SDA 1000-5100 Large Dehumidifying Dryers with AP0 Controls

SDA 1000-5100 Large Dehumidifying Dryers with AP0 Controls
SDA 1000-5100 Large
Dehumidifying Dryers
with AP0 Controls
Part Number: 882.00292.00
Bulletin Number: DH1-605-1
Effective: 04/28/2008
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 2008
All rights reserved.
Shipping Info
Unpacking and Inspection
You should inspect the large dehumidifying dryer for possible shipping damage.
Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
; Large Dehumidifying Dryer
; Bill of lading
; Packing list
; Operating and Installation packet
; Electrical schematic and panel layout drawings
; Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the parts and services department
immediately at [262] 641-8610. Have the item and order numbers ready. Hold the items
until you receive shipping instructions.
Large Dehumidifying Dryers
ii
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
Credit Returns
Prior to the return of any material authorization must be given by the manufacturer. A
RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00
minimum) restocking charge.
ALL returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
No credit will be issued for material that is not within the manufacturer’s warranty period
and/or in new and unused condition, suitable for resale.
Warranty Returns
Prior to the return of any material, authorization must be given by the manufacturer. A
RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
All returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given, at the manufacturer’s
discretion. If the item is found to be defective in materials or workmanship, and it was
manufactured by our company, purchased components are covered under their specific
warranty terms.
Large Dehumidifying Dryers
iii
Table of Contents
CHAPTER 1: SAFETY................................................................ 7
1-1
1-2
1-3
How to Use This Manual ............................................................................................. 7
Safety Symbols Used in this Manual .....................................................................7
Warnings and Precautions .......................................................................................... 8
Responsibility .............................................................................................................. 9
General Responsibility...........................................................................................9
Operator Responsibility .........................................................................................9
Maintenance Responsibility.................................................................................10
Reporting a Safety Defect ...................................................................................11
CHAPTER 2: FUNCTIONAL DESCRIPTION ........................... 12
2-1
2-2
2-3
2-4
2-5
2-6
Models Covered in This Manual................................................................................ 12
General Description................................................................................................... 12
Specifying a Drying System ................................................................................12
What is Desiccant?..............................................................................................12
The Closed Loop Drying System.........................................................................12
The Process/Regeneration Cycle........................................................................13
Sequence of Operation .......................................................................................14
Controller Description................................................................................................ 15
Standard Features..................................................................................................... 16
Mechanical Features ...........................................................................................16
Electrical Features...............................................................................................16
Options ...................................................................................................................... 17
Closed-Loop Regeneration .................................................................................17
Process Aftercooler .............................................................................................17
Process Air Dust Collector...................................................................................18
Material Overdrying Protection ............................................................................18
Mechanical Options .............................................................................................19
Electrical Options ................................................................................................19
Safety Devices and Interlocks ................................................................................... 20
CHAPTER 3: MECHANICAL INSTALLATION ........................ 22
3-1
3-2
3-3
3-4
3-5
3-6
3-7
Uncrating the Equipment........................................................................................... 22
Rigging and Placing Unit ........................................................................................... 22
Making Electrical Connections .................................................................................. 22
Checking for Proper Blower Rotation ........................................................................ 23
Making Dryer/Drying Hopper Process Air Connections ............................................ 24
Connecting Aftercooler/Precooler Cooling Water (Optional)..................................... 25
Using the Drying Hopper Air Trap ............................................................................. 26
CHAPTER 4: CONTROLS........................................................ 27
4-1
Controller Description and Operation ........................................................................ 27
Identifying Control Panel Indicator Lights and Switches for the Standard
Controller.............................................................................................................27
Process Air Temperature Controller ....................................................................27
Large Dehumidifying Dryers
iv
Setting the Process Air Temperature ..................................................................29
Restoring the Process Air Temperature Controller (E5CN) to Factory Settings..29
Process Air Dew Point Display ............................................................................32
Setting the High Dew Point Alarm .......................................................................32
Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup ................32
Redundant Safety Controller Display ..................................................................33
Setting the Redundant Safety Controller .............................................................33
Restoring the WATLOW Redundant Safety Controller to Factory Setup ............33
CHAPTER 5: OPERATION....................................................... 35
5-1
5-2
5-3
5-4
5-5
Initial Start-up ............................................................................................................ 35
Pre-Startup Checks .............................................................................................35
Auto-Tuning the Dryer .........................................................................................35
Shutting Down the Dryer .....................................................................................35
Dryer Operation Procedures ..................................................................................... 36
Controller Operation (Without Optional Alarm Horn & Reset Button).................36
Alarm Display Messages........................................................................................... 39
Auto-Tuning the Dryer ............................................................................................... 40
Shutting Down the Dryer ........................................................................................... 40
CHAPTER 6: MAINTENANCE ................................................. 41
6-1
6-2
6-3
Maintenance Schedule.............................................................................................. 41
Preventative Maintenance......................................................................................... 42
Cleaning or Replacing the Process Air Filters .....................................................42
Cleaning or Replacing the Regeneration Filter....................................................43
Calibrating the Dirty Filter Alarm..........................................................................43
Checking the Dewpoint Control System ..............................................................44
Corrective Maintenance ............................................................................................ 45
Symptoms of Worn Out Desiccant ......................................................................45
Replacing the Desiccant......................................................................................45
Replacing the Process Heater (Electric Dryers) ..................................................46
Replacing the Regeneration Heater (Electric Dryers) .........................................47
CHAPTER 7: TROUBLESHOOTING ....................................... 49
7-1
7-2
7-3
7-4
7-5
Introduction................................................................................................................ 49
Basic Troubleshooting............................................................................................... 49
Alarms ....................................................................................................................... 51
Alarm Descriptions .................................................................................................... 51
Determining Temperature Controller Errors or Sensor Errors................................... 52
Using a Thermocouple ........................................................................................52
Using a Platinum Resistance Thermometer ........................................................52
CHAPTER 8: APPENDIX.......................................................... 53
8-1
8-2
8-3
8-4
Technical Specifications............................................................................................ 53
Annex B Information ............................................................................................53
Aftercooler Design Specifications........................................................................53
Drawings and Diagrams ............................................................................................ 54
Spare Parts List......................................................................................................... 56
8-5 Dryer Identification (Serial Number) Tag............................................................. 57
Large Dehumidifying Dryers
v
8-4
8-5
8-5 Dryer Identification (Serial Number) Tag............................................................. 58
Technical Assistance................................................................................................. 59
Parts Department ................................................................................................59
Service Department.............................................................................................59
Sales Department................................................................................................59
Contract Department ...........................................................................................59
Large Dehumidifying Dryers
vi
Chapter 1: Safety
1-1
How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining the large
dehumidifying dryer. The purpose is to assist you in applying efficient, proven techniques
that enhance equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The 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 large dehumidifying dryer. We can also provide the assistance of a factory-trained
technician to help train your operator(s) for a nominal charge. This section includes
instructions, checks, and adjustments that should be followed before commencing with
operation of the dryer. These instructions are intended to supplement standard shop
procedures performed at shift, daily, and weekly intervals.
The 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 the dehumidifying dryer provides excellent,
long service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER!
DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING!
WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
Caution!
CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property damage.
Large Dehumidifying Dryers
Safety
7
Dryer Safety Tags
Tag
Description
Tag
Read Operation &
Installation Manual
PE
1-2
Description
High Voltage Inside
Enclosure
Hot!
Lifting Point
Protected Earth
Ground
Earth Ground
Warnings and Precautions
Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes. This may include, but
is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international
regulations.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:
; Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.
; Follow all SAFETY CODES.
; Wear SAFETY GLASSES and WORK GLOVES.
; Work only with approved tools and devices.
; Disconnect and/or lock out power before servicing or maintaining the equipment.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
; Make sure the equipment and components are properly GROUNDED before you
switch on power.
; When welding or brazing in or around this equipment, make sure VENTILATION is
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with
sheet metal. An approved FIRE EXTINGUISHER should be nearby and ready for
use if needed.
; Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
Large Dehumidifying Dryers
Safety
8
; 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.
1-3
Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machines should become familiar with their operation
as described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.
General Responsibility
No 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.
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
Large Dehumidifying Dryers
Safety
9
employer probably has established a set of safety rules in your workplace. Those rules, this
manual, or any other safety information will not keep you from being injured while operating
your equipment.
Learn and always use safe operation. Cooperate with co-workers to promote safe practices.
Immediately report any potentially dangerous situation to your supervisor.
; NEVER place your hands or any part of your body in any dangerous location.
; NEVER operate, service, or adjust the dryer without appropriate training and first
reading and understanding this manual.
; NEVER try to pull material out of the dryer with your hands while it is running!
; Before you start the dehumidifying dryer, check the following:
• Remove all tools from the dryer;
• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the
area;
; If your dryer has been inoperative or unattended, check all settings before starting.
; At the beginning of your shift and after breaks, verify that the controls and other
auxiliary equipment are functioning properly.
; Keep all safety guards in place and in good repair. NEVER attempt to bypass,
modify, or remove safety guards. Such alteration is not only unsafe, but will void the
warranty on your equipment.
; When changing control settings to perform a different mode of operation, be sure
selector switches are correctly positioned. Locking selector switches should only be
adjusted by authorized personnel and the keys removed after setting.
; Report the following occurrences IMMEDIATELY:
•
•
•
•
•
unsafe operation or condition
unusual dryer action
leakage
improper maintenance
NEVER stand or sit where you could slip or stumble into the
dehumidifying dryer while working on it.
; DO NOT wear loose clothing or jewelry, which can be caught while working on the
dryer. In addition, cover or tie back long hair.
; Clean the dehumidifying dryer and surrounding area DAILY, and inspect the
machine for loose, missing or broken parts.
; Shut off power to the dryer when it is not in use. Turn the switch to the OFF
position, or unplug it from the power source.
Maintenance Responsibility
Proper maintenance is essential to safety. If you are a maintenance worker, you must make
safety a priority to effectively repair and maintain equipment.
Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric
supplies and all accessory equipment at the machine, and disconnect and lockout electrical
and pneumatic power. Attach warning tags to the disconnect switch and air shutoff valve.
Large Dehumidifying Dryers
Safety
10
When you need to perform maintenance or repair work on a dehumidifying dryer above floor
level, use a solid platform or a hydraulic elevator. If there is a permanently installed catwalk
on your dryer, use it. The work platform should have secure footing and a place for tools and
parts. DO NOT climb on the dehumidifying dryer, machines, or work from ladders.
If you need to repair a large component, use appropriate handling equipment. Before you use
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)
be sure the load does not exceed the capacity of the handling equipment or cause it to become
unstable.
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using
them to lift a load.
Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.
When you have completed the repair or maintenance procedure, check your work and remove
your tools, rigging, and handling equipment.
Do not restore power to the dehumidifying dryer until all persons are clear of the area. DO
NOT start and run the dryer until you are sure all parts are functioning correctly.
BEFORE you turn the dehumidifying dryer over to the operator for production, verify all
enclosure panels, guards and safety devices are in place and functioning properly.
Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should
immediately discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.
Large Dehumidifying Dryers
Safety
11
Chapter 2: Functional Description
2-1
Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for 600-3000 cfm
Large Dehumidifying Dryers with AP0 control. These dryers are available with electric
heaters or gas burners. Gas dryers are indicated with a “G” in the model number. Model
numbers are listed on the serial tag. Make sure you know the model and serial number of
your equipment before contacting the manufacturer for parts or service.
Our dehumidifying dryers are designed to generate heated, dehumidified air at carefully
controlled temperatures for use in closed-loop plastic drying systems. Dehumidifying dryers
are sized to meet the specific requirements stated by the Customer at the time of purchase.
2-2
General Description
Moisture removal from hygroscopic (moisture attracting) plastic pellets is an essential step in
the manufacture of high-quality plastic products.
Our Dehumidifying Dryers are used by the plastics industry to generate very low dewpoint
air that is heated to a controlled temperature for drying plastic pellets and regrind.
The drying system consists of a dry air source and drying hoppers with process heating
controls. The dry air source controls two primary sub-systems, the process air and the
regeneration circuit. Each dryer has a left and a right desiccant bed so that one bed can
regenerate while the other is in use. 2000-3000 cfm dryers feature two sets of desiccant beds,
for a total of four desiccant beds.
The drying system can be configured for one drying hopper or for as many as 20 hoppers.
The process air heater can be located on the dryer or on each individual drying hopper.
Heaters that are located on the drying hoppers can be set up with their own independent
controls or can be controlled centrally using the main dryer controller.
Specifying a Drying System
There were many variables considered in the selection of your drying system, including: type
of materials, residence time, throughput of the extruder or injection molding machine,
ambient air moisture and temperature, and the altitude at the processing site. Should your
operating environment change, we can advise you on necessary equipment, process time and
temperature modifications.
What is Desiccant?
Desiccant is a material that attracts and holds (absorbs) water from the air. The desiccant our
dryers use is a synthetic crystalline metal aluminosilicate that is blended with a clay binder
and formed into beads.
Absorbed water is driven from saturated desiccant by heating it to a high temperature
(reducing the desiccant's capacity to hold water) and forcing air through it. This moisture
removal process is called "regeneration".
The Closed Loop Drying System
These dehumidifying dryers force hot, dry air through the resin in the drying hopper, where
the air picks up moisture from the material and is drawn back to the dryer. In the dryer,
Large Dehumidifying Dryers
Functional Description
12
moisture is stripped from the air by a desiccant bed. The dried process air is then re-heated
and delivered back into the drying hopper to dry material again.
This system is a "closed loop", because ambient (outside) air is never introduced into the
process air. The closed loop system is used by the manufacturer because the process air is
typically much drier than ambient air, even after carrying moisture out of the plastic resin.
Recycling process air maintains drying efficiency at a consistently high level.
The Process/Regeneration Cycle
There are two desiccant beds in a dryer up to 1500 cfm. Larger dryers have two beds each
for right and left beds. While one desiccant bed is on-line in the process air loop, the other is
off-line being regenerated (see Figure 1).
When a desiccant bed is on-line, it absorbs moisture from the process air. The desiccant will
become saturated with moisture and need to be regenerated. The dryer automatically redirects
the process airflow to the second bed and starts regenerating the first bed.
During regeneration, air is heated to approximately 550°F and forced through the saturated
desiccant. The moisture driven off the desiccant is bled to the atmosphere. The regeneration
heater is then turned off while the regeneration blower continues to blow air through the
desiccant bed until it is cooled.
Figure 1: Regeneration Cycle
AD600-AD1500
Dryer Flow Schematic
Right Desiccant in
Regeneration
Regeneration
Blower
Regeneration
Filter
Dryer Valve
Regeneration
Heaters
Insulated
Drying
Hopper
Process
Heater
Regeneration
Exhaust
Left Desiccant
Process
Filter
Right Desiccant
Process
Blower
Large Dehumidifying Dryers
Functional Description
13
AD600-AD1500
Dryer Flow Schematic
Left Desiccant in
Regeneration
Regeneration
Blower
Regeneration
Filter
Dryer Valve
Regeneration
Heaters
Process
Heater
Regeneration
Exhaust
Left Desiccant
Insulated
Drying
Hopper
Process
Filter
Right Desiccant
Process
Blower
Sequence of Operation
When the dryer is started, the main air valve rotates 360º and then moves to place the last
successfully regenerated desiccant bed online. If the dryer was powered off using the main
power disconnect or E-stopped, then the regenerating bed is placed back into regeneration,
and the regeneration cycle is started over. The main air valve is allowed a period of time to
move from one position to the other. If the main air valve does not complete positioning
within the allotted time, then a “Main Air Valve Fail” alarm is generated and the dryer stops
the process air blower and disables the drying hoppers and regeneration circuit.
If the closed loop regeneration option is enabled, the regeneration closed loop valve moves to
the open loop position. The system always begins the cooling phase for a regeneration cycle
using ambient (open loop) air. The closed loop regeneration valve is allowed a period of time
to move from the closed to the open loop position and a “Closed Loop Valve” alarm is
generated if the valve fails to reach the commanded position within this time. This alarm will
disable the regeneration circuit but does not stop the process air system or drying hoppers.
Once the main air valve and closed loop regeneration valve are in place, the process air
blower starts. The system monitors the process air blower’s overload, starter auxiliary contact
feedback and air pressure. Loss of any of these items when the process air blower is running
will cause the process air blower and the drying hopper’s process heaters to shut down.
The process air heaters will turn on after a delay to allow the process air blower to accelerate
the operating speed.
During normal operation, one set of desiccant beds is connected to the process air circuit
while the other set is being regenerated. When the offline beds are done regenerating, they
will be switched into the process air circuit and the other beds will be regenerated. The
default bed switch setting is based on time. If the Dewpoint Switch option is enabled, the
beds will switch when the process air dewpoint reaches the dewpoint switch point. The
dewpoint option will automatically disable itself and an alarm will be generated if the
dewpoint sensor or related electronics fail.
Large Dehumidifying Dryers
Functional Description
14
2-3
Controller Description
The AP0 control package uses a relay logic controller to control the operation of the dryer.
See below for descriptions of each screen.
Figure 2: Controller Screen Descriptions
Regen Set Screen. Displays heating and cooling times for regeneration. Also used to
change times if necessary.
Material Miser OFF Screen. Used to enable material miser valve.
Material Miser ON Screen. Used to disable material miser valve.
Closed Loop Regen OFF Screen: Used to enable closed loop cooling on
regeneration.
Closed Loop Regen ON Screen: Used to disable closed loop cooling on
regeneration.
I/O Status Screen. Used to view the status of inputs and outputs for the dryer.
Alarm Screen. Shows which alarm the dryer gets.
Large Dehumidifying Dryers
Functional Description
15
2-4
Standard Features
Mechanical Features
; 180ºF – 250ºF Drying temperature range
; High regeneration temperature control safeties
; 13X desiccant (molecular sieve)
; Easy to access process and regeneration
; High pressure centrifugal blower
; Dew point +15º F to –40º F
Electrical Features
; Electrically-actuated air valve
; NFPA79, UL & CUL machinery electrical standards (Electric Dryers) includes:
•
NEMA 12 controls, components & enclosure
•
Non-fused electrical disconnect
•
Solid state relays for heater control
•
Branch fusing
•
Lockable power disconnects
•
Regeneration temperature control
•
“Process high temp” indication light and audible alarm
•
Sequence shutdown switch
; NFPA86, UL, AGA & CGA machinery electrical standards (Gas Dryers)
; Available supply voltages of 208, 230, 460, 575/3/60 and 400/3/50
Large Dehumidifying Dryers
Functional Description
16
2-5
Options
Closed-Loop Regeneration
An optional regeneration closed-loop valve and heat exchanger can be used to close the
regeneration loop during the cooling portion of the regeneration cycle. If this option is
enabled on the dryer, air will be bled to the atmosphere until the heating portion of the
regeneration cycle is finished. Then, the regeneration closed loop valve will direct air through
a water-cooled heat exchanger and back into the regeneration loop (see Figure 3 and Section
3-6: Connecting Aftercooler/Precooler Cooling Water).
Figure 3: Closed Loop Regeneration
Regeneration
Blower
Regeneration
Blower
AD600-AD1500
Dryer Flow Schematic Dryer Valve
Regeneration Closed Loop
Cooling is Activated
Regeneration
Filter
AD600-AD1500
Dryer Flow Schematic
Regeneration Heating is
Activated
Optional
Regeneration
Closed Loop
Cooler
Regeneration
Heaters
Regeneration
Heaters
Dryer Valve
Regeneration
Filter
Optional
Regeneration
Closed Loop
Cooler
Regenerarion
Exhaust
Regeneration
Exhaust
Optional
Regeneration
Closed Loop
Valve
Optional
Regeneration
Closed Loop
Valve
Left Desiccant
Left Desiccant
Process Aftercooler
The optional aftercooler cools the moist air returning to the dryer from the drying hopper.
The aftercooler can cool the return air from 250ºF to about 150ºF. This maintains the dryer’s
efficiency and condenses the unwanted plasticizer from the air stream. The aftercooler
requires a cooling water connection (see Figure 4).
Figure 4: Process Aftercooler
Mounting
Brackets
High
Temperature
Gasket
Mounting Brackets
Cooling Coil
Cooling Coil
Pipe Gasket
Stainless Steel
Cooler Housing
Stainless Steel Cooler
Housing
High
Temperature
Gasket
Cooling Coil
Cooling Coil
Cover Plate
Large Dehumidifying Dryers
Cooling Coil
Pipe Gasket
Functional Description
Cooling Coil
Cover Plate
17
Process Air Dust Collector
The optional process air dust collector consists of a filter, dust can, pressure gauge, and
optional pressure switch (see Figure 5). The gauge will let you know whether it is time to
clean out your filters. The optional dirty filter alarm will be activated if the filter is dirty.
Figure 5: Process Air Dust Collector
Filter Check
Gage
Differential
Pressure
Switch
Thumb Screws
PS
Cartridge Filter
Dust Shroud
Filter Retainer
F
Slide Gate
E
Clamp
Dust Pan
Dust Level
Indicator
Material Overdrying Protection
Material Overdrying Protection is an automatic system used to reduce the chance of overdrying, and possibly melting, the resin in the drying hopper. Material Overdrying Protection
activates when the return temperature is above a set value, indicating that all the resin in the
hopper is dry.
The control system monitors the return air temperature and automatically changes the process
air setpoint to the SET BACK SETPOINT value when the return air temperature rises above
the set back temperature. The process air setpoint returns to normal when the return air
temperature falls below the SETUP TEMPERATURE value. The target values for
changing the process air setpoint can be adjusted on the Mat Protect screen.
Recommended Temperature Settings
Drying Temperature (ºF)
Setpoint
Large Dehumidifying Dryers
160 180 200 220 240 260 280 300 320 340 360
120 125 130 135 135 140 150 160 170 180 200
Functional Description
18
Figure 6: Material Miser/Air Balance Valve
Temperature
Probe
Valve
Proofing
Switch
Coupling
Drying
Hopper
Mechanical Options
; Low temperature operation (120°F to 250°F)
; High temperature operation (180°F to 400°F)
; Precooler (Required for temperatures below 180°F, used with low temperature
operation)
; Aftercooler (Required for temperatures above 250°F, used with high temperature
operation)
; Plasticizer trap / Aftercooler w/filter
; Automatic airflow reduction valve 13X desiccant
; Closed loop cooling valve
; Dew point +15°F to -80°F
; Sound insulation for under 85 DBA noise level
; Dust collector
Electrical Options
; Hopper mounting of the process heater box
; Remote operator interface (with standard controller only)
; CSA approval
; UL rating
; 400/3/50 supply voltage (includes CE compliance)
Large Dehumidifying Dryers
Functional Description
19
2-6
Safety Devices and Interlocks
This section includes information on safety devices and procedures that are inherent to the
large dehumidifying dryer. This manual is not intended to supersede or alter safety standards
established by the user of this equipment. Instead, the material contained in this section is
recommended to supplement these procedures in order to provide a safer working
environment.
At the completion of this section, the operator and maintenance personnel will be able to do
the following:
•
Identify and locate specific safety devices.
•
Understand the proper use of the safety devices provided.
•
Describe the function of the safety device.
Safety Circuit Standards
Safety circuits used in industrial systems protect the operator and maintenance personnel
from dangerous energy. They also provide a means of locking out or isolating the energy for
servicing equipment.
Various agencies have contributed to the establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the
organizations that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the large
dehumidifying dryer; however, it is the responsibility of the personnel operating and
maintaining the equipment to familiarize themselves with the safety procedures and the
proper use of any safety devices.
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch
must be held closed with the device it is to protect. If the switch fails, it will go to the open
condition, tripping out the safety circuit.
At no time should the safety device fail and allow the operation to continue. For example, if
a safety switch is guarding a motor, and the safety switch fails, the motor should not be able
to run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used on the large dehumidifying dryer are primarily concerned with electrical power
disconnection and the disabling of moving parts that may need to be accessed during the
normal operation of the machines.
Some of the safety devices utilize a manual activator. This is the method of initiating the
safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable
handle, there may be a location for a padlock. Personnel servicing the equipment should
place a padlock in the lockout handle.
Large Dehumidifying Dryers
Functional Description
20
In addition to the safety devices listed above, these dehumidifying dryers are equipped with a
line cord plug. This allows the operator or maintenance personnel to unplug the system from
its power source and tag it out. The plug can then be tagged with any number of approved
electrical lockout tags available at most electrical supply stores.
WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning the dehumidifying dryer. Failure to do so may
result in serious injury. No one but the person who installed the lockout may remove it.
Large Dehumidifying Dryers
Functional Description
21
Chapter 3: Mechanical Installation
3-1
Uncrating the Equipment
The large dehumidifying dryers 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, inserting forklift under the base. The forks must be equidistant
from the centerline of the unit and the unit must be balanced on the forks. Lift slowly
and only high enough to clear the skid. Use a pry bar if necessary to carefully remove
the skid from the unit.
4. Lower slowly.
5. Remove the temporary hardware that has been installed to prevent the side panels
from shifting in transit. Retain the crating material for reshipping the components in
case hidden shipping damage is found.
3-2
Rigging and Placing Unit
As with all equipment installations, follow all applicable codes and regulations.
„ Locate close to the process to reduce piping expense.
„ Locate adjacent to drain and city water sources (If equipped with aftercooler).
„ Consult a structural engineer to assure that the floor, mounting pad or structural steel
support is of adequate strength.
„ Allow for required service clearances necessary for maintenance and easy access to all
components.
3-3
Making Electrical Connections
Refer to local electrical codes, the schematic, and connection diagrams supplied with this unit
and the serial tag for wiring considerations. Run all wiring in conduit if codes require it.
Label all wiring to make any future troubleshooting easier.
When making electrical connections to your dryer, ensure that you take into consideration
and make arrangements for the following:
; A qualified electrician should make all electrical connections.
; 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 five percent (5%).
; 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.
Large Dehumidifying Dryers
Mechanical Installation
22
; The power drop must include a ground wire.
; Make sure all electrical connections are tight.
3-4
Checking for Proper Blower Rotation
After the electrical connections have been made, check the process and regeneration blowers
for proper blower rotation. Check blower rotation before making process air connections
between the dryer and hoppers, and before connecting cooling water (for the optional
aftercooler).
Blowers should rotate in a clockwise direction. See Figure 7.
The blowers are rotating properly when air flows from the delivery outlet.
Incorrect phasing of power leads will cause backward rotation of blower motors and
contamination of the desiccant.
If both blowers are rotating improperly, reverse any two wires at the fused disconnect outside
the dryer or at the disconnect/terminal in the control enclosure. This assures that both blowers
will be rotating in the proper direction.
If just one blower is rotating incorrectly, reverse the wires at the motor starters.
Figure 7: Checking Blower Rotation
Process Blower
Large Dehumidifying Dryers
Regeneration Blower
Mechanical Installation
23
3-5
Making Dryer/Drying Hopper Process Air Connections
When making process air connections to your dryer, ensure that you take into consideration
and make arrangements for the following:
; Use high-temperature flexible dryer hose or rigid tubing to connect the dryer to the
drying hopper.
; Keep the delivery (to the drying hopper) hose as short as possible to minimize heat
loss. Insulated hose is recommended and available for maximum energy savings.
; Do not use insulated hose on the return (from the drying hopper)
; Do not shorten the return hose. The return air to the blower must be 150°F or below.
; Make sure the hoses are not kinked.
; Drying hopper air inlet and outlet locations vary, but always connect the hoses so the
dry process air from the dryer enters the bottom of the drying hopper and flows out
the top to return to the dryer inlet.
Figure 8: Dryer/Drying Hopper Process Air Connections
Process Air Heater on Dryer
Process Air Heater on Drying Hopper
Drying System with Dust Collector and
Process Air Heater on Dryer
Large Dehumidifying Dryers
Mechanical Installation
24
3-6
Connecting Aftercooler/Precooler Cooling Water (Optional)
Support both sides of the fitting when making the cooling water connections to prevent
damage to the aftercooler coil. See Figure 9.
Connect 85°F water to the inlet closest to the exiting air side of the aftercooler coil. This will
cool the process air about 100°F and raise the water-out temperature about 10°F. The table
below lists available aftercooler models and their flow rates.
Figure 9: Aftercooler Components & Flow Rates
Mounting Brackets
Cooling Coil
Cooling Coil
Pipe Gasket
Stainless Steel Cooler
Housing
High
Temperature
Gasket
Cooling Coil
Cover Plate
Mounting
Brackets
High
Temperature
Gasket
Stainless Steel
Cooler Housing
Cooling Coil
Cooling Coil
Cover Plate
Large Dehumidifying Dryers
Cooling Coil
Pipe Gasket
Mechanical Installation
After cooler
cooler
After
Model
Model
600
AD600
850
AD850
1000
AD1000
1250
AD1250
1500
AD1500
2000
AD2000
2500
AD2500
3000
AD3000
Water
Flow
Water
Flow
(GPM)
( GPM )
1010
1010
15
15
15
15
20
2520
3025
3530
35
25
3-7
Using the Drying Hopper Air Trap
Our exclusive air trap assembly in the top of the drying hopper prevents ambient air from
contaminating the material being dried. To ensure that air does not enter the drying system,
do the following (See Figure 10):
; Keep the material level above the bottom edge of the air trap for maximum
efficiency.
; Use a hopper loader or vacuum conveying system to maintain the proper material
level.
Figure 10: Drying Hopper Air Trap
Suggested material level
for the optimum
efficiency.
Flapper Valve
of the loader
Return air from the
drying hopper.
Air Trap
Insulation
Delivery low dew point,
heated air to the drying
hopper.
Recommended process
temperature control
thermocouple location.
Large Dehumidifying Dryers
Mechanical Installation
26
Chapter 4: Controls
4-1
Controller Description and Operation
Identifying Control Panel Indicator Lights and Switches for the Standard
Controller
Switches
System OFF/ON/START Switch. This switch energizes or de-energizes control power to
the indicator panel and starts the dryer. (The controller can be energized without the dryer
running.)
Indicator Lights
Alarm Light. This feature works in conjunction with the alarm horn to warn the operator of
a high bed safety temperature, a regeneration heater fault, or a blower failure. This warning
is reset by pressing the alarm silence button.
Process Air Temperature Controller
Our dryers use a microprocessor-based PID temperature controller for maintaining process air
temperature. The controller is a modular, self-contained unit that can be removed from the
mounting housing. All parameters except for the process air set point are factory set and
adjusted; normally, no field adjustment to the internal controls is necessary.
Figure 11: Typical Process Air Temperature Controller
PV
SV
Large Dehumidifying Dryers
Controls
27
Identifying Process Air Temperature Controller LED Indicators
Indicator
Name
Description
PV
Process Value
Numeric LED
During normal operation, the process value (PV)
numeric LED indicator displays the process
temperature at the To Process thermocouple. It
also lists parameters during setup and error
messages if any errors occur.
Set Value
Numeric LED
During normal operation, the set value (SV)
numeric LED indicator displays the process set
point temperature selected for the dryer. The dryer
then maintains this set point temperature. This
LED indicator also displays parameter and pre-set
function values during configuration setup.
OUT1
Out 1 LED
Lit when Control Output 1 is on. The Out1
indicator lights when the controller signals the
process heaters to be energized.
OUT2
Out 2 LED
Lit when Control Output 2 is on. Not used in
this application.
AT
AT LED
Flashes during auto-tuning in process value (PV)
screen.
Indicator
Name
Description
ALARM1
ALARM 1 LED
Lights in the Operation Indicator Section when
the output function assigned to auxiliary output
1 turns on. The ALARM1 indicator lights when
the process temperature falls below the set point
temperature by more than the alarm deviation
value. Advisory alarm does not interrupt operation
of the dryer.
Indicator
Name
Description
ALARM2
ALARM 2 LED
Lights in the Operation Indicator Section when
the output function assigned to auxiliary output
1 turns on. The ALARM2 indicator lights when
the process temperature exceeds the set point
temperature by more than the alarm deviation
value. Alarm output de-energizes the heaters.
Heaters re-energize when the temperature falls
within the acceptable range.
8.8.8.8
SV
8.8.8.8
Large Dehumidifying Dryers
Controls
28
Identifying Temperature Controller Keys
Indicator
Name
Description
Mode Key
Press the Mode key to shift the display to the next
set of parameters. The menu screen displays.
Down Key
Press the Down arrow key to lower the process air
set point temperature. During setup, it lets you
decrease the value of the parameter displayed on
the set point LED readout.
Up Key
Press the Up arrow key to raise the process air set
point temperature. During setup, it lets you
increase the value of the parameter displayed on
the set point LED readout.
Setting the Process Air Temperature
When setting the process air temperature, consult with the resin manufacture for the
recommended drying temperature.
To change the process air temperature set point with the dryer running:
Press
to raise the set point to the temperature you want.
Press
to lower the set point to the temperature you want.
Restoring the Process Air Temperature Controller (E5CN) to Factory Settings
If the preset parameters on the controller have been tampered with and it no longer properly
controls temperature and displays dew point, you can restore the controllers to the factory
setup. Call the Service Department for detailed instructions.
E5CN Operating Parameters
The E5CN controller has several mode selections. Within each mode are numerous
parameters that can be set.
The factory has set the security level to protect the critical parameters from being accidentally
changed. Below is an explanation of the operating modes you will have access to and on the
following page are the manufacturers’ default settings.
Large Dehumidifying Dryers
Controls
29
Available E5CN Modes
Operation Level
Indicator
Name
Description
Run/Stop Mode
(r-S)
When “RUN” is selected, the control is running.
When “STOP” is selected, the control is stopped.
When the control is stopped, the STOP display
lights. The default is set to “RUN.”
Alarm Value 1
Mode (AL-1)
This setting is used to indicate how many degrees
the process temperature will be allowed to exceed
the set point temperature. An alarm output will deenergize the heaters.
Name
Description
Auto-Tune Mode
(At)
See Page 41 of Chapter 5 for instructions on how
to Auto-Tune your dryer.
Adjustment Level
Indicator
Note: Although the controller is calibrated at
the factory, the manufacturer
recommends that the unit be AutoTuned prior to dryer startup.
Temperature Input
Shift Mode (TnS)
This setting is used to offset an error between the
set point and the actual temperature. The entire
input range is shifted by a set figure
preprogrammed by the operator.
Proportional Band
Mode (P)
This setting controls the amount in which the
manipulated variable (MV) is proportionate to the
deviated value or controller error.
Integral Time
Mode (I)
Setting this feature, gives the control an action that
is proportionate to the time integral of the control
error. By using this setting, proportional action is
used in combination with integral action to offset
the control error and the set point will begin to
match the control temperature (PV or process
value).
Derivative Time
Mode (d)
Setting the derivative control provides the
controller with the ability to correct for a future
error in the previously set process output.
Large Dehumidifying Dryers
Controls
30
Entering Operating Parameters to Select Modes
To enter the display:
1. Press the
Mode Display key to view the Run/Stop & Alarm 1 Modes.
and
to set the higher or lower the values of the
2. Press
parameter or turn that function On or Off.
The SV readout displays the different values for the parameter within a mode.
3. To switch modes within a level, press and hold the
key for one (1) second.
Level Display
The PV readout will display the different parameters within each mode.
4. Use short presses on the
within a mode.
Mode Display key to display each parameter
The SV readout displays the different values for the parameter within a mode.
5. Press
and
to set the higher or lower the values of a parameter
or turn that function On or Off.
6. Press
Level Key once to return to the Process Temperature Setting.
Figure 12: Settings for Process Temperature Controller (E5CN), Part No. A0555757
Mode
Operation
Mode
Adjustment
Large Dehumidifying Dryers
Parameter
Run/Stop
Alarm value 1
Setting range
Run/Stop
-1999 to 9999
Default
Run
0
Manuf. setting
25
Parameter
AT execute/cancel
Temperature input shift
Proportional Band
Integral Time
Derivative Time
Setting range
ON, OFF
-199.9 to 999.9
0.1 to 999.9
0 to 3999
0 to 3999
Default
OFF
0.0
8.0
233
40
Manuf. setting
?
?
?
?
Controls
31
Process Air Dew Point Display
Optional
The Process Air Dew Point meter indicates the current process air delivery moisture content.
Standard dryers use a microprocessor-based controller for displaying dew point air
temperature. 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.
Figure 13: Typical Dew Point Display Monitor
PV
OUT1
SV
OUT2 MANU STOP RMT
AT
SUB1
AT
E5CK
OMRON
Note:
The only functional buttons on this controller are the up and down
keys.
Setting the High Dew Point Alarm
The high dew point alarm setting is changed by pressing the up and down keys to input the
alarm value. The factory setting for Alarm Value 1 (AL-1 ) is -10°F (-23°C).
Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup
If the preset parameters on the controller have been tampered with and it no longer functions
properly, call the Service Department. This controller is not meant to be modified.
Note:
Large Dehumidifying Dryers
The dew point alarm monitors and indicates a deviation from the
set point.
Controls
32
Redundant Safety Controller Display
Optional
The Redundant Safety Controller limits the process air temperature from exceeding the upper
temperature range set by the E5CN Temperature Controller. Standard dryers use a
microprocessor-based controller for limiting the process air temperature. 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.
Figure 14: 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
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. This controller is not meant to be modified.
WATLOW Operating Parameters
The WATLOW controller has only one mode selection; ALARM.
The factory sets 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.
Large Dehumidifying Dryers
Controls
33
Entering Operating Parameters to Select Modes
To enter the display:
1. Press both the Up
and Down
keys for three seconds from the home page.
The word SEE will appear in the upper display and PAGE will appear in the lower
display.
2. Press the Advance Key
3. Press the Up
to move through the parameter prompts.
or Down
keys to change the parameter value.
4. Press the RESET Key at any time to return to the Home Page display.
Figure 15: Setting List for Redundant Safety Controller (WATLOW), Part No. A0555757
Mode
SEn
Lin
C-F
S.dEC
IS.En
Sc.Lo
Parameter
Sensor Type
Thermocouple Linearization
Temperature Units
Temp. Decimal Places
INFOSENSE™
Process Scale 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
UdSP
Upper Display Look
LdSP
Lower Display Look
LOC
Lockout
Large Dehumidifying Dryers
Setting range
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
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 accessible, (3) Full
Lockout.
Controls
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
Manf. setting
H (1)
0
Process
-
Limit 1
High Set
-
0
2
400
High
-
34
Chapter 5: Operation
5-1
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.
Auto-Tuning the Dryer
1. For Auto-tuning, press the beige button once. The AT screen will show with the
setting OFF.
2. Press the UP arrow to change the setting to ON.
3. Press the beige button again to go back to the Temperature Screen. Your actual
temperature will start to flash for about 10-20 minutes with the temperature
fluctuating up and down during that period. After the flashing stops, it means autotuning has finished.
Shutting Down the Dryer
1. Turn off the conveying system supplying the drying hopper.
2. When processing is complete, close the hopper slide gate and shut down any in-line
companion equipment, such as the aftercooler.
3. Turn the Dryer OFF/ON/START selector switch to OFF.
4. Turn the system’s disconnect switch to OFF.
5. If needed, empty the drying hopper.
6. For maintenance or a long term shutdown, open (de-energize) the electrical
disconnects at the dryer and at the power drop.
Large Dehumidifying Dryers
Operation
35
5-2
Dryer Operation Procedures
Controller Operation (Without Optional Alarm Horn & Reset Button)
1. Turn the disconnect on the control panel to the ON position. Power is applied to the
voltage line fuses, line side of the control power switch and the temperature
controller.
2. Turn the control power switch to the ON position. Power is applied to the
programmable relay and dew point controller. The valve will move to the start
position as follows:
a. The bed switch 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 is generated. “VM” is displayed on the relay screen, the alarm
light is activated. The valve motor, heaters, and blower shut off.
To restart the dryer, cycle control power to deactivate the alarm light and
restart the valve motor sequence.
Note:
WARNING!
The relay screen which contains the Alarm Display Messages is
located inside the controller enclosure. For a list of Alarm Display
Messages, see Page 39.
Do not attempt to check the Alarms on the Controller located within the
unit enclosure unless you are a qualified electrician!
c. The valve will normally complete one full cycle (revolution).
If the drying process shuts down due to an alarm, the dryer has been setup to
have the following operational features:
• The bed in process at power-down will remain in process.
• The bed in regeneration at power-down will remain in regeneration.
• The regeneration timing cycle will restart from the beginning.
3. Once the control power is on and no fault conditions exist, turning the OFF-ONSTART switch to the START position will start the dryer as follows:
a. The process heater is turned on and controlled by the E5CN controller.
b. The process & regen blowers are started.
c. The regen heater is turned on and the regeneration timing sequence is
initiated. The regen heater is controlled by the E5CN controller. For default
timing settings for regeneration, see the table below.
4. If either the left or right bed safety temperature switch opens, a regen heater fault is
generated. “RS” is displayed on the relay screen. The alarm light is activated. The
process heater, regen heater, and process/regen blowers are turned off.
Turn the OFF-ON-START switch to the START position to deactivate the alarm
light and restart the dryer. If either switch is still open, the dryer will not restart.
Large Dehumidifying Dryers
Operation
36
5. If the Regen E5CN controller faults, a regen high heat fault is generated. “RH” is
displayed on the relay screen. The alarm light is activated. The process heater, regen
heater, and process/regen blower are turned off.
Turn the OFF-ON-START switch to the START position to deactivate the alarm
light and restart the dryer. If the fault condition still exists, the dryer will not restart.
6. If the process regen overload trips, a regen blower fault is generated. “RB” is
displayed on the relay screen. The alarm light is activated. The process heater, regen
heater, and process & regen blowers are turned off.
Reset the motor overload and turn the OFF-ON-START switch to the START
position to deactivate the alarm light and restart the dryer.
7. If the process heater safety temperature switch opens, a process heater fault is
generated. “PS” is displayed on the relay screen. The alarm light is activated. The
process heater, regen heater, and process/regen blowers are turned off.
Turn the OFF-ON-START switch to the START position to deactivate the alarm
light and restart the dryer. If the switch is still open, the dryer will not restart.
8. If the Process E5CN controller faults, a process high heat fault is generated. “PH” is
displayed on the relay screen. The alarm light is activated. The process heater, regen
heater, and process/regen blower are turned off.
Turn the OFF-ON-START switch to the START position to deactivate the alarm
light and restart the dryer. If the fault condition still exists, the dryer will not restart.
9. If the optional redundant high temperature safety device faults, a redundant safety
fault is generated. “PR” is displayed on the relay screen. The alarm light is
activated. The process heater, regen heater, and process/regen blower are turned off.
Turn the OFF-ON-START switch to the START position to deactivate the alarm
light and restart the dryer. If the fault condition still exists, the dryer will not restart.
10. If the process blower overload trips, a process blower fault is generated. “PB” is
displayed on the relay screen. The alarm light is activated. The process heater, regen
heater, and process & regen blowers are turned off.
Reset the motor overload and turn the OFF-ON-START switch to the START
position to deactivate the alarm light and restart the dryer.
11. The valve position limit switch enables the right bed heater and provides an input
signal to the programmable relay when actuated by the cam lobe. When the cam lobe
position is high, the right bed is activated. When the cam lobe position is low, the
left bed is activated. Each heater is ON-OFF controlled by the regen E5CN
controller.
12. Upon completion of the HEAT portion of the regeneration sequence, the regen
heaters are disabled by the programmable relay and the COOL time begins.
13. 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. If the valve or switch malfunctions, a bed switch fault is generated. “BV” is
displayed on the relay screen. Contact the service department for assistance
14. When a dew point fault is generated by the dew point controller, the alarm light will
activate. The alarm light will flash, indicating a non-critical fault. “DP” is displayed
Large Dehumidifying Dryers
Operation
37
on the relay screen. Press ALARM RESET to deactivate the alarm until the next dew
point fault occurs.
15. Use the right arrow key to display the REGEN SET screen (Screen 1). Use the up &
down arrow keys to select the parameter to change. Use the + & - keys to change the
parameter value. Press the OK key to accept and store the changed values. Press
ESC to cancel changes.
REGEN
SET
HEAT 45
COOL 20
Screen 1.
16. Use the right arrow key to display the Material Miser screen. Use the + key to enable/
disable this feature. See Screens 2 & 3.
MATERIAL
MISER OFF
PRESS + TO
ENABLE
Screen 2.
MTL MISER ON
+ TO DISABLE
MM IS :
NOT ACTIVE
Screen 3.
17. Use the right arrow key to display the Closed Loop Regen screen. Use the + key to
enable / disable this feature. See Screens 4 & 5.
CLOSED LOOP
REGEN OFF
PRESS + TO
ENABLE
Screen 4.
CL REGEN ON
+ TO DISABLE
CL IS :
NOT ACTIVE
Screen 5.
Large Dehumidifying Dryers
Operation
38
18. Turn selector switch to START position to start the dryer. The bed switch valve will
cycle to a known good position. The process & regen blowers will start. Process &
Regen heaters are enabled. A new regen heat/cool cycle is started. Blower alarms are
enabled 5 seconds after startup. Dew Point alarm is enabled 5 minutes after startup.
All other alarms are enabled with no delay.
19. Material Miser. When this feature is enabled, the panel light will illuminate and the
screen will display ‘ACTIVE’ when airflow is reduced to the drying hopper. When
airflow to the hopper is normal, the light is extinguished and the screen reads
“INACTIVE”.
20. Closed Loop Regeneration. When this feature is enabled, the screen will display
‘ACTIVE’ when regen airflow is in closed loop (cooling). When regen airflow is
normal, the screen reads “INACTIVE”.
21. The dryer is shut off by turning the control power switch to the OFF position.
5-3
Alarm Display Messages
Note:
The relay screen which contains the Alarm Display Messages is
located inside the controller enclosure and may be seen through the
window on the front of the control box.
1. Non-critical alarms. The following alarms are con-critical and will NOT shut down the dryer:
a. Dew Point.
b. Process / Regen Dirty Filter.
c. Process heat low temp alarm.
d. Closed Loop Valve Motor fault.
2. Critical alarms. The following alarms are critical and WILL shut down the dryer. Alarms are silenced
by turning the Off/On/Start switch to the start position. The dryer will restart if the alarm condition is
no longer present.
a. Process blower fault.
b. Regen blower fault.
c. Process heater high temp switch.
d. Regen heater high temp switches.
e. Regen valve motor fault.
f. Process high temp alarm (TCU).
g. Regen high temp alarm (TCU).
h. Redundant safety alarm.
3. Viewing alarm codes. See Screen 6. The alarm screen is displayed any time an alarm is active, and
can also be accessed by pressing the right arrow key. Each alarm is assigned a 2 letter code as
follows:
ALARM CODES:
PB - PROCESS BLOWER
RB - REGEN BLOWER
Large Dehumidifying Dryers
Operation
39
PF - PROCESS FILTER
RF - REGEN FILTER
CV - CLOSED LOOP VALVE
BV - BED SWITCH VALVE
PS - PROCESS TEMP SWITCH
RS - REGEN TEMP SWITCH
PH - PROCESS HI TEMP
PL - PROCESS LOW TEMP
RH - REGEN HI TEMP
DP - DEWPOINT
PR - REDUNDANT SAFETY
5-4
ALARMS :
PB RB
BV PS RS
PH PL RH
Screen 6.
Auto-Tuning the Dryer
1. For Auto-tuning, press the beige button once. The AT screen will show with the
setting OFF.
2. Press the UP arrow to change the setting to ON.
3. Press the beige button again to go back to the Temperature Screen. Your actual
temperature will start to flash for about 10-20 minutes with the temperature
fluctuating up and down during that period. After the flashing stops, it means autotuning has finished.
5-5
Shutting Down the Dryer
1. Turn off the conveying system supplying the drying hopper.
2. When processing is complete, close the hopper slide gate and shut down any in-line
companion equipment, such as the aftercooler.
3. Turn the Dryer OFF/ON/START selector switch to OFF.
4. Turn the system ON/OFF switch to OFF.
5. If needed, empty the drying hopper.
6. For maintenance or a long term shutdown, open (de-energize) the electrical
disconnects at the dryer and at the power drop.
Large Dehumidifying Dryers
Operation
40
Chapter 6: Maintenance
6-1
Maintenance Schedule
The checklist below contains a list of items that should be inspected and/or replaced to keep
your Large Dehumidifying Dryer operating at peak efficiency. Perform each inspection at
the regular intervals listed below.
Dryer Model #
EVERY WEEK
Serial #
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Inspect all filters for wear,
replace/clean if dirty or
worn
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
Inspect desiccant. Replace
if brown or broken
- Photocopy this page for your maintenance records -
Large Dehumidifying Dryers
Maintenance
41
6-2
Preventative Maintenance
Cleaning or Replacing the Process Air Filters
Regular filter cleaning will keep your dryer operating at peak efficiency. The process air
filters protect the centrifugal blowers from plastic fines being drawn in from the drying
hopper. Filters should be cleaned when airflow restriction trips the dirty filter alarm. Filters
should be replaced at least once a year.
Caution!
Operating the dryer without the process air filters installed will void the
warranty.
On 600-1500 cfm dryers, there is a single high-temperature (up to 350ºF) filter mounted
above the process blower on the rear of the dryer. On 2000-3000 cfm dryers, there are two
high-temperature (up to 350ºF) filters located in the housing under the blower platform on the
left rear corner of the dryer.
Vacuuming. Vacuum cleaning is the preferred method for cleaning the process air filters
because compressed air or high-pressure washing can damage the filter. Vacuuming removes
most large particles and surface contaminant. Use a commercial duty vacuum cleaner and
vacuum the filter from the air intake (dirty) side only.
Compressed Air Cleaning. Blow clean, dry compressed air up and down the pleats, blowing
out the filter from the clean side. Do not shoot the air in a criss-cross motion against the grain
of the pleats—this won’t clean the filter, and it may damage it. Compressed air should be less
than 100 psi—use a 1/8 diameter nozzle at least 2 inches away from the filter.
Figure 16: Process Filter Housing
High
Temeprature
Gasket
Stainless Steel
Filter Housing
High
Temperature
Cartridge Filter
High
Temperature
Cartridge Filter
Stainless Steel
Filter Housing
Stainless Steel
Filter Housing
Cover
Filter Housing
Cover Latches
High
Temeprature
Gasket
600-1500 cfm dryers
Large Dehumidifying Dryers
Maintenance
Filter Housing
Cover Latches
High
Temeprature
Gasket
Stainless Steel
Filter Housing
Cover
2000-3000 cfm dryers
42
Use the following procedure to clean or replace the filter cartridges:
1. Turn off and/or lock out electrical power to the dryer.
2. Remove the hand knobs or clamps securing the filter access cover and remove the
cover.
3. Remove the nut on the center-retaining rod to remove a filter cartridge.
4. Vacuum, blow out, or wash the filter.
5. Inspect the filter - a damaged filter should not be reused. Check the following:
„ Hold a light bulb behind the filter element to find holes,
tears, fatigued paper or residual dirt.
„ Inspect the end plates—damage here could allow air to
bypass the filter.
„ Look for rust on the end plates and metal core—rust
particles could flake off and contaminate the dryer and resin.
„ Check the gasket for damage—a damaged gasket will allow
contaminants into the process. Replace if needed.
6. Return the filter cartridge to its original position and tighten the nut on the centerretaining rod to secure the filter cartridge.
7. Secure the filter access cover with the hand knobs or threaded fasteners.
Cleaning or Replacing the Regeneration Filter
Large dryers are equipped with a filter in the regeneration air loop located at the back of the
dryer. Regular filter cleaning will keep your dryer operating at peak efficiency.
Caution!
Operating the dryer without the regeneration air filters installed will void
the warranty.
1.
2.
3.
4.
Turn off and/or lock out electrical power to the dryer.
Remove the knob securing the filter.
Remove the filter from the post.
Vacuum or carefully blow out the filter with compressed air. If the filter is worn or
can't be cleaned, replace it.
5. Slide the filter back onto its post and tighten knob back on the filter.
Calibrating the Dirty Filter Alarm
Your dryer may be equipped with a Dirty Filter alarm. When the alarm sounds, it is time to
clean or change the filter. The Dirty Filter alarm is tested and calibrated at the factory, but it
can be adjusted in the field. Be sure that your filter is clean, and use the following procedure
to calibrate the alarm.
1. Remove the process air return filter element from its housing.
2. Block off approximately 50% of the filter’s surface area to simulate a dirty filter.
3. Reinstall the cartridge and secure the cover.
4. While the process blower is operating, adjust the trim screw on the differential
pressure switch until the alarm light just comes on.
Large Dehumidifying Dryers
Maintenance
43
5. Remove the restricted filter cartridge from the housing again. The alarm light should
stay off when the process blower operates if the switch is adjusted correctly.
6. Re-install the obstructed cartridge filter. The alarm light should go on again if the
switch is adjusted correctly.
7. Fine tune the switch setting so it consistently warns of a blocked filter and does not
falsely indicate a blockage of a clean filter.
8. Remove the restriction from the filter element and re-install the clean filter. The
alarm light should remain off.
Checking the Dewpoint Control System
The Dewpoint Switch option on dryers depends on the proper operation of the dewpoint
sensor and its control board. The dewpoint sensor is in the process air stream and is therefore
susceptible to contamination.
Dewpoint sensor life is dependent on:
„
Air temperature and flow passing over the sensor.
„
The amount of fines [dust] in the process air.
„
The amount of plasticizer vapor in the process air.
The dryer operator should monitor the initial dewpoint sensor readings and establish a
periodic replacement schedule as needed.
Caution! Do not attempt to check the continuity or resistance of a dewpoint sensor. The
sensor will be destroyed.
If you suspect that the dewpoint readings on the dewpoint meter are incorrect, a dewpoint
simulation calibrator is available from the manufacturer [part number A0549143]. This
device simulates various dewpoint outputs. It can confirm proper operation of the dewpoint
sensor and dewpoint system control board.
Use the following procedure to check the dewpoint sensor and dewpoint control board:
1. Remove the sensor cable from the sensor hex nut adapter.
2. Connect the cable to the plug on the rear of the simulator.
3. Turn the rotary knob on the simulator to each position and note the readings on the
dewpoint meter on the dryer's control panel. The readings should correspond within a
degree or two across the entire range.
4. If the readings agree, the control board is OK. Dewpoint sensor replacement is
recommended. If the readings do not agree, replace the control board and run the test
again to rule out the possibility of a bad sensor.
Note:
Do not attempt to make any adjustments to the components on the dewpoint
control board.
5. When testing is finished, re-connect the control cable to the sensor adapter.
Large Dehumidifying Dryers
Maintenance
44
6-3
Corrective Maintenance
Symptoms of Worn Out Desiccant
The moisture adsorption capacity of the desiccant used in Large Dehumidifying Dryers
degrades after an indefinite period of time. Useful life depends on variables such as material
moisture content, plasticizer vapors in the return air and number of regeneration cycles.
Your dryer may need new desiccant if it exhibits any of the following symptoms:
• The plastic material is not being dried sufficiently (high scrap/reject rate).
• The air temperature at the top of the regenerating desiccant bed rapidly climbs to
350°F or more shortly after the start of regeneration, even though a saturated bed has
just started heating.
• The process air dewpoint, measured with a portable dewpoint monitor, is higher than
-10°F throughout the process drying cycle.
• Smoke or dust is being blown out of the process air outlet.
• Noticeable amounts of desiccant in the beds is a medium-brown color, or darker.
If any of these signs are noticed, the desiccant in the desiccant beds should be replaced.
Desiccant replacement kits are available from the Parts Department. If you wish, the
desiccant beds can be repacked at your site by a service technician.
WARNING!
DESICCANT MATERIAL CAUSES EYE IRRITATION
BREATHING MAY BE HARMFUL/MAY CAUSE SKIN IRRITATION!
• Do not get in eyes.
• Avoid prolonged contact with skin.
• Use with adequate ventilation.
• Wash thoroughly after handling.
FIRST AID:
In case of eye contact, immediately flush eyes with plenty of water for
at least 15 minutes. If irritation persists, see a physician.
Replacing the Desiccant
Follow the procedure below to change the desiccant. See Figure 17 below for desiccant
tower components.
1. Disconnect electrical power to the dryer.
2. Remove the bolts and nuts securing the covers of each desiccant canister. Remove
the covers and set them aside.
3. With a shop vacuum that has a 4 micron HEPA filter, carefully remove all desiccant
from each tower.
4. Inspect all screens for tears or burn-through spots.
5. Fill each canister with 13X, 8 x 12 bead desiccant.
Large Dehumidifying Dryers
Maintenance
45
6. Inspect the gaskets on each of the covers. Replace if necessary.
7. Re-install the covers.
Figure 17: Desiccant Tower Assembly
Regeneration
Heater Cover.
High
Temperature
Gaskets.
Regeneration
Heaters
Heater Element
Mounting Plate.
Viewing Glass, for
checking the status of
the desiccant inside.
Access cover can be
removed in order to
replace desiccant.
High
Temperature
Gaskets.
Stainless Steel
Hollow Core
Desiccant Tank
Desiccant Tank
Mounting
Platform
Figure 18: Desiccant Replacement Amounts
Dryer
CFM
600
850
1000
1250
1500
2000
2500
3000
Desiccant Required per Tower
“13 X”, 8 x 12 Bead
Total
175
350
175
350
300
600
300
600
300
600
300
1200
300
1200
300
1200
Replacing the Process Heater (Electric Dryers)
Large Dryers have a number of single phase Calrod-type heater elements wired in a delta
formation. They are mounted on top of the dryer or to the drying hopper. The number and
wattage of the heaters varies with model, voltage, temperature range, etc., but the
replacement procedure is the same.
DANGER!
Disconnect and lock out power before heater replacement.
Large Dehumidifying Dryers
Maintenance
46
1. Remove the bolts securing the process heater access cover.
2. Sketch the heater wiring configuration so the heaters may be re-wired properly.
Heaters are mounted on a common plate of three or six for easy maintenance.
3. Remove the jumper bars and wires for the heater plate assembly(ies) being removed
or replaced.
4. Remove the bolts securing the heater plate assembly and slide out the assembly.
Avoid damaging the gaskets.
5. Remove individual heaters for replacement by removing the large brass nuts and
washers.
6. Re-install the heaters and heater plate assemblies in reverse order, replacing gaskets
if necessary.
Caution!
Heater loops should not touch each other. "Hot spots" will lead to
premature heater failure.
7.
Re-install the jumper wires and bars according to the sketch made earlier.
8.
Re-secure the process heater access cover.
Figure 19: Process Heater Box Assembly
High
Temperature
Gasket
Heater Elements
Stainless Steel
Heater Housing
Cover
Heater Elements
Double Wall
Stainless Steel
Heater
Housing
High
Temperature
Gasket
Heater Element
Mounting Plate
Heater Element
Mounting Plate
Double Wall
Stainless Steel
Heater
Housing
Heater Assembly
Gude Bars
High
Temperature
Gasket
Heater Assembly
Gude Bars
Stainless Steel
Heater Housing
Cover
Hex Nut For
Securing the Heater
Wire
Washer
Heater Element
Mounting Hex Nut
High Temperature
Washer / Gasket
Heater Element
Heater Wire with
Crimped on Closed
Loop Connector
Heater Element
Bulkhead Fitting
Heater Mounting
Plate
Heater Assembly
Guide Bar
Replacing the Regeneration Heater (Electric Dryers)
The regeneration heaters are wired in the delta formation, mounted in the core of the descant
tanks.
DANGER!
Disconnect and lock out power before heater replacement.
Large Dehumidifying Dryers
Maintenance
47
1.
2.
3.
4.
5.
6.
Access the desiccant canisters by removing the panels on the dryer.
Remove the Regeneration Heater Cover.
Unscrew the six (6) screws on the Heater Element Mounting Plate.
Slide out the heater assembly, taking care to not damage the gaskets.
Unscrew the heater loops that need to be replaced.
Re-install the new heaters. Securely tighten all fasteners.
Caution!
7.
8.
9.
10.
The heater loops should not touch each other. This will create "hot spots"
and lead to premature heater failure.
Insert the heater assembly back into the desiccant canister.
Fasten the six (6) screws on the Heater Element Mounting Plate.
Re-secure the Regeneration Heater Cover.
Re-install the dryer panels.
Figure 20: Regeneration Heater Box Assembly
Regeneration
Heater Cover.
Heater Element
Mounting Plate.
Viewing Glass, for
checking the status of
the desiccant inside.
High
Temperature
Gaskets.
Regeneration
Heaters
Access cover can be
removed in order to
replace desiccant.
High
Temperature
Gaskets.
Stainless Steel
Hollow Core
Desiccant Tank
Desiccant Tank
Mounting
Platform
Large Dehumidifying Dryers
Maintenance
48
Chapter 7: Troubleshooting
7-1
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.
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.
7-2
Basic Troubleshooting
Problem
Little or no air
coming from
process delivery
tube.
Suction in delivery
tube, pressure from
the return tube.
Loss or reduction of
process air
temperature.
Possible Cause
Dirty Filters
Desiccant beds contaminated by
material or plasticizer leaking
into the system.
Blower fuse(s) blown.
Overload tripped.
Blower fins filled with dust or
contaminants.
Phase is reversed on power drop
coming into the dryer.
Process heaters are faulty.
Solid-state temperature controller
faulty.
Process temperature was adjusted
in error by plant personnel.
Large Dehumidifying Dryers
Troubleshooting
Corrective Action
Clean or replace filters.
Replace desiccant See page 46.
Fix problem and Replace fuse(s).
Fix problem and reset the
overload.
Remove blower side plate, clean
baffles, replace.
Stop the Dryer.
If the dryer was connected to the
drying hopper, check to see if the
desiccant and process air heater
has been contaminated with resin.
If so, replace the desiccant and
remove any resin carry-over.
Otherwise, change the phase of
two legs of the three-phase power
drop. Never change the phase at
the motor starters unless only one
of the two blowers is rotating
improperly.
Check for open or shorted heaters.
Replace if required. Check the
fuses.
Replace.
Make sure that plant personnel are
aware of the proper temperature
set point. A sign posted next to the
control would be helpful.
49
Problem
Loss or reduction in
drying capacity.
Possible Cause
Process heaters are faulty.
Desiccant beds are contaminated.
Material being dried differs from
material specified at the time of
purchase.
Break in flex hose to/from drying
hopper.
Blower fins filled with dust or
contaminants.
Material in drying
hopper cakes, or
meltdown occurs.
Process temperature set too high
due to operator error.
High temperature alarm not set
properly.
Process set point is out of
acceptable range.
Poor Dew Point
Performance.
Large Dehumidifying Dryers
Burned out regeneration heater.
Contaminated or worn out
desiccant.
Leaking process air hoses.
Dryer is being operated beyond its
capacity.
Bad dew point sensor.
Fouled dew point sensor manifold.
Troubleshooting
Corrective Action
Replace.
Replace desiccant.
Drying systems are designed for
the material that was originally
specified. Different materials may
need a longer residence time or
different drying temperature.
Inspect for air leaks; replace if
necessary.
Remove blower side plate, clean
baffles, replace. Replace filter
elements.
Check resin manufacturer's data
sheet for proper drying
temperature. Make sure plant
personnel are aware of the correct
process temperature Set Point.
See Section “Temperature Screen
Setup” on page 29.
Restore temperature controller to
factory pre-sets. Auto-tune if
necessary.
Repair or replace.
Replace.
Repair or replace.
Check dryer and drying hopper
sizing.
Replace.
Clear obstruction. Air should flow
freely through sensor.
50
7-3
Alarms
The Alarm Screen will pop up to show what alarm the dryer is having that moment. Look
through the window on the door to see the screen.
7-4
Alarm Descriptions
Alarm
Code
BV
CV
PS
RS
PH
PL
RH
DP
PB
RB
PF or RF
PR
Alarm Description
The Main Air Valve did not maintain or find
position.
Possible Motor or Limit Switch Failure.
The Closed Loop Cooling Valve did not find
position.
Possible Motor or Limit Switch Failure.
The process supply air temperature switch
opened.
Possible thermocouple failure.
The regeneration air temperature switch opened.
Possible thermocouple failure.
Process air temperature deviation is above high
limit value.
Possible solid state relay failure.
Process air temperature deviation is below low
limit value.
Possible heater failure.
Regeneration air temperature deviation is above
high limit value.
The dew point value is above the high limit
value.
Possible ambient air contamination or failed
regeneration cycle.
Process blower is not running.
Possible overload fault, contactor fault.
Regeneration blower is not running.
Possible overload fault, contactor fault.
Process air filter (PF) or regen air filter (RF)
requires cleaning.
The process redundant air temperature
thermocouple is out of range.
Possible thermocouple or solid state relay
failure.
Large Dehumidifying Dryers
Troubleshooting
Alarm Effect
Immediate
Shut Down
Immediate
Shut Down
Process
Shut Down
Regeneration
Shut Down
Process
Shut Down
Alert Only
Regeneration
Shut Down
Alert Only
Process
Shut Down
Regeneration
Shut Down
Alert Only
Immediate
Shut Down.
51
7-5
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.
Using a Platinum Resistance Thermometer
If the controller displays a temperature of about 0.0°C (32ºF) when you insert a 100-ohm
resistor between terminals A and –B of the controller, and you short-circuit controller
terminals +B and –B, the controller is normal and the sensor is probably broken, shortcircuited, or incorrectly wired.
Other service problems or questions can be answered by contacting the Service
Department.
Large Dehumidifying Dryers
Troubleshooting
52
Chapter 8: Appendix
8-1
Technical Specifications
Annex B Information
The following design information is provided for your reference:
1. No modifications are allowed to this equipment that could alter the CE compliance
2. Ambient temperature:
0 degrees Celsius – Maximum (104 degrees Fahrenheit)
3. Humidity range:
50% relative humidity
4. Altitude:
Sea level
5. Environment:
Clean, dust-free and non-explosive
6. Radiation:
None
7. Vibration:
Minimal, i.e. machine mounting
8. Allowable voltage fluctuation:
+/- 10%
9. Allowable frequency fluctuation:
Continuous
+/- 1%
Intermittent
+/- 2%
10. Nominal supply voltage:
460/3/60 (Verify on serial number tag)
11. Earth ground type: TN (system has one point directly earthed through a protective
conductor)
12. Power supply should include a ground connection.
13. Over-current protection is supplied in the dryer, but additional protection should be
supplied by the user.
14. The door-mounted disconnect serves as the electrical disconnect device.
15. Dryer is not equipped with local lighting.
16. Functional identification
17. Dryer is equipped with a CE mark
18. Dryer is supplied with an operating manual in the language of the destination
country.
19. Cable support may be required for power cord, depending on final installation.
20. No one is required to be in the interior of the electrical enclosure during the normal
operation of the unit. Only skilled electricians should be inside the enclosure for
maintenance.
21. Doors can be opened with a screwdriver, but no keys are required.
22. Two-hand control is not required or provided.
23. All dryers should be moved around and set in a place with a lift truck or equivalent.
24. There are no frequent repetitive cycles that require manual control⎯repetitive
functions are automatic while the dryer is operating.
25. An inspection report detailing the functional test is included with the dryer.
26. The machine is not equipped with cableless controls.
27. Color-coded (harmonized) power cord is sufficient for proper installation.
Aftercooler Design Specifications
Entering water temp.
ºF
85ºF
Large Dehumidifying Dryers
ºC
29ºC
Appendix
53
8-2
Drawings and Diagrams
Regeneration
Blower
Insulated
Drying
Hopper
Regen.
Filter
Process
Air Filter
Process
Heater
Optional
Regeneration
Closed Loop
Cooler
Regen.
Optional
Regeneration Exhaust
Closed Loop
Valve
Optional
After-cooler
Right Desiccants
Left Desiccants
Dryer Valve
Process
Blower
Airflow Schematic: 2000-3000 cfm dryers (4 desiccant beds). Left desiccant beds are
regenerating—closed loop regeneration is activated.
Regeneration
Blower
Insulated
Drying
Hopper
Regen.
Filter
Process
Air Filter
Process
Heater
Optional
Regeneration
Closed Loop
Cooler
Regen.
Optional
Regeneration Exhaust
Closed Loop
Valve
Optional
After-cooler
Right Desiccants
Left Desiccants
Dryer Valve
Process
Blower
Airflow Schematic: 2000-3000 cfm dryers (4 desiccant bed). Left desiccant beds are
regenerating in open-loop regeneration mode.
Large Dehumidifying Dryers
Appendix
54
Filter Check
Gage
Differential
Pressure
Switch
Thumb Screws
PS
Cartridge Filter
Dust Shroud
Filter Retainer
F
Slide Gate
E
Clamp
Dust Level
Indicator
Dust Pan
Optional dryer dust collector
Large Dehumidifying Dryers
Appendix
55
Large Dehumidifying Dryers
1000CFM
1000CFM
1000CFM
1250CFM
1250CFM
1250CFM
1250CFM
1250CFM
1500CFM
1500CFM
1500CFM
1500CFM
1500CFM
2000CFM
2000CFM
2000CFM
2500CFM
2500CFM
2500CFM
3000CFM
3000CFM
400V 50 HZ 3PH
460V 3PH
575V 60 HZ 3PH
208V 3PH
230V 3PH
400V 50 HZ 3PH
460V 3PH
575V 60 HZ 3PH
208V 3PH
230V 3PH
400V 50 HZ 3PH
460V 3PH
575V 60 HZ 3PH
400V 50 HZ 3PH
460V 3PH
575V 60 HZ 3PH
400V 50 HZ 3PH
460V 3PH
575V 60 HZ 3PH
400V 50 HZ 3PH
460V 3PH
3000CFM
1000CFM
230V 3PH
575V 60 HZ 3PH
1000CFM
208V 3PH
850CFM
575V 60 HZ 3PH 850CFM
460V 3PH
850CFM
230V 3PH
400V 50 HZ 3PH 850CFM
850CFM
208V 3PH
600CFM
575V 60 HZ 3PH 600CFM
30
Appendix
575V 60 HZ 3PH 3000CFM
3000CFM
460V 3PH
400V 50 HZ 3PH 3000CFM
575V 60 HZ 3PH 2500CFM
2500CFM
460V 3PH
400V 50 HZ 3PH 2500CFM
575V 60 HZ 3PH 2000CFM
2000CFM
460V 3PH
400V 50 HZ 3PH 2000CFM
575V 60 HZ 3PH 1500CFM
1500CFM
460V 3PH
1500CFM
230V 3PH
400V 50 HZ 3PH 1500CFM
1500CFM
208V 3PH
575V 60 HZ 3PH 1250CFM
1250CFM
1250CFM
230V 3PH
400V 50 HZ 3PH 1250CFM
1250CFM
460V 3PH
45
39
39
78
18 Feet
1
1
1
1
1
1
1
1
1
1
45
39
39
1
1
1
1
1
45
39
30
60
18 Feet
1
1
1
1
1
39
39
21
42
18 Feet
1
1
1
1
1
39
30
21
208V 3PH
2
1
1200 Lbs.
4.5 Rolls
4
4
5
1000CFM
2
1
1200 Lbs.
4.5 Rolls
4
4
5
1000CFM
2
1
1200 Lbs.
4.5 Rolls
4
4
5
230V 3PH
1
1
600 Lbs.
3.0 Rolls
2
2
3
39
30
21
1
1
1
1
1
1
1
1
1
1
30
21
1
1
1
1
1
600 Lbs.
3.0 Rolls
2
2
3
1
1
1
1
1
21
1
1
1
1
1
208V 3PH
850CFM
575V 60 HZ 3PH 850CFM
460V 3PH
850CFM
230V 3PH
1
1
1
1
1
1
1
1
1
1
1
400V 50 HZ 3PH 850CFM
850CFM
208V 3PH
600CFM
575V 60 HZ 3PH 600CFM
600CFM
230V 3PH
460V 3PH
600CFM
208V 3PH
350 Lbs.
2.25 Rolls
2
2
3
1
1
1
1
1
600 Lbs.
2.75 Rolls
2
2
3
575V 60 HZ 3PH 1000CFM
1
1
1
1
1
1000CFM
1
1
1
1
1
460V 3PH
1
1
1
1
1
400V 50 HZ 3PH 1000CFM
1
1
1
1
1
350 Lbs.
2.25 Rolls
2
2
3
LEVEL 2 ( Electrical Components )
PART #
SIZE Description
A0558000
9A Contactor, IEC
A0558002
16A Contactor, IEC
A0558004
32A Contactor, IEC
A0558040
Overload, IEC, 12-32A
A0558079
Overload, IEC, 1 - 2.9A
A0569887
Overload, IEC, 5 - 15A
A0569895
48A Relay, Solid State
A0505417
Relay, 4PDT, Regeneration T'Couple
A0567058
Relay, SPDT
A0554555
*
Circuit Board, Dew Point
A0548556
*
Sensor, Dew Point
LEVEL 2 ( Mechanical Components )
PART #
SIZE
Description
A0566544
3500 Watts Heater Element 208/220 Volts
A0566547
3500 Watts Heater Element 230 Volts
A0566549
3500 Watts Heater Element 400 Volts
A0566549
3500 Watts Heater Element 460 Volts
A0566549
3500 Watts Heater Element 575 Volts
A0566415
Heater Element Gasket
A0566682
1/4" OD Teflon Tube.
460V 3PH
600CFM
LEVEL 1 ( Mechanical Components )
PART #
SIZE Description
W00015435
Dew Point Sensor Insert
A0548556
Dew Point Sensor
A0568271
Dew Point Sensor Cable
A0566467
Valve switch
A0570595
Process Air Filter 600-850 CFM
A0568062
Process Air Filter 1000-3000 CFM
A0566531
Regeneration Air Filter 600-850 CFM
A0572408
Regeneration Air Filter 1000-3000 CFM
W00018051
13X molecular Sieve Desiccant ( 8 X 12 Beads )
W00013983
High Temperature Gasket (15 Ft Roll)
A0566564
Desiccant Tank Sight Glass
A0572479
Desiccant Tank Sight Glass Gasket
A0566676
High Temperature Snap Switch.
LARGE DRYER SPARE PARTS LIST 600,850,1000,1250,
1500,2000,2500, AND 3000
400V 50 HZ 3PH 600CFM
3
3
3
3
2
1
2
1
1
2
1
400V 50 HZ 3PH 600CFM
LEVEL 1 ( Electrical Components )
PART #
SIZE Description
A0536474
50
Fuse, Process Heater Elements
A0536471
35
Fuse, Regen Heater Elements
A0534846
20
Fuse, Process Blower
A0545343
3.5 Fuse, Regen Blower
A0538001
3.2 Transformer, Control Primary
A0538017
6
Transformer, Control Secondary
A0538005
5
Transformer, Valve Motor Primary
A0534842
10
Transformer, Valve Motor Secondary
A0540997
1
Fuse, Control, PLC
A0540995
0.75 Fuse, Control, Output/Power Supply
A0542207
3
Fuse, Control, Power Supply Out
600CFM
LARGE DRYER SPARE PARTS LIST 600,850,1000,
1250,1500,2000,2500, AND 3000
230V 3PH
Spare Parts List
208V 3PH
8-3
66
45
39
78
18 Feet
78
66
45
90
18 Feet
120
18 Feet
56
90
78
66
78
158
18 Feet
90
90
180
18 Feet
LEVEL 3 ( Mechanical Components )
PART #
SIZE
Description
A0542302
8" O.D. by 12 Ft Long Hi Temp Hose.
A0571107
3" O.D. by 12 Ft Long Hi Temp Hose.
A0570519
Return Air Cooling Coil 600-850 CFM
A0566849
Return Air Cooling Coil 1000-1500 CFM
A0568147
Return Air Cooling Coil 2000-3000 CFM
A0568233
Closed Loop Cooling Coil
A0546119
208-230/460 Volt Blower, 600 CFM
A0562555
575 Volt Blower, 600 CFM
A0565900
208-230/460 Volt Blower, 850 CFM
A0572510
380 Volt Blower, 1000 CFM
A0572509
230/460 Volt Blower, 1000 CFM
A0572511
575 Volt Blower, 1000 CFM
A0559792
380 Volt Blower, 1250 CFM
A0559903
230/460 Volt Blower, 1250 CFM
A0559998
575 Volt Blower, 1250 CFM
A0553766
230/460 Volt Blower, 1500 CFM
A0572513
380 Volt Blower, 2000 CFM
A0572512
230/460 Volt Blower, 2000 CFM
A0572514
575 Volt Blower, 2000 CFM
A0572516
380 Volt Blower, 2500 CFM
A0572515
230/460 Volt Blower, 2500 CFM
A0572517
575 Volt Blower, 2500 CFM
A0559815
380 Volt Blower, 3000 CFM
A0568211
230/460 Volt Blower, 3000 CFM
A0560003
575 Volt Blower, 3000 CFM
W00015335
Dew Point Sensor Manifold
A0548558
Gasket for the Dew Point Sensor
W00015436
Plastic Nut for the Dew Point Sensor
A0572502
O-Ring for Main Valve
A0566879
Main Valve Motor
A0565249
Filter housing Latch
A0565250
Filter Housing Strike
A0566466
Closed Loop Cooling Valve Motor
A0547006
Knob for the Regeneration Filter
A0537908
Handle for Panels.
A0568205
Latch for Panels
A0542231
8" Hose Clamp
A0571107
3" Hose Clamp
Large Dehumidifying Dryers
1
1
3000CFM
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
575V 60 HZ 3PH 3000CFM
460V 3PH
400V 50 HZ 3PH 3000CFM
2500CFM
575V 60 HZ 3PH 2500CFM
460V 3PH
400V 50 HZ 3PH 2500CFM
2000CFM
575V 60 HZ 3PH 2000CFM
460V 3PH
400V 50 HZ 3PH 2000CFM
1500CFM
575V 60 HZ 3PH 1500CFM
460V 3PH
1500CFM
230V 3PH
400V 50 HZ 3PH 1500CFM
1500CFM
208V 3PH
1250CFM
575V 60 HZ 3PH 1250CFM
460V 3PH
1250CFM
230V 3PH
400V 50 HZ 3PH 1250CFM
1250CFM
208V 3PH
1000CFM
575V 60 HZ 3PH 1000CFM
460V 3PH
1000CFM
230V 3PH
400V 50 HZ 3PH 1000CFM
1000CFM
208V 3PH
850CFM
575V 60 HZ 3PH 850CFM
460V 3PH
850CFM
230V 3PH
400V 50 HZ 3PH 850CFM
850CFM
208V 3PH
600CFM
575V 60 HZ 3PH 600CFM
460V 3PH
600CFM
Description
PLC, Controller
PLC, Temperature Control Module
PLC, Analog Input Module
PLC, Touch Screen
Power Supply, 24VDC
Redundant Temperature Safety Controller
400V 50 HZ 3PH 600CFM
SIZE
600CFM
PART #
A0567930
A0567932
A0569896
A0567933
A0563932
A0568961
230V 3PH
8-4
LEVEL 3 ( Electrical Components )
208V 3PH
LARGE DRYER SPARE PARTS LIST 600,850,1000,1250,
1500,2000,2500, AND 3000
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3.2 Feet
1
4
4
1
1
8
24
16
6
1
1
1
3.2 Feet
1
4
4
1
1
8
24
16
6
Appendix
1
1
1
3.2 Feet
1
4
4
1
1
12
36
16
6
1
1
1
3.2 Feet
1
4
4
1
1
12
36
16
6
1
1
1
3.2 Feet
1
4
4
1
1
12
36
16
6
1
1
1
3.2 Feet
1
4
4
1
1
16
48
32
6
57
1
1
1
3.2 Feet
1
4
4
1
1
16
48
32
6
1
1
1
1
3.2 Feet
1
4
4
1
1
16
48
32
6
8-5
Dryer Identification (Serial Number) Tag
(Located on back of Dryer)
XXX Series Dryer
Model Number XXX-15
Max Drying Capacity HR
460V
Serial Number 060701R
1
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
Large Dehumidifying Dryers
Appendix
City, State Zip Code
58
8-5
Technical Assistance
Parts Department
Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610 Fax: [262] 641-8653
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] 423-3183 or call [262] 641-8610
Emergencies after 5pm CST, call [847] 439-5655
We have a qualified service department ready to help. Service contracts are available for most
products. Service contracts are available for most of our products. www.acscustomerservice.com
Sales Department
Call [262] 641-8610 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 [262] 641-8610 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.
Sterling, Inc.
2900 S. 160th Street
New Berlin, WI 53151
www.sterlco.com
Large Dehumidifying Dryers
Appendix
59
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