the alarm to go off at a specific deviation from set point (on the high or low side).
When these settings have been made, the operator now has a choice of returning to the
DRYER MENU, BACK (takes you back to the DRYER MENU) or pressing MORE to
take you to screen 2 of 3 of the DRYER SETUP screen.
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Buy pressing the MORE screen, you can choose for the temperatures to display in degrees F
or degree C. (Note; Changing the temperature scale, requires adjusting the alarm values.)
When these settings have been made, the operator now has a choice of returning to the
DRYER MENU, BACK (takes you back to the DRYER SETUP 1 of 3) or pressing MORE
to take you to screen 3 of 3 of the DRYER SETUP screen.
NOTE: At this display, before you change any of the settings, you need to test the
thermocouple readings in Ice water (32°F at sea level, and boiling water 212°F at sea
level). Then you may change these settings accordingly to make sure the controller is
displaying the correct temperature.
Setting Values
By pressing and holding the numbers in the LOW TEMP ALARM or the HIGH TEMP
ALARM buttons, the following screen will be displayed:
Enter the values you would like to set in the screen by pressing the number keys. Press ENT
(Enter) when you are finished to set the new values or CLR (Clear) to erase the current
values and reenter new ones. To set the values in the next field, press ENT (Enter) to close
the screen shown above. Then select the next number field to enter new values.
Over-Drying Protection
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The PROCESS RETURN AIR TEMPERATURE displays the air temperature as it leaves
the drying hopper. If this temperature is above 150°F, an aftercooler is required.
By pressing the DISABLE or ENABLE the operator disable or enable this feature of the
dryer.
This feature is used to prevent the over drying of the plastic resin in the drying hopper.
At this point the operator has the choice of pressing MAIN MENU, DRYER MENU, or
MORE to access the screen 2 of 2 of the OVERDY PROTECTION for adjusting values.
SET BACK VALUES;
The SETPOINT is the secondary drying temperature set point. This is the temperature at
which the drying temperature will be reduced to after a certain delay time and when the
return air temperature has exceeded its set point..
The TEMP is the set point for the return air temperature of the drying hopper. When the
return air temperature exceeds this value, after a certain delay time, the process temperature
will be reduced to its secondary value (SETPOINT) to eliminate over drying of the plastic
material.
The DELAY is the time which will take for the dryer to switch the drying temperature set
point from primary drying temperature to secondary drying temperature or back to the
primary drying temperature set point.
SET UP TEMP;
The SETUP TEMP is the secondary temperature setting for the return air temperature. When
the return air temperature of the drying is lower than this set point, after a certain delay time,
the process temperature set point will switch back to the primary drying temperature set
point.
Once the parameters have been set for the drying process, the operator can return to the
DRYER MENU, MAIN MENU, or BACK to the screen 1 of 2 of the OVERDRY
PROTECTION.
Setting Values
By pressing and holding the numbers in the SET BACK DELAY button, the following
screen will be displayed:
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Enter the values you would like to set in the screen by pressing the number keys. Press ENT
(Enter) when you are finished to set the new values or CLR (Clear) to erase the current
values and reenter new ones.
The next feature in the DRYER MENU is the ALARMS button/screen.
Alarms (Retains 100 of the most recent alarms)
This screen allows the operator to review the number and type of issues that the Dryer has
encountered during its operation. The “Alarm History” screen is NOT reset-able.
Problems can be viewed by Date, Hour, and Comment.
Because of the size of the screen, only three (3) comments/alarms can be viewed at a time.
To view alarms not visible on the screen, press the DOWN button. To return to a particular
alarm, press the UP button to scroll upward in the alarm history.
Pressing CNV (Convey) in this screen will take the operator to the CONVEY STATUS of
the system. You will only get CNV alarms when conveying options are enabled (Nomad
only).
At this point the operator can return back to the DRYER MENU or MAIN MENU by
touching the appropriate button on the screen.
Auto Tune
This screen allows the operator to automatically tune the process air temperature control
algorithm to a specific drying application. The autotune sequence should be initiated if the
user feels there are unacceptable fluctuations in the process air temperature. The calculated
P, I, and D variables will be shown in the lower left hand portion of the screen for reference
purposes.
The autotune feature can be enabled by pressing the PUSH TO START PROCESS
AUTOTUNE button.
AUTOTUNE IN PROGRESS or PROCESS NOT ACTIVE will inform the operator of
the current status of this feature.
At this point the operator can return back to the DRYER MENU or MAIN MENU by
touching the appropriate button on the screen.
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Dew Pt Setup
This screen allows the operator to set the dew point alarm value.
The HIGH LIMIT ALARM VALUE is an audible/visual alarm which will sound when
the process air dew point rises to this value. Values can be set for degrees Fahrenheit
between – 40 through +15 degrees and degrees Celsius between -40 through -10
degrees.
Setting Values
By pressing and holding the numbers in the HIGH DEW PT ALARM, the ALARM
STARTUP DELAY or the ALARM BED SW DELAY buttons, the following screen will
be displayed:
Enter the values you would like to set in the screen by pressing the number keys. Press ENT
(Enter) when you are finished to set the new values or CLR (Clear) to erase the current
values and reenter new ones. To set the values in the next field, press ENT (Enter) to close
the screen shown above. Then select the next number field to enter new values.
Once this feature has been set, the operator can return back to the DRYER MENU or MAIN
MENU by touching the appropriate button on the screen.
Auto Start
This screen allows the operator to set the time and day that the dryer will start
automatically. Reference page 32, Make sure the clock is set to current date ant time.
Pressing NEXT DAY allows the operator to scroll forward through the days of the week to
select the day they desire the dryer to start. Pressing PREV DAY allows the operator to
scroll backward through the days of the week to select the day they desire the dryer to start.
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By touching the ON TIME and OFF TIME sections on the screen, the operator can enter the
values for the time they wish the dryer to turn on and off. See the next page for instructions
on setting values for this feature.
Pressing the AUTOSTART TIMER DISABLED button will activate this dryer feature.
Pressing AUTOSTART TIMER ENABLED will deactivate this feature.
Once this feature has been set, the operator can return back to the DRYER MENU or MAIN
MENU by touching the appropriate button on the screen.
Setting Values
Enter the values you would like to set in the screen by pressing the number keys. Press ENT
(Enter) when you are finished to set the new values or CLR (Clear) to erase the current
values and reenter new ones. To set the values in the next field, press ENT (Enter) to close
the screen shown above. Then select the next number field to enter new values.
Main Menu
This screen allows you to jump to the different areas of the controller to set, monitor, and
operate different features of the Drying/Conveying System. Conveying screens are used only
with Nomad dryers.
NO USER LOGGED ON, indicates that the password to access certain features of the dryer
is not entered. USER LOGGED ON, indicates that the password to access certain features of
the dryer is still active and these features can be accessed and changed.
Help Menu
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System Menu
The screen shown above will allow the operator to set/review operating parameters for the
following:
The above screen will allow the operator to set/review operating parameters;
•
SYSTEM SETUP
•
SET CLOCK
•
HOUR METERS
•
ALARM HISTORY
•
I / O STATUTUS (Input and output status)
•
SYSTEM BACKUP
•
SERVICE
•
MAIN MENU
SYSTEM SETUP
This screen allows the operator to set alarm and password features.
ALARM OFF DUR is the amount of time (0-99 minutes) that the alarm and horn will stay
off after the alarm silence button is pushed. (When this function is set to 0, this feature will
never turn off. When it is set to 99, it will stay off until another alarm occurs.)
OPER PW is the four (4) digit number that allows access to the station and pump status
screen and the station operator screen. (When this feature is set to 0000 these screens are not
password protected.)
OPER PW DUR is the amount of time (5-99 minutes) the password will allow access to the
associated screens. The screen changes to the station status screen when the time expires.
SETUP PW is the four (4) digit number that allows access to the setup screens. (When this
is set to 0000 there is no password protection.). Store password in a secure location.
SETUP PW DUR is the amount of time (5-99) the password will allow access to the
associated screens. When the time expires, the screen changes to the station status screen.
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Note: If password(s) feature is enabled, please write down your
passwords and file them in a secure location.
At this point the operator can return back to the MAIN MENU or SYSTEM MENU by
touching the appropriate button on the screen.
Set Clock
This menu allows the operator to set the AUTOSTART CLOCK and the ALARM CLOCK.
Press the SET AUTOSTART CLOCK or the SET ALARM CLOCK buttons to set the
times and dates on these features.
Set Auto Start Clock
This screen allows the user to set the 7-day timer which can be programmed for daily or
weekly (over midnight) on/off operation. An internal battery backup holds the settings in
memory when the dryer is de-energized.
Setting Values
By pressing the numbers (Month, Day, Year, Hours and Minutes) under Set Clock on the
previous screen shown above, the following screen will appear:
Enter the values you would like to set in the screen by pressing the number keys. Press ENT
(Enter) when you are finished to set the new values or CLR (Clear) to erase the current
values and reenter new ones. To set the values in the next field, press ENT (Enter) to close
the screen shown above. Then select the next number field to enter new values.
Pressing the SET TIME button will enter the new information into the controller.
When the new information has been entered into the controller, the operator can return back
to the MAIN MENU or SYSTEM MENU by touching the appropriate button on the screen.
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Set Alarm Clock
In this screen the user can set the variables which are used to time and date stamp alarms.
This feature works in conjunction with the ALARM screen (See page 31) to notify the user of
issues which the Dryer had encountered during its operation.
Setting Values
Pressing the individual numbers in the second row of the screen shown above, the operator
can select the field (Month, Day, Year, Hours and Minutes) he wishes to change.
Enter the values you would like to set by pressing the number keys. Press ENT (Enter) when
you are finished to set the new values or CLR (Clear) to erase the current values and reenter
new ones. Press END to return back to the CLOCK MENU screen.
Press the SYSTEM MENU button in the CLOCK MENU SCREEN to return back to the
system menu screen and the next set of programmable features.
Hour Meters
This screen monitors the number of hours that the dryer, machine blower, and dryer blower
have operated.
In addition to monitoring the total number of hours of equipment operation, it also has resettable fields which allow the operator to set the counter back to zero. This is useful for
monitoring hours between equipment maintenance periods.
Press the DRYER RESET button, MB RESET button, and/or DB RESET button to reset
the counters.
When and if the counters have been reset on the controller, the operator can return back to the
MAIN MENU or SYSTEM MENU by touching the appropriate button on the screen.
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Input Status (UPDATE)
This screen allows the operator to view the status of the variables contributing to the input of
material into the drying system. It also is useful in troubleshooting system issues (i.e. a dirty
filter or low material level in a hopper).
At this point the operator may choose the SYSTEM MENU button to go back to the system
menu, or MAIN MENU to return to main menu, or press OUTPUTS to access the output
screen.
Output Status (UPDATE)
This screen allows the operator to view the status of variables contributing to the
disbursement of material from the drying system to the molding machine.
At this point the operator may choose the SYSTEM MENU button to go back to the system
menu, or MAIN MENU to return to main menu, or press OUTPUTS to access the output
screen.
SYSTEM SETTINGS
The SAVE SETTING button will save the current dryer parameter settings.
The RESTORE SETTINGS button will restore the dryer parameter settings that were saved
previously.
The RESTOR FACTORY DEFAULTS button will restore the initial dryer
parameter settings as the dryer was shipped from the factory.
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At this point the operator may choose to return to the SYSTEM MENU or MAIN
MENU by pressing the appropriate buttons.
Service Menu
This service menu screen is PASSWORD PROTECTED and meant for manufacturer
personnel use only.
Press the RETURN key to go back to the SYSTEM MENU.
Touching the MAIN MENU button in the SYSTEM MENU screen, will return the operator
back to the overall menu screen.
Alarm Screens
This screen allows the operator to review the number and type of issues that the
Drying/Conveying System has encountered during its operation.
Problems can be viewed by Date, Hour, and Comment.
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Because of the size of the screen, only three (3) comments/alarms can be viewed at a time.
To view alarms not visible on the screen, press the DOWN button. To return to a particular
alarm, press the UP button to scroll upward in the alarm history.
Pressing CNV (Convey) in this screen will take the operator to the CONVEY STATUS of
the system. You will only get CNV alarms with a Nomad dryer.
At this point the operator can return back to the DRYER MENU or MAIN MENU by
touching the appropriate button on the screen.
Alarm Screen Example
This is an example of what a typical Alarm screen looks like. The user will see the message
causing the alarm in the top half of the display with an ALARM SILENCE button in the
lower half.
To turn off the alarm, the user must press the ALARM SILENCE button. This will cancel the
alarm.
Redundant Safety Controller Display
Optional
The Redundant Safety Controller limits the process air temperature from exceeding specific
temperatures in case of a catastrophic failure of the primary PLC process air temperature
control system. The controller is a modular, self-contained unit removable from the
mounting housing. All parameters are factory set and adjusted; normally, no field adjustment
to the internal controls are necessary.
Figure5: Typical Redundant Safety Controller Display
Setting the Redundant Safety Controller
The Redundant Safety Controller alarm setting is changed by pressing the up and down keys
to input the alarm value. The upper display reading indicates the Process Value, while the
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lower display indicates the High Point Setting alarm value. The factory setting for the High
Point Alarm Value (L1-hi ) is 150°F (-23°C).
Restoring the WATLOW Redundant Safety Controller to Factory Setup
If the preset parameters on the controller have been tampered with and it no longer functions
properly, call the Service Department.
Note: This controller is not meant to be modified.
WATLOW Operating Parameters
The WATLOW controller has only one mode selection; ALARM.
The factory has set the security level to protect the critical parameters from being accidentally
changed. Below is an explanation of the modes you will have access to and the manufacturer
default settings.
Entering Operating Parameters to Select Modes
To enter the display:
and Down
keys for three seconds from the home page.
1. Press both the Up
The word SEE will appear in the upper display and PAGE will appear in the lower
display.
to move through the parameter prompts.
2. Press the Advance Key
3. Press the Up
or Down
keys to change the parameter value.
4. Press the RESET Key at any time to return to the Home Page display.
Figure 6: Setting List for Redundant Safety Controller (WATLOW), Part No. A0568961
Mode
SEn
Lin
C-F
S.dEC
IS.En
Sc.Lo
Parameter
Setting range
Sensor Type
Thermocouple Linearization
Temperature Units
Temp. Decimal Places
INFOSENSE™
Process Scale Low
0-3
0-10
Fahrenheit / Celsius
0 – 0.0
Yes / No
4.00 to 20.00 mA
1.00 to 10.00V
4.00 to 20.00 mA
1.00 to 10.00V
-999 to 999
Off, DiSP, Cont, both
Limit (2)
Both, High, Low
0.0 to 999.0
Off / Process Alarm / Limit (2)
Both / high / low
Sc.hi
Process Scale High
CAL
Ftr.E
Ot 1
LSd1
hyS1
Ot2
LSd2
Calibration Offset
Input Filter
Output 1 Function
Output 1 Limit Sides
Limit 1 Hysteresis
Output 2 Function
Output 2 Sides
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Default
0
0
F
0
No
4.00 mA
1.00V
20.00 mA
5.00 V
0
OFF
(2)
Both
1.0
OFF
Both
Manuf.
setting
H (1)
0
400
High
-
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UdSP
Upper Display Look
LdSP
Lower Display Look
LOC
Lockout
None, Process Value, Limit 1 Low Set,
Limit 1 High Set, Limit 2 Low Set, Limit
2 High Set, Alarm 2 Low Set, Alarm 2
High Set, Limit 3 Low Set, Limit 3 High
Set, Alarm 3 Low Set, Alarm 3 High Set
None, Process Value, Limit 1 Low Set,
Limit 1 High Set, Limit 2 Low Set, Limit
2 High Set, Alarm 2 Low Set, Alarm 2
High Set, Limit 3 Low Set, Limit 3 High
Set, Alarm 3 Low Set, Alarm 3 High Set
(0) no lockout, (1) Programming and
Setup Page Locked, (2) Limit Set
Points are the only Operation Page
parameters accesible, (3) Full Lockout.
Process
-
Limit 1
High Set
-
0
2
4-2 System Operation Procedures
1. Turn the disconnect switch on the control panel to the ON position. Power is applied to the voltage
line fuses and line side of the control power switch.
2. Turn the control power switch to the ON position. Power is applied to the PLC and touch screen.
Push the start button on the PLC and the valve will move to the start position as follows:
a. The valve motor rotates until the cam switch makes 2 transitions.
b. If the cam switch does not make a transition within 10 seconds, a valve
motor fault alarm is generated. The alarm horn and light are activated. The
valve motor, heaters, and blower shut off. Pressing the ALARM SILENCE
pushbutton will deactivate the alarm horn and light.
Note: Cycle control power to restart the dryer.
c. The valve will normally complete one full cycle (revolution). If sequence
shutdown is not initiated (in 10 Seconds) and control power switch or
disconnect are turned off:
1.
The bed in process at power-down will remain in
process.
2.
The bed in regeneration at power-down will remain in
regeneration.
3.
The regeneration timing cycle will restart from the
beginning.
3. Once the control power is on and no fault conditions exist, turning the Off-On switch to the ON
position and pressing the START button on the touch screen will start the dryer as follows:
a. The process heater is turned on and controlled by the PLC.
b. The process/regen blower is started.
c. The regen heater is turned on and the regeneration timing sequence is
initiated. The regen heater is controlled by the PLC.
Portable Drying/Conveying Systems
Chapter 4: Operation
38 of 63
4. If either the left or right bed safety temperature switch opens, a REGEN TEM SAFETY is
generated. The alarm horn and light are activated. The process heater, regen heater, and
process/regen blower are turned off. Pressing the ALARM SILENCE button on the touch screen
will deactivate the alarm horn and light.
5. Turn the Off-On switch to the ON position and push the touch screen START button to restart the
dryer. If the switch is still open, the dryer will not restart.
6. If the PLC/touch screen faults, the optional redundant high temperature safety device opens, or the
process heater safety switch opens, a process heater fault is generated. The alarm horn and light are
activated. The process heater, regen heater, and process/regen blower are turned off. Pressing the
ALARM SILENCE pushbutton will deactivate the alarm horn and light.
7. Turn the Off-On switch to the ON position and push the START button to restart the dryer. If the
fault condition still exists, the dryer will not restart.
8. If the process blower overloads trips, a PROCESS BLOWER FAIL is generated. The alarm horn
and light are activated. The process heater, regen heater, and process/regen blower are turned off.
Pressing the ALARM SILENCE button will deactivate the alarm horn and light.
9. Reset the motor overload and turn the Off-On switch to the ON position and push the START
button on the touch screen to restart the dryer.
10. The valve position limit switch enables the right bed heater and provides an input signal to the PLC
when actuated by the cam lobe. Each heater is controlled by the PLC.
11. Upon completion of the HEAT portion of the regeneration sequence, the regen heaters are disabled
by the PLC and the COOL time begins.
12. Once the COOL time has expired, the valve motor is turned on until the cam switch makes a
transition. Upon making a transition, the timing sequence is restarted for the new bed.
13. When a HIGH DEW POINT alarm is generated by the dew point controller, the alarm horn and
light will activate. Press ALARM SILENCE to deactivate the alarm until the next HIGH DEW
POINT alarm occurs.
14. The dryer is shut off by pushing the SHUTDOWN button on the PLC or turning the control power
On/Off switch to the OFF position.
15.
Refer to the schematic drawing enclosed in the control enclosure.
4-3
Shutting Down the Dryer
1 Turn off the conveying system supplying the drying hopper and/or machine. Press the
SHUTDOWN button for the dryer to complete its cycle.
2 When processing is complete, close the hopper slide gate and shut down any in-line companion
equipment, such as the aftercooler.
3 If the dryer is shut down using the SHUTDOWN button on the dryer status screen, the process
heater will shut off and the bed regeneration process will be completed. When the dryer is started at a
later date the process air will be directed through the bed that was regenerated last.
4 If the dryer control switch is turned off without using the dryer shutdown feature, the dryer and the
on board conveying system will stop immediately. When the dryer is started at a later date, the
process air will be directed through the last bed that was being used when the dryer control switch
was turned off. If a bed was being regenerated when the dryer control switch was turned off, the
regeneration process would begin over again on that same bed.
Portable Drying/Conveying Systems
Chapter 4: Operation
39 of 63
Chapter 5: Maintenance
5-1
Preventative Maintenance Schedule
The checklist below contains a list of items which should be inspected and/or replaced to
keep your Portable Drying/Conveying System operating at peak efficiency. Perform each
inspection at the regular intervals listed below.
System model #
Every Day
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
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
Inspect all filters for
wear, replace/clean
if dirty or worn.
Every week
Check to make
sure that all hose
connections are
air tight.
Every month
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
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 -
Portable Drying/Conveying Systems
Chapter 5: Maintenance
40 of 63
5-2
Preventative Maintenance
This section describes maintenance procedures which will increase the longevity and
efficiency of your Portable Drying/Conveying System. Perform them at the regular intervals
listed on the checklist on the previous page.
Servicing Process Air Filters
Caution!
Operating the dryer without the process air filter installed voids your
warranty!
Filter cleaning is an important part of your dryer maintenance program.
Dehumidifying dryers have a single cartridge canister-type filter in the process air loop. The
filter protects blowers from plastic fines drawn in from the drying hopper and prevents the
desiccant from being contaminated. Regular filter cleaning is essential to keep your dryer
operating at peak efficiency.
You can blow or vacuum the dirt out of the filter with compressed air, but remember, it could
become damaged from high-pressure blowing.
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, then remove the cover.
• Remove the nut on the center retaining rod to remove the filter cartridge.
Figure7: Air Filter Location and Disassembly
Air In
Air Out
Thumb Nut
Dust Can
Portable Drying/Conveying Systems
Clamp
Filter
Cartridge
Filter Housing
Chapter 5: Maintenance
41 of 63
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 commercialduty (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 inside out. Remove loose dirt from the filter with compressed air or
vacuum from the outside.
Caution!
DO NOT clean/wash filter with water!
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!
•
Check the gasket for damage. A damaged gasket allows
contaminants into the process. Replace as needed.
Servicing the Dew Point Monitor
The accuracy of the dew point monitor on mini 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.
Once every six months, the dryer operator should monitor the initial dew point sensor
readings and establish a periodic replacement schedule as needed.
Caution!
Do not attempt to check the continuity or resistance of the dew point sensor.
The sensor will be destroyed!
Portable Drying/Conveying Systems
Chapter 5: Maintenance
42 of 63
5-3
Corrective Maintenance
This section provides you with the information necessary to correct or repair any issues
which might appear during the normal operation of your dehumidifying dryer. Although we
have listed how to perform these procedures, it is recommended that you call the Service
Department to have any in-depth maintenance performed.
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 the condition of the
process filter, how much dust and fines have been passed through the filter and got into the
desiccant chamber, and plasticizer vapors in the return air.
WARNING!
Handling desiccant material is HAZARDOUS.
Wear an N-100 type safety filter mask or equivalent to avoid prolonged
breathing of desiccant dust. Wear safety goggles and gloves to avoid
contact with eyes and skin.
•
Handle with adequate ventilation.
•
Wash hands thoroughly after handling.
+ FIRST AID +
In case of eye contact, immediately flush eyes
with plenty of water for at least 15 minutes.
SEE A PHYSICIAN IMMEDIATELY IF IRRITATION PERSISTS.
Replacing Worn Desiccant
Caution!
DESICCANT BEDS ARE HOT DURING OPERATION.
To avoid burn hazard, make sure desiccant beds are sufficiently cool
before replacing worn desiccant.
To access the Desiccant Bed:
1. Disconnect electrical power to the dryer.
2. Using a 1/8” Allen wrench, remove the four (4) 10-32 button head screws holding the
Desiccant Cap to the Regeneration Heater.
3. Remove the Desiccant Cap.
4. With a shop vacuum, carefully remove all desiccant from each tower.
Portable Drying/Conveying Systems
Chapter 5: Maintenance
43 of 63
Figure 8: Desiccant Bed Location and Disassembly
Undo (4) 10-32 Button
Head Screws using 1/8
Allen Wrench
Desiccant Cap
1" Wide x 1/8" Thick Silicon
Strip and Stick Gasket
13X Molecular Sieve
8x12 Beads
Regeneration Heater
Regeneration
Thermocouple
16 Mesh 0.028 Diameter Wire
Stainless Steel Screen
(2) 4-40 screws
Hi Temperature
Snap Switch
1" Wide x 1/8" Thick High
Temperature Gasket
Caution!
You should properly dispose of any discarded desiccant.
Consult local disposal regulations for more information.
Inspect each lower desiccant screen for tears or holes where desiccant burned-through.
Replace as needed.
1. After cleaning each chamber, add the full amount of bead desiccant specified per bed. Amounts are
listed in the Desiccant Amounts Table below. Smooth the top level, and finally add another
layer of the remaining bead desiccant to the top. Make sure this layer is level and smooth.
Tap the chambers with a rubber melet gently for one or two minutes to make sure the
desiccant is packed tight. Add more desiccant if required.
2. Repeat the previous step for the other bed.
3.
3. Inspect the gaskets and replace if necessary. Place the screen in between the desiccant tank and the
cap.
4. Reconnect all the hoses and panels when done.
Portable Drying/Conveying Systems
Chapter 5: Maintenance
44 of 63
Figure 9: Required Desiccant Amounts
Dryer
model
15 cfm
30 cfm
60 cfm
8 x 12 bead Total
Part no.
lbs.
7.0
W00018051
15.75
37.5
Kg
3.25
7.25
17.0
Replacing the regeneration heaters
Procedures (see figure 8).
1. Sketch the heater wiring configuration so you can properly re-wire the heater.
5
Remove the ceramic nuts and wires to the heater plate assembly being removed or replaced.
6
Remove the six (6) 10-32 button head screws securing the process heater plate using a 1/8” Allen
wrench and slide out the assembly.
7
Remove the heater(s) from the mounting plate by removing the large brass nuts and washers.
8
Re-install the heater(s) 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!
2.
Reinstall the wires based on the sketch you made earlier.
Reinstall the ceramic nuts to each heater terminal.
Replacing the Process Heater
The dehumidifying dryers utilize a single-phase Calrod-type heater element. This heater
element is mounted in the center compartment below the desiccant beds. Although the
replacement procedure is the same for each heater, the wattage varies by model, voltage,
temperature range, etc.
WARNING!
Hazardous electrical current present.
Disconnect and lock out power before you replace heater elements!
Figure 10: Process Heater Location and Disassembly
Undo (6) 10-32 Button
Head Screws using 1/8
Allen Wrench
1" Wide x 1/8" Thick High
Temperature Gasket
(2) 4-40 screws
Hi Temperature
Snap Switch
Portable Drying/Conveying Systems
Chapter 5: Maintenance
45 of 63
Procedures
1. Sketch the heater wiring configuration so you can properly re-wire the heater.
2. Remove the ceramic nuts and wires to the heater plate assembly being removed or
replaced.
3. Remove the six (6) 10-32 button head screws securing the process heater plate using
a 1/8” Allen wrench and slide out the assembly.
4. Remove the heater(s) from the mounting plate by removing the large brass nuts and
washers.
5. Re-install the heater(s) 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!
6. Reinstall the wires based on the sketch you made earlier.
7. Reinstall the ceramic nuts to each heater terminal.
Replacing/Cleaning the Cooling Coils
WARNING!
Hazardous electrical current present.
Disconnect and lock out power before you replace heater elements!
Figure 11: Cooling Coil Location and Disassembly
1" Wide x 1/8" Thick High
Temperature Gasket
Undo (4) 10-32 Button
Head Screws using 1/8
Allen Wrench
Use compressed air or a steam
cleaner to blow the dust off or clean
any oily residue on the coil.
Water flow requirement:
If used as an After-Cooler: 3 to 4 GPM @80F.
If used as a Plasticizer Trap: 3 to 4 GPM @ 40F to 45F.
Note: To clean the cooling coil, use compressed air or a steam
cleaner to blow the dust off or clean any oily residue on the
coil.
Portable Drying/Conveying Systems
Chapter 5: Maintenance
46 of 63
Replacement Procedures
1. Shut down the dryer, tag out and lock out the controls if necessary.
2. Shut the water off to the cooling coil.
3. Remove the four 10-32 bolts.
4. Gently slide the cooling coil out.
5. Visually inspect the coil for leaks, dirt, and ant sign of volatiles.
6. Blow the dust out, or if the coil is covered with plasticizer, steam clean it.
7. Place the coil back in its housing. Make sure the gasket is OK, replace if necessary.
8. Inset the four 10-32 bolts back in place.
9. Turn the water to the cooling coil back on.
Portable Drying/Conveying Systems
Chapter 5: Maintenance
47 of 63
Chapter 6: Troubleshooting
6-1
Introduction
The utmost in safety precautions should be observed at all times when working on or around
the machine and the electrical components. All normal trouble-shooting must be
accomplished with the power off, line fuses removed, and with the machine tagged as out of
service.
The use of good quality test equipment cannot be over-emphasized when troubleshooting is
indicated. Use a good ammeter that can measure at least twice the AC and DC current that
can be encountered for the machine. Be sure that the voltmeter has at least minimum
impedance of 5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales.
Popular combination meters, VOM and VTVM can be selected to provide the necessary
functions.
Before making haphazard substitutions and repairs when defective electrical components are
malfunctioning, we recommend that you check the associated circuitry and assemblies for
other defective devices. It is common to replace the obviously damaged component without
actually locating the real cause of the trouble. Such hasty substitutions will only destroy the
new component. Refer to wiring diagrams and schematics.
Locating mechanical problems, should they occur, is relatively straightforward. When
necessary, refer to the parts catalog section.
Alarm Message
Cause
Corrective Action
Dryer Status
VALVE
POSITION
FAULT
The limit switch on the
valve may not have
been wired correctly.
The switch is indicating the
incorrect desiccant tank is in
regeneration. Check the
wiring of the switch against
the wiring diagram. Make
sure all the wire connections
are tight.
- Dryer Shuts down:
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm light is ON
- Alarm horn is ON.
VALVE MOTOR
OVERIDE
The valve has made
enough rotations and
the correct position of
the valve was not
detected.
Limit switch may be out of
position. Re-adjust the
switch to make sure it trips
when it is at the high
position, and it does not
touch the cam when it is at
the low position.
- Dryer Shuts down:
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm light is ON
- Alarm horn is ON.
Limit switch may be faulty.
Replace the switch and
make sure the wires are
connected correctly.
Portable Drying/Conveying SystemsChapter 6: Troubleshooting
48 of 63
Alarm Message
PROCESS
SENSOR FAIL
Cause
The process
temperature
thermocouple is
open.
Dryer Status
The process temperature
thermocouple is not connected
to the temperature controller.
Make sure the connections are
correct and tight.
- Dryer Shuts Down:
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm light is ON
- Alarm horn is ON.
The process temperature
thermocouple is damaged.
Replace the thermocouple.
The regeneration temperature
thermocouple is not connected
to the temperature controller.
Make sure the connections are
correct and tight.
The regeneration temperature
thermocouple is damaged.
Replace the thermocouple.
REGEN
SENSOR FAIL
The Regeneration
temperature
thermocouple is
open.
PROCESS HIGH
TEMP
The process
temperature has
exceeded the alarm
set point.
Portable Drying/Conveying Systems
Corrective Action
Make sure the process filter is
clean. Clean or replace if
necessary.
Double check the alarm set
point. 35°F
Check the positioning of the
thermocouple inside the air
inlet of the drying hopper. The
tip of the thermocouple should
be centered to the tube, and
not touching any metal part of
the tube.
The drying temperature set
point is lower than dryer
capabilities. Check the dryer
specs.
Make sure all the hose
connections are tight.
Make sure the regeneration
timing cycle matches the
specs. If not contact Service
department.
Chapter 6: Troubleshooting
- Dryer Shuts Down:
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm light is ON
- Alarm horn is ON.
- Dryer Shuts Down:
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm light is ON
- Alarm horn is ON
49 of 63
Alarm Message
PROCESS
SENSOR FAIL
Cause
The process
temperature
thermocouple is
open.
REGEN
SENSOR FAIL
The Regeneration
temperature
thermocouple is
open.
PROCESS HIGH
TEMP
The process
temperature has
exceeded the alarm
set point.
Portable Drying/Conveying Systems
Corrective Action
Dryer Status
The process temperature
thermocouple is not connected
to the temperature controller.
Make sure the connections are
correct and tight.
- Dryer Shuts Down:
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm light is ON
- Alarm horn is ON.
The process temperature
thermocouple is damaged.
Replace the thermocouple.
The regeneration temperature
thermocouple is not connected
to the temperature controller.
Make sure the connections are
correct and tight.
The regeneration temperature
thermocouple is damaged.
Replace the thermocouple.
Make sure the process filter is
clean. Clean or replace if
necessary.
Double check the alarm set
point. 35°F
Check the positioning of the
thermocouple inside the air
inlet of the drying hopper. The
tip of the thermocouple should
be centered to the tube, and
not touching any metal part of
the tube.
The drying temperature set
point is lower than dryer
capabilities. Check the dryer
specs.
Make sure all the hose
connections are tight.
Make sure the regeneration
timing cycle matches the
specs. If not contact Service
department.
Chapter 6: Troubleshooting
- Dryer Shuts Down:
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm light is ON
- Alarm horn is ON.
- Dryer Shuts Down:
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm light is ON
- Alarm horn is ON
50 of 63
Alarm Message
Cause
Corrective Action
Dryer Status
REGEN LOW
TEMP
The regeneration
temperature did not
get within the alarm set
point.
- Dryer Normal :
- Process blower ON.
- Process heaters ON.
- Regen heaters ON.
- Alarm Message ON.
- Alarm horn is OFF.
PROCESS
LOOP BREAK
The process drying air
temperature has not
made any
improvement toward
the drying temperature
set point for more than
480 seconds.
HIGH DEW
POINT
The dew point reading
has exceeded the dew
point alarm set point.
Make sure all the hose
connections inside the dryer
are tight.
Check the regeneration
heater fuses. Replace if
necessary.
Check the heater contactors.
Replace if necessary.
Check the heaters. Replace
if necessary.
Check incoming voltage to
the dryer specs.
Check the positioning of the
thermocouple inside the air
inlet of the drying hopper.
The tip of the thermocouple
should be centered to the
tube, and not touching any
metal part of the tube.
Make sure all the hose
connections are tight.
For drying temperature of
250°F or higher, delivery air
hose should be insulated.
Check the heater contactors.
Replace if necessary.
Check the heaters. Replace
if necessary.
Check incoming voltage to
the dryer specs.
Make sure the process air
filter is clean. Clean or
replace if necessary.
Make sure all the hose
connections and all the
components of the dryer
have proper seals on them
(desiccant tanks, heater box,
filters, after-cooler … ).
Tighten the connections and
replace any damaged seals.
Make sure the regeneration
timing cycle matches the
specs. If not contact Service
department.
Desiccant may be
contaminated and blocking
the air flow. Check
desiccant, replace if
necessary.
Portable Drying/Conveying Systems
Chapter 6: Troubleshooting
- Dryer Shuts Down :
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm Message ON.
- Alarm horn is ON.
- Dryer Normal :
- Process blower ON.
- Process heaters ON.
- Regen heaters ON.
- Alarm Message ON.
- Alarm horn is OFF.
51 of 63
Alarm Message
Cause
Corrective Action
Dryer Status
PROCESS
BLOWER FAIL
The process blower
pressure switch did not
detect enough
pressure.
Make sure the process air
filter is clean. Clean or
replace if necessary.
Check the rotation of the
blower.
Check the pressure switch
hose connection. Replace
hoses or the pressure
switch.
Check the over load rating
against the wiring diagram.
Adjust accordingly.
Check the wiring of the
blower. Make sure it is wired
for the proper voltage.
Check the process blower
fuses for any fault. Replace
if necessary.
Check the blower motor
starter. Replace if
necessary.
Check the blower motor.
Replace if necessary.
Check the incoming voltage
against the name plate of
the dryer.
Check the heater fuses,
replace if necessary.
Make sure the wiring is
correct and wire connections
are tight.
Check the process heater
safety contactor. Replace if
necessary.
Make sure the process air
filter is clean. Clean or
replace if necessary
Make sure the filter housing
is installed correctly, and the
connections are tight.
Check the hoses to the filter
pressure differential switch is
connected correctly, are not
damaged, and all the
connections are tight.
Replace the hoses if
necessary.
Check the wiring
connections to filter pressure
differential switch against the
print. Tighten the
connections.
- Dryer Shuts Down :
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm Message ON.
- Alarm horn is ON.
Process blower
overload has tripped.
Process blower motor
has failed.
PROCESS
HEATER FAIL
The process heater
safety contactor is not
responding.
DIRTY FILTER
The filter pressure
differential switch has
tripped.
Portable Drying/Conveying Systems
Chapter 6: Troubleshooting
- Dryer Shuts Down :
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm Message ON.
- Alarm horn is ON.
- Dryer Normal :
- Process blower ON.
- Process heaters ON.
- Regen heaters ON.
- Alarm Message ON.
- Alarm horn is OFF.
52 of 63
Alarm Message
Cause
Corrective Action
Dryer Status
DIRTY FILTER
The filter pressure
differential switch has
tripped.
- Dryer Normal :
- Process blower ON.
- Process heaters ON.
- Regen heaters ON.
- Alarm Message ON.
- Alarm horn is OFF.
VALVE MOTOR
FAIL
The limit switch on the
valve may not have
been wired correctly.
P RETURN
SENSOR FAIL
The return air
temperature
thermocouple is open
or failed.
PROCESS
TEMP SAFETY
The high temperature
snap switch of the
process heater box
has tripped.
REGEN TEMP
SAFETY
The high temperature
snap switch on of the
regeneration heater
boxes has tripped
Check the pressure setting
of the filter pressure
differential switch against the
print. Adjust accordingly.
Check the filter pressure
differential switch to make
sure it is functioning.
Replace is necessary.
The switch is indicating the
incorrect desiccant tank is in
regeneration. Check the
wiring of the switch against
the wiring diagram. Make
sure all the wire connections
are tight.
The return air temperature
thermocouple is not
connected to the
temperature controller. Make
sure the connections are
correct and tight.
The return air temperature
thermocouple is damaged.
Replace the thermocouple.
Make sure the process air
filter is clean. Clean or
replace if necessary.
Make sure all the hose
connections are tight.
The process heater
contactor has failed in the
closed position. Check
heater contactor, replace if
necessary.
Check the high temperature
snap switch, replace if
necessary.
Make sure the process air
filter is clean. Clean or
replace if necessary.
Make sure all the hose
connections are tight.
The Regeneration heater
contactor has failed in the
closed position. Check
heater contactor, replace if
necessary.
Check the high temperature
snap switches, replace if
necessary.
Portable Drying/Conveying Systems
Chapter 6: Troubleshooting
- Dryer Shuts Down :
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm Message ON.
- Alarm horn is ON.
- Dryer Normal :
- Process blower ON.
- Process heaters ON.
- Regen heaters ON.
- Alarm Message ON.
- Alarm horn is OFF.
- Dryer Shuts Down :
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm Message ON.
- Alarm horn is ON.
- Dryer Shuts Down :
- Process blower OFF.
- Process heaters OFF.
- Regen heaters OFF.
- Alarm Message ON.
- Alarm horn is ON.
53 of 63
6-2
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 short-circuit controller input terminals, the controller is normal and the sensor is probably
broken, short-circuited, or incorrectly wired.
Other service problems or questions can be answered by contacting the Service
Department.
Portable Drying/Conveying Systems
Chapter 6: Troubleshooting
54 of 63
Chapter 7: Appendix
7-1
Warranty
Unless otherwise specified, this product includes a Standard ONE YEAR PARTS.
Warranty Specifications
The manufacturer hereby expressly warrants all equipment manufactured by it to be free from
defects in workmanship and material when used under recommended conditions, as set forth
in the operating manuals for such equipment. THE FOREGOING EXPRESS WARRANTY
IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, GUARANTIEES,
AGREEMENTS, AND SIMILAR OBLIGATIONS OF THE COMPANY AND/OR
MANUFACTURER (UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE
PAGE OR LIMITED BY THE MANUFACTURERS’ WARRANTY FOR PARTS). The
Company’s obligation is limited to repair or replace FOB the factory any parts that are
returned, prepaid, within one year of equipment shipment to the original purchaser, and
which in the Company’s opinion, are defective. Any replacement part assumes the unused
portion of this warranty.
Warranty Restrictions
This parts warranty does not cover any labor charges for replacement of parts, adjustment
repairs, or any other work. This warranty does not apply to any equipment which, in the
Company’s opinion, has been subjected to misuse, negligence, or operation in excess of
recommended limits, including freezing or which has been repaired or altered without the
Company’s express authorization. If the serial number has been defaced or removed from the
component, the warranty on that component is void. Defective parts become the property of
the warrantor and are to be returned immediately, without any further use or handling.
Warranty Liabilities
THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY
SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT
RESULT FROM THE USE OF THIS PRODUCT. Some states do not allow the exclusion or
limitation of special, consequential or incidental damages, so the above limitation may not
apply to you. The Company’s obligation for parts not furnished as components of its
manufactured equipment is limited to the warranty of the manufacturers of said parts. The
company neither assumes nor authorizes any other persons to assume for it any liability in
connection with the sale of its equipment not expressed in this warranty. No person, agent,
manufacturer, distributor, dealer, installer or company is authorized to change, modify or
extend the terms of this warranty in any manner whatsoever.
The time within which an action must be commenced to enforce any obligation of the
Company’s arising under this warranty, or under any statute or law of the United States or
any state thereof, is hereby limited to the duration of this warranty. Some states do not permit
this limitation, so the above may not apply to you. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state. For transactions
involving the potential applicability of international law or that of a foreign country,
this warranty policy and the procedures hereunder shall be governed by
Portable Drying/Conveying Systems
Chapter 7: Appendix
55 of 63
applicable federal and state law, but not by the United Nations Convention on Contracts for
the Sale of Goods.
Customer Responsibilities
Any sales, use, or other tax incident to the replacement of parts under this warranty is the
responsibility of the purchaser.
7-2
Optional Components
The following is a list of options which your Portable Drying/Conveying System may have
been equipped with:
• High Temperature Option (with Aftercooler)
• Casters.
7-3
Technical Specifications
Annex B Information
The following design information is provided for your reference:
1.
2.
3.
4.
5.
6.
7.
8.
9.
No modifications are allowed to this equipment that could alter the CE compliance
Ambient temperature:
40 degrees Celsius – Maximum (104 degrees Fahrenheit)
Humidity range:
50% relative humidity
Altitude:
Sea level
Environment:
Clean, dust-free and non-explosive
Radiation:
None
Vibration:
Minimal, i.e. machine mounting
Allowable voltage fluctuation:
+/- 10%
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 and conveying system, but
additional protection should be supplied by the user.
14.
The door-mounted disconnect serves as the electrical disconnect device.
15.
Dryer and conveying system are not equipped with local lighting.
16.
Functional identification
17.
Dryer and conveying system are equipped with a CE mark
18.
Dryer and conveying system are 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.
Portable Drying/Conveying Systems
Chapter 7: Appendix
56 of 63
22.
23.
24.
25.
26.
27.
Two-hand control is not required or provided.
All dryers and conveying equipment should be moved around and set in a place
with a lift truck or equivalent.
There are no frequent repetitive cycles that require manual control⎯repetitive
functions are automatic while the drying and conveying system is operating.
An inspection report detailing the functional test is included with the dryer and
conveying system.
The machine is not equipped with cable less controls.
Color-coded (harmonized) power cord is sufficient for proper installation.
Aftercooler Design Specifications
Entering water temp.
ºF
85ºF
50°F (If used as Plasticizer trap)
7-4
ºC
29ºC
10°C (If used as Plasticizer trap)
Drawings and Diagrams
Figure 12: Standard Model (180°F to 250°F) Air Flow Schematic
Pressure switch, makes
sure the blower is
functioning correctly.
Dryer valve
High pressure peripheral
regenerative blower.
2”
Hose
2”
Hose
Utilizing -40F dew
point air to regenerate
and cool the
desiccant.
2”
Hose
13X Molecular
Sieve 8x12
beads.
Return Air
Temperature
Thermocouple
Position
Make-Up
Air
Low watt density
heaters, can
operate safely
with minimum air
flow.
Double wall
constructed heater
housing and
desiccant
container.
Regeneration
thermocouple,
monitors and
controls the
regeneration
temperature
Process /
Regeneration
Air Filter
2” Hose
High
temperature
snap switches,
monitor the heat
status of the
heater housings.
2-1/2” Hose
Insulated
stainless steel
drying hopper
Process Air
Temperature
Thermocouple
Position
2-1/2” Hose
Portable Drying/Conveying Systems
Chapter 7: Appendix
57 of 63
Figure 13: High Heat Model (180°F to 400°F) Air Flow Schematic
Pressure switch, makes
sure the blower is
functioning correctly.
High pressure peripheral
regenerative blower.
Dryer valve
2”
Hose
Optional Return
Air Cooler
2”
Hose
Utilizing -40F dew
point air to regenerate
and cool the
desiccant.
2”
Hose
13X Molecular
Sieve 8x12
beads.
Low watt density
heaters, can
operate safely
with minimum air
flow.
Double wall
constructed heater
housing and
desiccant
container.
Regeneration
thermocouple,
monitors and
controls the
regeneration
temperature
Process /
Regeneration
Air Filter
2” Hose
High
temperature
snap switches,
monitor the heat
status of the
heater housings.
Return Air
Temperature
Thermocouple
Position
2-1/2” Hose
Insulated
stainless steel
drying hopper
Process Air
Temperature
Thermocouple
Position
2-1/2” Insulated
Delivery Air Hose
Portable Drying/Conveying Systems
Chapter 7: Appendix
58 of 63
Figure 14: Low Heat Model (120°F to 250°F) Air Flow Schematic
High pressure
peripheral
regenerative blower.
Pressure switch, makes
sure the blower is
functioning correctly.
Dryer valve
2”
Hose
Utilizing -40F dew
point air to
regenerate and cool
the desiccant.
13X Molecular
Sieve 8x12
beads.
Double wall
constructed
heater housing
and desiccant
container.
Regeneration
thermocouple,
monitors and
controls the
regeneration
temperature
Process /
Regeneration
Air Filter
Low watt density
heaters, can
operate safely with
minimum air flow.
Return Air
Temperature
Thermocouple
Position
2-1/2”
Hose
Insulated
stainless steel
drying hopper
High temperature
snap switches,
monitor the heat
status of the heater
housings.
Optional Pre-Cooler for
Low Temperature
Operation 120F to 180F
Portable Drying/Conveying Systems
Chapter 7: Appendix
59 of 63
7-5
Spare Parts List
LEVEL 1 ( Mechanical Components )
PART #
SIZE Description
W00015435
Dew Point Sensor Insert Cable
A0548556
Dew Point Sensor
A0566467
Valve switch
W0005247
Process Air Filter
W00018051
13X molecular Sieve Desiccant ( 8 X 12 Beads )
W00013983
High Temperature Gasket.
A0566676
High Temperature Snap Switch.
Portable Drying/Conveying Systems
60CFM
575V 60 HZ 3PH 60CFM
460V 3PH
60CFM
400V 50 HZ 3PH 60CFM
230V 3PH
60CFM
220V 50 HZ 3PH 60CFM
208V 3PH
30CFM
575V 60 HZ 3PH 30CFM
460V 3PH
30CFM
400V 50 HZ 3PH 30CFM
230V 3PH
220V 50 HZ 3PH 30CFM
30CFM
3
208V 3PH
3
575V 60 HZ 3PH 15CFM
15CFM
460V 3PH
15CFM
15CFM
400V 50 HZ 3PH 15CFM
230V 3PH
LEVEL 1 ( Electrical Components )
PART #
SIZE Description
A0568932
2
Fuse for the Heater Elements
A0568933
2.5 Fuse for the Heater Elements
A0568934
3
Fuse for the Heater Elements
A0534039
3.5 Fuse for the Heater Elements
A0534040
4
Fuse for the Heater Elements
A0534041
5
Fuse for the Heater Elements
A0534042
6
Fuse for the Heater Elements
A0534043
7
Fuse for the Heater Elements
A0534044
8
Fuse for the Heater Elements
A0534046
10 Fuse for the Heater Elements
A0534047
12 Fuse for the Heater Elements
A0534048
15 Fuse for the Heater Elements
A0534049
20 Fuse for the Heater Elements
A0568936
25 Fuse for the Heater Elements
A0434051
30 Fuse for the Heater Elements
A0568909
1
Fuse for the Process Blower
A0568910
1.125 Fuse for the Process Blower
A0568911
1.25 Fuse for the Process Blower
A0534804
2
Fuse for the Process Blower
A0568917
2.5 Fuse for the Process Blower
A0550577
3
Fuse for the Process Blower
A0568919
3.2 Fuse for the Process Blower
A0568921
4.5 Fuse for the Process Blower
A0550593
5.6 Fuse for the Process Blower
A0538062
6
Fuse for the Process Blower
A0568922
6.25 Fuse for the Process Blower
A0568923
7
Fuse for the Process Blower
A0568926
10 Fuse for the Process Blower
A0538069
12 Fuse for the Process Blower
A0536892
1.25 Fuse for the transformer
A0536894
1.6 Fuse for the transformer
A0536895
1.8 Fuse for the transformer
A0538001
3.2 Fuse for the transformer
A0538002
3.5 Fuse for the transformer
A0568941
2.8 Fuse for the transformer
A0558078
0.3-1 Motor Overload
A0558079
1-2.9 Motor Overload
A0558082
1.6-5 Motor Overload
208V 3PH
DRYER SPARE PARTS LIST AD15, AD30, AD60
220V 50 HZ 3PH 15CFM
Figure 15: Level 1 Spare Parts List (Electrical & Mechanical)
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
2
2
2
2
2
1
1
1
Chapter 7: Appendix
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4.75 Lbs.
135 Inches
3
2
2
1
1
2
2
2
2
1 (ALL)
1
2
2
2
2
3
2
1
1
1
1
12.25 Lbs.
163 Inches
3
1
1
1
1
27.5 Lbs.
188 Inches
3
60 of 63
1
1
1
1
1
A0548555
1
1
1
4
5
0
0
0
0
0
7
0
0
0
0
0
*
Dew Point Circuit Board
LEVEL 2 ( Mechanical Components )
PART #
SIZE
Description
A0548621
Ceramic Cap for the End of Heater Elements
A0566478
750 Watts Heater element 208/220 Volts
A0566479
750 Watts Heater element 230 Volts
A0566480
750 Watts Heater element 400 Volts
A0566481
750 Watts Heater element 460 Volts
A0566482
750 Watts Heater element 575 Volts
A0566483
1250 Watts Heater Element 208/220 Volts
A0566484
1250 Watts Heater Element 230 Volts
A0566485
1250 Watts Heater Element 400 Volts
A0566486
1250 Watts Heater Element 460 Volts
A0566487
1250 Watts Heater Element 575 Volts
A0566601
2500 Watts Heater Element 208/220 Volts
A0566602
2500 Watts Heater Element 230 Volts
A0566603
2500 Watts Heater Element 400 Volts
A0566604
2500 Watts Heater Element 460 Volts
A0566605
2500 Watts Heater Element 575 Volts
A0568139
Screen Cover for the Desiccant Tanks
A0568140
Screen Cover for the Desiccant Tanks
A0568141
Screen Cover for the Desiccant Tanks
A0566682
1/4" OD Teflon Tube.
A0566415
Washer / Gasket for the Heater Elements
2
2
2
2
2
2
2
2
5
5
2
4
60CFM
460V 3PH
4
5
2
4
5
2
4
5
2
4
5
0
0
0
0
0
2
575V 60 HZ 3PH 60CFM
60CFM
230V 3PH
LEVEL 2 ( Electrical Components )
PART #
SIZE Description
A0558000
Motor Starter
400V 50 HZ 3PH 60CFM
60CFM
208V 3PH
220V 50 HZ 3PH 60CFM
30CFM
460V 3PH
575V 60 HZ 3PH 30CFM
30CFM
230V 3PH
400V 50 HZ 3PH 30CFM
30CFM
208V 3PH
220V 50 HZ 3PH 30CFM
575V 60 HZ 3PH 15CFM
15CFM
460V 3PH
400V 50 HZ 3PH 15CFM
15CFM
230V 3PH
208V 3PH
DRYER SPARE PARTS LIST AD15, AD30, AD60
220V 50 HZ 3PH 15CFM
15CFM
Figure 16: Level 2 & 3 Spare Parts List (Electrical & Mechanical)
0
0
0
0
0
4
3
3
3
3
3
3
2
5 Feet
8
2
5 Feet
14
5 Feet
10
1
1
Redundant Temperature Safety Controller
1
1
1
1
1
1
1
1
1
LEVEL 3 ( Mechanical Components )
PART #
SIZE
Description
A0534059
2" O.D. by 12 Ft Long Hi Temp Hose.
A0534060
2-1/2" O.D. by 12 Ft Long Hi Temp Hose.
A0566535
Return Air Cooling Coil
A0536628
208/460 Volt Process Blower.
A0536629
575 Volt Process Blower
A0534079
208/460 Volt Process Blower.
A0535351
575 Volt Process Blower
A0552439
208/460 Volt Process Blower.
A0552440
575 Volt Process Blower
W00015335
Dew Point Sensor Manifold
A0548558
Gasket for the Dew Point Sensor
Portable Drying/Conveying Systems
1
1
Chapter 7: Appendix
1
1
1
1 1
60CFM
460V 3PH
1
1
1
575V 60 HZ 3PH 60CFM
60CFM
230V 3PH
60CFM
208V 3PH
220V 50 HZ 3PH 60CFM
30CFM
460V 3PH
575V 60 HZ 3PH 30CFM
30CFM
230V 3PH
400V 50 HZ 3PH 30CFM
220V 50 HZ 3PH 30CFM
30CFM
208V 3PH
575V 60 HZ 3PH 15CFM
15CFM
460V 3PH
15CFM
400V 50 HZ 3PH 15CFM
Description
Power Disconnect
400V 50 HZ 3PH 60CFM
A0568961
SIZE
230V 3PH
PART #
A0567921
208V 3PH
LEVEL 3 ( Electrical Components )
220V 50 HZ 3PH 15CFM
15CFM
DRYER SPARE PARTS LIST AD15, AD30, AD60
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
61 of 63
7-6
Returned Material Policy
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.
7-7
Dryer Identification (Serial Number) Tag
(Located on back of Dryer)
Company Logo
XXX Series Dryer
Model Number XXX-15
Max Drying Capacity HR
460V
Serial Number 060701R
1Ǿ
Date of Manufacture 06/2003
4.5A
Over-current Protection Device (s) 4.5A Total
Frequency 50/60Hz
Compressed air supply None
Dryer Mass 400 lbs/(180 KG)
Electrical Diagrams &
Pneumatic Diagram
Street Address
Telephone Number
Portable Drying/Conveying Systems
City, State Zip Code
Chapter 7: Appendix
62 of 63
7-8
Technical Assistance
Parts Department
Call toll-free 7am–5pm CST [800] 423-3183 or call [630] 595-1060, Fax [630] 475-7005
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.
Service Department
Call toll-free 8am–5pm CST [800] 233-4819 or call [630] 595-1060
Emergencies after 5pm CST, call [847] 439-5655
We have a qualified service department ready to help. Service contracts are available for most
products.
Sales Department
Call [630] 595-1060 Monday–Friday, 8am–5pm CST
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales
Department for the name of the sales representative nearest you.
Contract Department
Call [630] 595-1060 Monday–Friday, 8am–5pm CST
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 nonunion installations.
Portable Drying/Conveying Systems
Chapter 7: Appendix
63 of 63
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