User Manual - Electrical
Contents
1. 3 1 Positioning Your Dryer The dehumidifying dryer system was designed to be wheeled into place The entire assembly is mounted on a rugged compact frame and is equipped with sturdy 4 10 cm heavy duty casters It is important to leave room to access the dryer from the front rear and at least one side for repair and regular maintenance ACAUTION Use caution and observe safety rules when placing your dryer 3 2 Making Electrical Connections MDB Series dryers are designed for three phase voltage operation Refer to the unit nameplate for proper voltage and amperage requirements NOTICE Refer to National Electric Code NEC Article 430 24 through 430 26 for proper feeder conductor and supply disconnect sizing AWARNING Maintain a safe ground and disconnect the power supply before servicing the unit A qualified electrician should make the proper connections Disconnect and lock out electricity using OSHA 29CFR 1910 147 standards when you need a service call Bring properly sized power leads and ground from a fused disconnect installed by your electrician to the unit Provide external overcurrent protection to the unit using circuit breakers or fuses If you use fuses make sure that they are dual element time delay fuses sized according to your electrical code Make sure that all electrical connections are tight 3 3 Checking for Proper Blower Rotation Three Phase Models To check each blower for proper rotation pr2. e Solid state relays for process heater Large Dehumidifying Dryers General Information 13 2 4 Safety Features 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 National Fire Protection Agency NFPA 70 amp 79 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 MDB 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 ZA 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 General Information 14 Chapter 3 Installation
3. 1 000g cm3 VALOX 815 Use the Material Select screen to recall the material recipe to use Pressing the Load button will make the highlighted recipe current and return to the Hopper Setup screen Pressing the Setup button will call up the Material Setup screen described below Process Autotune Screen HOPPER 1 AUTOTUNE IN PROGRESS START HOPPER 1 AT 0 00SEC Use the Process Autotune screen to start or stop autotune for the process heater Also values can be manually entered although this is generally discouraged Autotune should be performed on initial startup after installation and any time a process change occurs that affects air flow through the hopper The values will change after a successful autotune When autotune is in progress the banner message is displayed on this screen and AT indicators are displayed on Status screens Controls 19 Material Setup Screen ZA Material Setup Configure Material E Em 4 VALOX 815 Regrind Pct 20 x Material Density 801 OOO Brass New Use the material setup screen to make changes to the current material recipe Changing the regrind percent will recalculate density although density can also be manually entered Press the Save button to make changes permanent otherwise changes will be lost when a new recipe is selected or the dryer power is shut off Press the Copy button to create a new recipe using the current recipe as a template Press the Ne
4. PLC Left Right output indicators temperature condition l Power light is off power wiring to PLC Faulty PLC PLC Power light is on Run light is off and or Replace PLC Error light is on indicators both off Check resin manufacturer s data sheet for proper drying Process temperature set too temperature Make sure plant high due to operator error personnel are aware of the correct process temperature Material in drying hopper set point set properly alarm Process set point is out of Restore temperature acceptable range controller to factory pre sets Function set for degrees Celsius 9C set point at degrees Fahrenheit F Verify correct Celsius or Fahrenheit settings Burned out regeneration Repair or replace heater Contaminated or worn out l Replace desiccant Leaking process air hoses Repair or replace OOT OCW PIPE omnes Dryer operates beyond its Check dryer and drying capacity hopper sizing Bad dew point sensor Fouled dew point sensor Clear obstruction Air should manifold flow freely through sensor Troubleshooting 40 Problem Possible cause Corrective action The DIN PID Controller is not Properly insert the controller inserted properly into the l i into the housing housing The power supply is not Properly connect the power connected to its terminals supply to the power supply properly terminals Supply a voltage of 85 to 240 VAC or 20 29 VAC DC to the p
5. IN PROCESS LEFT BED REGEN HEAT RIGHT BED IN PROCESS RIGHT BED REGEM HEAT REGEN CONTACTOR CYCLES REGEN AIR FILTER These screens are used to view current hour meter and KWH meter values Note that meters can only be reset via the Setup menu Hour Meter screens see section 4 2 Users screen This screen is used to change passwords for Userl or Superl That user must be logged on to be able to change the password User2 amp Super2 passwords cannot be changed Controls 27 Splash screen Hearer Cantral Syretenm Central Drying System PLC PN 000 00000 00 HMI PN 745 0104 7 02 PLC Ver 001 100 HMI Yer 1 246 This screen is used to view the current PLC HMI software versions and software part numbers Graphical Trend screens PROCESS INLET TEMPERATURE Setpoint 175 F These screens are used to graphically track all dryer temperatures Process inlet shown above Process exit Regen heater Regen exit Dew point Controls 28 4 4 Central Drying System Additional Screens If you are operating an MDB Series Central Drying System the aforementioned control screenshots are still applicable but there are a few changes that have to be noted to some of the screens LOGOFF SETUP MENU Setup Menu Compared to the Setup Menu for the standard DryPro Control this Setup Menu does not have the Dewpoint button HOPPER MATERIALS OVERDRY PROTECT TIME amp DATE HOUR METERS SYSTEM SYSTEM SETUP LOGO
6. or maintaining this product Every six months inspect all electrical connections for secure attachment For further information see the Maintenance Chapter in this manual Every month inspect all electrical connections for secure attachment and that all warning labels are in place For further information see the Maintenance Chapter in this manual Every month check heater elements for continuity using an ohmmeter For further information see the Maintenance Chapter in this manual Mandatory Symbol Description Explanation Read Operators Manual This equipment must be operated and maintained by properly trained personnel The information contained within this manual must be read and understood prior to operating this equipment Lock Out This equipment is operated with 3 phase electrical power Therefore when performing any maintenance operations we recommend following the local standards for performing a lock out tag out procedure Vill E 4 N J SS y 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 f
7. FF System Setup The System Setup Screen for the Central Drying System does not have the Sequence Shutdown button DENSITY IN lb ft3 TEMPS IN FARENHEIT ALARM SILENCE HOPPERS DRYING HOPPERS STATUS g A Drying Hopper Status Screen lt Because CDS Systems can have many hoppers this screen was added to make each Press 19 hopper easily accessible Simply press the H hopper and its associated status screen will 0 0 CF 0 0 cr 0 0 CEM 0 0 CEM 0 0 CF appear Y INLET 0 INLET 0 INLET 0 INLET 0 Y 0 RETURN 0 RETURN 0 RETURN 0 RETURN 0 RETURN 0 Press 19 Press 19 Press 19 Press 19 Press 19 7 8 9 10 0 0 CF 0 0 CF 0 0 CFM 0 0 CFM 0 0 CF INLET 0 INLET 0 INLET 0 INLET 0 INLET 0 RETURN 0 RETURN 0 RETURN 0 RETURN 0 RETURN 0 Controls 29 4 5 Program Upgrade Procedures The DryPro PLC and touch screen use either a EEPROM module or compact flash memory card for program upgrades Occasionally a program upgrade will become available from ACS for the DryPro PLC touch screen or both Follow the instructions in this document to upgrade the specific component PLC Program Upgrade Dry Pro PLC field upgrade instructions Record current dryer settings Turn off power Remove memory cassette cover Insert Memory cassette MET Ex ss E Controls 30 Turn dip switch 2 on slide to right side 3 Peripheral USB port 4 Analog adjuster 5 Extern
8. MDB Series Dehumidifying Dryers Central Drying Systems Operation and Installation Manual Electrical Edition 50 100 150 255 CFM 85 170 255 380 M hr Part Number 882 02900 00 Bulletin Number DRY 1 690 00 Effective August 2014 Use in Conjunction with MDB Mechanical Manual 882 99969 00 CDS Mechanical Manual 882 02569 00 If Applicable an ACS company Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2014 All rights reserved Shipping Info Unpacking and Inspection You should inspect the MDB 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
9. New Berlin WI 53151 02 234 Warszawa Phone 1 262 641 8600 Phone 48 22 390 9720 Fax 1262 641 8653 Fax 48 22 390 9724 Appendix 43 8 2 Annex B Information The following design information is provided for your reference l Ze Eco a E fs 12 13 14 15 16 17 18 19 20 21 22 23 24 25 No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature 0 40 degrees Celsius Maximum 104 degrees Fahrenheit Ambient Humidity range 0 50 relative humidity Altitude Sea level Environment Clean and non explosive Radiation None Vibration Minimal 1 e machine mounting Allowable voltage fluctuation 10 Allowable frequency fluctuation Continuous 1 Intermittent 2 Nominal supply voltage Verify on serial number tag 11 Earth ground type TN system has one point directly earthed through a protective conductor Incoming Power supply should include a ground connection Over current protection is supplied in the dryer but additional protection should be supplied by the user The door mounted disconnect serves as the electrical disconnect device Dryer is equipped with a CE mark On applicable models Dryer is supplied with an operating manual in the language of the destination country Cable support may be required for power cord depending on final installation No one is required to be in the interior of the electrical enclo
10. Through this group the safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor B NEVER place your hands or any part of your body in any dangerous location B NEVER operate service or adjust the dryer without appropriate training and first reading and understanding this manual NEVER try to pull material out of th
11. 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 M MDB Dehumidifying Dryer M Bill of lading M Packing list M Operating and Installation packet M Electrical schematic and panel layout drawings M Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For immediate assistance please contact the correct facility located in the technical assistance section of this manual Have the order number and item number available Hold the items until you receive shipping instructions 111 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 materia
12. al analog settings input connector P 6 DIP switch Cassette slot Turn on Power Wait for Backup indicator to turn off Turn off power Remove memory cassette Replace cover Turn off dip switch 2 Resume normal operation Restore settings that have changed Return upgrade kit to ACS for credit Power up the dryer inspect and verify the new version number s Start the dryer as required Dry Pro HMI field upgrade instructions Turn off power Remove existing compact flash note orientation Retain existing compact flash for re installation nsert upgrade compact flash Turn on power HMI will transfer upgrade database from compact flash HMI will return to normal operation Turn off power Remove upgrade compact flash Re install existing compact flash HMI is ready for normal operation Return field upgrade kit to ACS for credit Controls 31 CompactFlash Insert Face Up Note Do not remove or insert the CompactFlash card while power is applied Refer to Front Panel LEDs 4 6 Alarms amp Faults Faults Shuts down equipment Alarms Does not shut down equipment Faults are assigned to conditions that could cause damage to either the dryer components or the material in the drying hopper while alarms are assigned to conditions that would allow an undesirable or inefficient Process condition to exist Because
13. e associated passwords Valid user names and passwords are Operl 1234 Oper2 1111 Superl 2468 Super2 1593 Operl amp Superl passwords can be changed Only properly trained and qualified personnel are allowed to use the above passwords to change any dryer settings Supervisors should keep track of these passwords and who is allowed to use them The following DryPro screenshots are for navigational reference only and do not reflect the proper settings for your drying system because application dictates the settings Itis the customer s responsibility to verify that the temperatures are applicable to the material being dried Consult the resin s manufacturer to verify these temperatures Also note that some of the settings mentioned below may not yet be available on your system Consult ACS with any questions you may have Controls 16 4 2 Standard DryPro Setup The customer can fine tune the dryer by changing values and turning options on or off All setup screens are accessed from the setup menu LOGOFF SETUP MENU HOPPER DEWPOINT MATERIALS OVERDRY HOUR METERS PROTECT TIME amp DATE SYSTEM Access to setup functions require supervisor password LOGOFF SYSTEM SETUP TEMPS IN FARENHEIT ALARM EX SILENCE MIN SEQUENCE SHUTDOWN DENSIT Y IN Ib ft3 Use the System Setup display to e Select whether temperatures are displayed in Fahrenheit or Celsius e Select metric or standa
14. e dryer with your hands while it is running Before you start the dehumidifying dryer check the following Remove all tools from the dryer e 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 1n place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration 1s 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 e 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 i
15. e left bed will be placed into Process If the left bed did not finish regeneration then the left bed will be placed into regeneration and the right bed will be placed into Process The Process blower s will start When air flow is verified all enabled heaters will begin heating the process supply air to their respective set points There is an adjustable time delay between the Process blowers starting and the drying hoppers Process supply air heaters starting to allow the Process supply air heater to come up to operating temperature The drying hoppers can be started in a staggered manner where the control waits an adjustable time between starting each drying hopper ACS recommends that the customer execute an auto tune cycle on the regeneration beds and drying hoppers when the dryer is placed into service for the first time The regeneration blower starts When air flow is verified the bed in regeneration is brought to the pre set regeneration temperature The bed remains at the regeneration temperature until either a pre set time has expired or the beds outlet air temperature rises above the Bed Break target value at which point the regeneration heaters are turned off and the bed is allowed to cool for either a pre set time period or until the bed outlet temperature reaches the Cool Down target value If the closed loop regeneration option was purchased then the closed loop valve will place the cooling bed into closed loo
16. e password is required for screens Setup Menu and Auto Start Timers Service password is required for screens Service ACS qualified personnel only Controls 23 Dryer Status screen E ACTUAL SETPOINT 75 DEWPOINT 35 A Dryer Start Stop Restart button B Dryer Status message C Auto Start Timer Active indicator D Process temperature setpoint and dewpoint E Hopper Status indicator Button Hopper color indicates status Touching hopper graphic calls up Hopper Status screen F Auto Tune Setback Active indicators Displayed only when auto tune AT is in progress or setback SB is active G Regen Status Indicators Button Regen bed and heater icons indicate status Touching any graphic of the regen system heaters beds blower calls up the Regen Status screen H Regen Heater Temperature This appears adjacent to the bed currently in the regeration cycle Each Regen heater also may indicate AT when autotune is in progress for a regen heater I Regen Exit Temperature NOTICE Touching any current temperature value will display the associated graphical trend screen Controls 24 Hopper Status screen DRYING HOPPER STATUS gt y Setpoint Actual Material PET PET Throughput 0 lb hr Residence Time 300 Min Regrind 0 Z This screen displays the current values for the drying hopper as well as allowing for changing the drying temperature Operator or above pas
17. e the phase of two legs of the three phase power drop Check for open heaters Process heaters are faulty Replace if required Loss or reduction of process Solid state Relay faulty Replace the Relay air temperature Train plant personnel about Process temperature was l l proper temperature set point improperly adjusted and operation Process heaters are faulty Desiccant beds are Replace desiccant contaminated Drying systems are designed for the material which was originally specified Different materials may need a longer residence time or different drying temperature Break in flex hose to from TPAR for air leaks replace if necessary drying hopper Material being dried differs from material specified at the time of purchase Loss or reduction in drying capacity Troubleshooting 39 Problem Possible cause Corrective action 5 Check for proper operation of DIO vaio BST valve MEE Repair or Loss or reduction in drying fango SMN replace if necessary capacity Cont d O with dusta e aus plate contaminants ae ge rao LA Replace filter elements Insufficient power to PLC Check power supply and Power LED is off power wiring to PLC T egenerallon peice Raul Phe PLO Power light is on Run light is off and or Replace PLC Error light is on Regenerating bed cool down None Verify that blower contactor is Blower Input indicator is off on Check input wiring to
18. er to abide by the foregoing recommendations in order to make operator safety a reality 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machines should become familiar with their operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No matter who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production Loss of a skilled operator temporarily or permanently Breakdown of shop morale Costly damage to equipment Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level
19. erial Overdry Protection Dryer Operating Time ee UT U oum um um o a Process Set Temperature Setback Setback Setpoint Setup Process Air Temperature Return Air Temperature Controls 21 Hour Meters Setup screens HOUR METERS 1 SINCE TOTAL SER VICE PROCESS HEATER R PROCESS AIR BLOWER R PROCESS AIR FILTER R REGEN AIR BLOWER REGEN AIR FILTER REGEN HEATER LOGOFF HOUR METERS 2 SINCE TOTAL SER VICE LEFT BED IN PROCESS R 0 LEFT BED REGEN HEAT R 0 RIGHT BED IN PROCESS R RIGHT BED REGEN HEAT R REGEN CONTACTOR CYCLES R REGEN AIR FILTER CR Use these screens to view and or reset the various hour meters associated with the dryer To reset a meter press the R button for 3 seconds Note that only the Since Service values are resettable Additionally hour meters can be viewed via the Main Menu screen but not reset Controls 22 4 3 Dryer Operation Screens Main Menu screen LOGOFF Users Eu ene sa Sa a TEAN LN LAM The Main Menu is the main navigational screen for the DryPro control system Password Requirements No password is required to access screens Dryer Status Regen Status Alarms Hour Meters Splash Screen Logo Icon and Users Screen Users Screen functionality depends on current password access Operator or above password is required for screens Hopper Status Supervisor or abov
20. l Dau ted 30 4 6 Alarms amp Faults recta tee te ero ett imc astm eo eie een ueste Pus I atte od aspe ER e beu 32 IMPR E gn T I E O O E E 33 CHAPTER 9 OPERATIONsisiiuiacvesaE RU EDEN EVE bl 34 9 1 oPre 5tartup CHECKS aos i n 34 9 2 SA s 34 5 3 How the Dryer Operates after Startup cooccccccoccocncoccocnconconnnonnonncononnncononnnnanonnnnnnos 35 AAA 36 CHAPTER 6 MAINTENANCE eee nnne 37 MERI dil nidad aiiac s 37 6 2 Preventative Maintenance CheckliSt oocooocccnnconncocncocncocnoncnconnconnconnnonncncnoncnnns 38 CHAPTER 7 TROUBLESHOOTING 39 Determining Temperature Controller Errors or Sensor Errors eese 41 CHAPTER 8 APPENDIAX ccccccceceececeecencecenceceececeeceneess 43 8 1 PECMMICAl ASSISISITOG einig cti cst etu tet bt M Mer vot e olia delete ad tiet E han D SEE 43 Patsand service Debarelib sweat tuom Ia EEUU EM Ud Feat eR an 43 Sales and Contracting Department sessi nennen nena nna nns 43 9 2 JANINE em informato mM sareei TEE 44 Sd REVISIONS Idle date it c E mE d Le Nd ME 45 vi Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining the mid sized dehumidifying dryer The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light co
21. l 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 1V Table of Contents CHAPTER 15 SARE irse VII 151 Howto Use TRS Manual 3 oit sce eee Lee unten a a ease Ree eu eee Pa ux IUE vii Safety Symbols Used in this Manual sessi esee Vil t2 Warnings and PrecaullofTSissceedss steadier eei ree ee na ober dee eed emt een i duit emt rotas lie e Ix ES RESPONSE dl add X Generar fsesDOHSIDIIV st ii X Operator Responso cosciente E FEE Crn D ua er EROR REY C x daa er Date RES Qtr X Maintenance Respo
22. nsibility 5 asi ear eoe o a pauco ca eae bae teu Feb Le vaa uade XII Reporting a Safety Defect eae anra ia Xii CHAPTER 2 GENERAL INFORMATION 13 2 1 Models Covered in This Manual cooccccnccccccncnccocncoccnnnnnnonnnnnnonconaroncnnanonnnnnnnnnnnanons 13 2 2 Necessary DOCUMENT pereant dune s uus 13 2 9 JXoOnWolFEealules rq eee ibt sionibus dcum em ance eatuiesu s au erai duas 13 2 4 Salety Feall eS eei ee a enc bet teneo svn dnte ei vea ie acd ted 14 CHAPTER 3 INSTALLATION sisas 15 8 1 Positioning YOU Di i diede once eeu rd En e Exe uk tuas oe eo descen beet d Eau 15 3 2 Making Electrical CONNECtIONS occoncoccconcccnconiccnconoconcnnonnnnanonnnnononnnnononnnnanenanennos 15 3 3 Checking for Proper Blower Rotati0ON oocooccoccnoccnoconocononononononononononononononanonanos 15 F ree rnase MOS cu estat d ei ee asad ae dte esie RU t cM EU 15 CHAPTER 4 CONTROLS iaa 16 As JDDIyPIO Data Ely csset aiite e de A as 16 4 2 Standard DryPto SetuP usce eee en yee pce ce t eig pa ee tas Econ ved ep su dore pega tes 17 4 3 Dryer Operation Screens sssssssesssseeesen eene nennen nnn nennen nnns n as 23 4 4 Central Drying System Additional Screens c oocccccccccncccncocncocncocncncnnncnnnnonononanonaninoss 29 4 5 Program Upgrade Procedures eie o rra Pate cest no DES nne cane gor E Beo EN Ee ad 30 PEE ProoranbU DOT AA accitis A in su sumta U
23. oceed using the following steps Y Locate the inlet and outlet ports on the side of the dryer where the hopper is attached to the dryer Place your hand over each port and verify that the return inlet has a vacuum present and that the outlet has pressure Y For the regenerative cycle blower there should be pressure leaving the exhaust port on top of the dryer and a vacuum present at the inlet of the regen filter In three phase models incorrect phasing of power leads can cause backward rotation of blower motors and CONTAMINATION OF THE DESICCANT Always check blower rotation before putting material in the drying hopper If the three phase blower rotates improperly reverse any two wires at the fused disconnect in the control enclosure This assures that the blower rotates in the proper direction Refer to the electrical schematics supplied with the control to verify the wiring Installation 15 Chapter 4 Controls 4 1 DryPro Data Entry Values and text are changed using on screen keypads The screen will display either a numeric or alphanumeric keypad depending on the type of data entry The appropriate keypad appears when a changeable value is pressed Minimum amp maximum values are indicated for each numeric value Values outside of these limits are rejected Passwords All functions except starting and stopping the dryer require a password Operator and supervisor access require the entry of a valid user name and th
24. ollow these safe practices T S KK KE KK T Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power When welding or brazing in or around this equipment make sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be nearby and ready for use if needed Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a us
25. ou 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 1 e lockout tagout or failure to maintain a clean and safe working xii Chapter 2 General Information 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for the MDB Series Dehumidifying Dryers with DryPro control Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service Our dehumidifying dryers are designed to generate heated dehumidified air at carefully controlled temperatures for use in closed loop plastic drying systems Moisture removal from hygroscopic moisture attracting plastic pellets is an essential step in the manufactu
26. ower supply terminals of the controller Check control power fuse for continuity Turn disconnect switch and control power switch ON Nothing displays when the PID controller is turned on No power is supplied or the supplied power is not within the specified range Disconnect switch or Control Power switch not set to ON Control Power fuse blown et ii Properly wire the terminals pd Negative is always red connection is wrong No compensating lead wires used for extension of the thermocouple Use proper compensating lead wires and terminals Use a dedicated thermo couple connector If a connector is a metal different from the thermocouple and controller a temperature error may result Sensor is broken or short aoe Replace with a good sensor circuited The controller is influenced separe nM oc e tar as possible from the origin of by noise or other induction the noise Celsius temperatures used Setup mode level 2 display instead of Fahrenheit or vice d U S V display shows versa setting Use Un Grounded Thermocouple Thermocouple and controller are connected by wires other Process value is abnormal or l than proper lead wires not obtained Grounded Thermocouple Determining Temperature Controller Errors or Sensor Errors Using a Thermocouple If the controller displays a temperature that is close to room temperature 70 F 21 C when you short circuit controller input terminals
27. p cooling as opposed to ambient cooling when the bed outlet temperature reaches the Closed Loop target value The pattern continues until the dryer is shut down by pressing the Stop button on the Dryer Status screen or the auto start feature reaches a preprogrammed stop event time However it is stopped the DryPro control puts the dryer into a sequenced shutdown e The drying process supply air heater s shut down and then the Process air blower shuts down after an adjustable delay and below an adjustable temperature e Any running regeneration cycle is allowed to finish and then the regeneration blower is shutdown e The dryer can be re started by pressing the Restart button on the Dryer Status screen Operation 35 5 4 Shutdown 1 Turn off the conveying system supplying the drying hopper 2 When processing is complete close the hopper slide gate and shut down any in line companion equipment such as the aftercooler 3 Press STOP on the Dryer Status Screen The sequence shutdown operation turns off process heaters and keeps the process blower on for twenty minutes to cool down the process The regeneration cycle of the off line bed completes the cycle before the dryer shuts down completely 4 To override the sequence shutdown turn the system ON OFF switch to OFF 5 To completely shut off the unit after sequence shutdown has completed turn the system ON OFF switch to OFF 6 Ifneeded empty the drying ho
28. pper 7 For maintenance or a long term shutdown open de energize the electrical disconnects at the dryer and at the power drop Operation 36 Chapter 6 Maintenance 6 1 Work Rules The installation operation and maintenance of this equipment is to be conducted in accordance with all applicable work and safety codes for the installation location This may include but is not limited to OSHA NEC CSA and any other local national and international regulations In addition you must observe the following specific work rules M Keep these operating instructions on hand and follow them when installing operating or maintaining your dryer M If these instructions become damaged or unreadable you can obtain additional copies from the manufacturer M Only qualified personnel familiar with this equipment should work on or with this unit M Work only with approved tools and devices E Disconnect power before servicing your dryer If the disconnect switch you installed has a lockout lock it in the OFF position before you perform any maintenance or service p youp y Maintenance 37 6 2 Preventative Maintenance Checklist Dehumidifying Dryer Systems System model Everv week Date Date Date Date Date Date Date Date Date Date Date Date Date dea By By By By By By By By By By By By By Inspect all filters for wear replace clean if dirty or worn Lock out electrical power and in
29. rd measure for volume amp density e Set the alarm silence duration e Setup Sequence Shutdown which allows the blowers to run for an additional set amount of time to cool off the system Controls 17 Hopper Setup LOGOFF DRYING HOPPER 1 SETUP Setback 0 m gt Actual Qe _ Normal SP HOPPER 1 AUTOTUNE PBT PET NA 111 0 LB HR 240 Min 96 Regrind 0 1 00 CFM LB HR Use the Hopper Setup screen to 1 Set the normal process temperature setpoint The material saver setpoints are set on the Overdry Protect Setup screen 2 Set the deviation limits for process temperature alarms Also set the standby time to allow the drying temperature to rise to the set value at system startup 3 Set the process ID for the hopper This can be a press ID product name or any other value that makes sense Also the hopper volume and heater KW are set These values are used in throughput and K WH calculations 4 Press the material name to call up the Material Select screen described below Selecting a new material recipe when the system is idle will automatically change the drying temperature setback temperature residence time and density If the dryer process is running selecting a new material has no effect on current settings 5 Press the Autotune button to call up the Process Autotune screen described below Controls 18 Material Select Screen y Material Select ES Residence Dry E Name Time temp Density
30. re in use and OFF otherwise fa value is less than a pre set limit o Process supply air temperature low deviation alarm Ifa value is greater than a pre set limit o Dryer high dew point alarm Fault List The following list describes all of the faults the control can detect Those described as faults are critical and will shut down the process regen or both subsystems Process blower air flow pressure fault Regen blower air flow pressure fault Closed loop CL valve position fault Left or right bed safety temperature faults Left or right bed high deviation faults Process air valve PRAV position fault left or right bed inlet outlet TC sensor faults Hopper 1 3 safety fault Hopper 1 3 high temperature deviation fault Hopper 1 3 inlet outlet TC sensor faults Controls 33 Chapter 5 Operation 5 1 Pre Startup Checks Verify that the drying hopper s is clean of rust prohibitive oil or any foreign objects Verify that process and return hose connections are tight If your dryer has a water cooled Aftercooler or Precooler make sure that sufficient cooling water flows properly through the coil and that you have bled any trapped air from the system Make sure that the Aftercooler or Precooler or closed loop cooler has the proper supply water temperature Check all companion equipment such as the sight glass loader and drying hopper loader verify that all convey tubing is in place and the loading system is read
31. re of high quality plastic products Our dehumidifying dryers are used to generate very low dew point air heated to a controlled temperature for drying plastic pellets and regrind Necessary Documents The documents listed below are necessary for the operation installation and maintenance of Cabinet Series dehumidifying dryers You can obtain additional copies from the manufacturer Make sure that the appropriate personnel are familiar with these documents M This manual Along with MDB Mechanical manual 882 99969 00 M The schematic and assembly drawings included in the customer information packet M The Customer Parts List included in the information packet M Operation and installation manuals for any optional controls or auxiliary equipment in the drying system Control Features e PLC based control platform e 5 7 full color touchscreen display Multiple communications options through HMI including Ethernet and RS 232 Serial communications e Individual hopper controls that communicate with main PLC e Support for up to 3 hoppers on MDB product line More than 3 with the CDS DryPro Control e Desiccant bed switching on either dewpoint or time e Material saver feature to control process heater should process become idle or slow down e Desiccant bed break temperature monitor to prevent desiccant from becoming heat damaged e 7 day timer for automatic startup e Dirty filter indicator e Expanded system diagnostics
32. rrective maintenance No other maintenance should be undertaken without first contacting a service engineer The General Information section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the mid sized dehumidifying dryer We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the dryer These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Controls and Operations chapters include a description of electrical and mechanical controls in addition to information for operating the dryer safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that the dehumidifying dryer provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible cau
33. ses and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation or practice that if not avoided ACAUTION may result in minor or moderate injury or in property damage vll Dryer Safety Tags Hazard Alert Symbol Description Explanation High Voltage Hazard The electrical enclosure is supplied with 3 phase electrical power Use caution when using or maintaining this product Auto start Hazard Equipment may start at any time Lock out tag out before servicing the machine Hot Surface Hazard When the unit operates above 212F 100C the surface of the unit may reach excessive temperatures Use caution when using
34. spect 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 Actual inspection Next scheduled Actual inspection inspection Date By inspection Date By Inspect desiccant Replace if brown or broken Scheduled Actual replacement Scheduled Actual replacement Every two ye ata replacement date Date Work done by replacement date Date Work done by Photocopy this page for your maintenance records Maintenance 38 Chapter 7 Troubleshooting Dirty filter Clean or replace filter Desiccant beds are contaminated by material or plasticizer leaking into the system Blower overload has tripped Reba conan owen reset the overload Blower fins filled with dust or Remove blower side plate contaminants clean baffles replace Stop the dryer Replace desiccant Little or no air coming from the process delivery tube If the dryer was connected to the drying hopper check to see if the desiccant and process air heater has been contaminated with resin Suction in delivery tube pressure from the return tube Phase is reversed on power drop coming into the dryer If so replace the desiccant and remove any resin carry over Otherwise chang
35. stserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com India 91 2032533552 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 2032533552 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more information please visit us at www acscorporate com Asia Australia United States ACS Suzhou ACS Schaumburg 109 Xingpu Road SIP 1100 E Woodfield Road Suzhou China 215126 Suite 588 Phone 86 8717 1919 Schaumburg IL 60173 Fax 86 512 8717 1916 Phone 1 847 273 7700 Fax 1847 273 7804 Europe Middle East Africa ACS New Berlin ACS Warsaw 2900 S 160 Street UI Dzia kowa 115
36. sure during the normal operation of the unit Only skilled electricians should be inside the enclosure for maintenance Doors can be opened with a screwdriver but no keys are required Two hand control is not required or provided MDB Dryers are designed to be wheeled into place If a hopper is attached the hopper must be empty while moving the dryer There are no frequent repetitive cycles that require manual control repetitive functions are automatic while the dryer is operating An inspection report detailing the functional test 1s included with the dryer The machine 1s not equipped with cableless controls Color coded harmonized power cord is sufficient for proper installation Appendix 44 8 3 Revisions Made Revision Bulletin Number Revision Date Changes Made Appendix 45 Notes Appendix 46
37. sword access is required As with the Dryer Status screen touching any current temperature value will display the associated graphical trend screen Regen Status screen REGEN STATUS Total Time Q0 Min Remain 0 Min Heat Time 0 Min Remain 0 Min Cool Time o Min Remain O Min DEWPOINT 35 F i LEFT BED REGEN EXIT 200 F HEATING Bed Break 0 F REGEN HTR 575 SETPOINT O This screen displays all current status values for the regen subsystem As with the Dryer Status screen touching any current temperature value will display the associated graphical trend screen Controls 25 Setup Menu screen See section 4 2 Auto Start Timer screen AUTOSTART TIMER hs IA SUN 2 00 AM 2 00 AM MON 2 00 Ah 2 00 Ah TUE 2 00 OM 2 00 AM WED 12 00 AM 12 00 AM THU 2 00 AM 2 00 AM 2 00 Ah 2 00 AN 12 00 12 00 Alv This screen is used to control the auto start functionality of the dryer AutoStart must be enabled for entered times to take effect A value of 12 00 AM is considered a non value and has no effect This screen requires supervisor password access Alarm History screen This screen displays a list of alarms that have occurred with descriptions and time Stamps Controls 26 Hour Meter Display screens HOUR METERS 1 SINCE TOTAL SER VICE PROCESS HEATER PROCESS HEATER KWH PROCESS AIR BLOWER PROCESS AIR FILTER REGEN AIR BLOWER REGEN HEATER HOUR METERS 2 SINCE TOTAL SER VICE LEFT BED
38. t from the power source X1 Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical and pneumatic power Attach warning tags to the disconnect switch and air shutoff valve When you need to perform maintenance or repair work on a dehumidifying dryer above floor level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk on your dryer use it The work platform should have secure footing and a place for tools and parts DO NOT climb on the dehumidifying dryer machines or work from ladders 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 y
39. the Process and regeneration systems of the dryer operate independently it is possible that a condition exists in the regeneration system that prevents it from operating while the Process system continues to operate without error Controls 32 When a fault or alarm condition occurs the screen displays an Alarm Banner showing the time date and a brief description The control will turn on an indicator light and an audible indicator when a fault or alarm occurs The alarm banner and light do not distinguish between faults and alarms The audible indicator can be silenced and the light turned off by pressing the Push to Silence button on either the alarm banner or alarm history display However depending on the customer s setup the audible indicator and the light may repeat after a pre set time if the alarm or fault condition still exists If a dryer fault occurs then either a Process Fault Push to Reset or a Regen Fault Push to Reset button appears on the overview displays Press the button to restart the failed system once the nature of the fault is understood and corrected If a drying hopper fault occurs then disable and re enable the drying hopper once the fault has been corrected Alarms generally take the following forms e f something should be ON and it s OFF or vice versa o Blower Motor Overloads should always be ON o Heater isolation contactors should be ON when the heaters a
40. the controller is normal and the sensor is probably broken short circuited or incorrectly wired Using a Platinum Resistance Thermometer Troubleshooting 41 If the controller displays a temperature of about 0 0 C 32 F when you insert a 100 ohm resistor between terminals A and B of the controller and you short circuit controller terminals B and B the controller is normal and the sensor is probably broken short circuited or incorrectly wired Troubleshooting 42 Chapter 8 Appendix 8 1 Technical Assistance Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service For immediate assistance please contact e North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com e Mexico Central amp South America Email acslatinamericacu
41. w button to create a new blank recipe Pressing the New or Copy button calls up the New Material Setup screen ZA New Material Setup Configure Material MFR Name Regrind Pct Cancel Material Density 1 000 cm3 BRL Use this screen for entering data for new recipes Pressing the Save button will write the new recipe to Compact Flash and return to the Material Setup screen Pressing Cancel will return to the Material Setup screen without making a new recipe Controls 20 on OTD 30 d Overdry Protect Setup screen LOGOFF SETBACK DISABLED SETPOINT OVERDR Y PROTECTION Setback F Setup C SETBACK ON TEMP ST ONLY SETBACK E C conver EU DELAY hin SETBACK BU mresiperice MN DELAY MIN TIME MIN Use this screen to configure overdry protection for your material Setback setpoint is the secondary drying temperature to use Setback is the hopper exit temperature that will cause the secondary setpoint to be activated Setback Delay is how long the exit temperature must be above the Setback setting before setback is activated Setup is the hopper exit temperature that will cause the drying temperature to be returned to the normal setpoint Additionally material setback can be activated based on convey activity from the hopper If selected a lack of convey activity for the set by Convey Delay will trigger setback but only after residence time has been satisfied Mat
42. y for operation Verify that all electrical connections are tight and the unit is properly grounded With main power on turn the dryer on until the process and regen blower starts verify blower rotation see section 3 3 Clean the rust preventing oil from inside the drying hopper Failure to clean the hopper fouls the desiccant and voids your warranty 5 2 Startup Turn on energize the disconnect switch in your power drop Turn the system ON OFF switch to ON to energize the display panel Close the slidegate at the bottom of the drying hopper s On three phase models make sure that the blowers turn in the right direction Fill the drying hopper with material Press START on the Dryer Status screen to start the system The process blower will start Set the process set point on the controller to the recommend drying temperature provided by the resin manufacturer Press and hold the Auto Tune key on the controller for two 2 seconds to initiate the auto tune function After the proper pre drying time for the initial hopper fill has elapsed fully open the drying hopper slide gate To allow proper residence time during continuous processing maintain the material level in the hopper at the midpoint of the air trap assembly Operation 34 5 3 How the Dryer Operates after Startup The main air valves will find home position If the left bed finished regeneration then the right bed will be placed into regeneration and th
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