User Manual
Contents
1. Error light is on Regenerating bed cool down None Verify that blower contactor is Blower Input indicator is off on Check input wiring to PLC Left Right output indicators temperature condition Power light is 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 9 Verify correct Celsius or Fahrenheit settings Burned out regeneration Repair or replace heater Contaminated or worn out desiccant Leaking process air hoses Repair or replace 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 54 Possible cause Corrective action The Din PID Controller is not Properly insert the controller inserted properly into the into the housing housing The power supply is not Properly co2. 4 Remove the bolts securing the heater plate assembly and slide out the assembly 5 Remove the heater from the mounting plate by removing the large brass nuts and washers 6 Re install the heater and heater plate assemblies in reverse order Install new heater gaskets and securely tighten all fasteners NCAUTION Heater loops should not touch each other Hot Spots lead to premature heater failure 7 Reinstall the wires based on the sketch you made earlier 8 Secure the heater access cover PROCESS HEATER MDB85 amp MDB170 MDB255 amp MDB380 PROCESS HEATERS Maintenance 48 MDB85 amp MDB170 Process Heater Process Heater Manifold Heater Gasket A0534251 Hex Cap Screw M6x1 0x16 M6 Lock Washer M6 Flat Washer High Temp Disconnect Switch 0566676 M3 Lock Washer 8 Socket Head Cap Screw M3x0 5x8 G12 pont gs Hardware is Metric Units Unless Specified MDB255 amp MDB380 Process Heater Process Heater Manifold Heater Box Cover Heater Gasket W00012917 Hex Cap Screw M6x1 0x20 Hex Cap Screw M6x1 0x16 M6 Lock Washer M6 Flat Washer Se e Hardware is Metric Units Unless Specified Maintenance 49 5 8 Replacing the Regeneration Heater The dehumidifying dryers use heater elements located below each desiccant bed AWARNING Disconnect and lock out power before you replace heater elements 1 Remove the cover plate secured by bolts Sketch th
3. Delivery Port Note The return port is hosed to the process filter inlet Regeneration Blower Regeneration filter Installation The regeneration filter inlet shown should be sucking air in for the regeneration cycle 30 3 3 Process Air Connections Between the Dryer and Drying Hopper Remove the cap plugs from the inlet discharge and bleed tubes before operation M Use high temperature flexible dryer hose to connect the dryer to the drying hopper Keep the delivery hose as short as possible to minimize heat loss Insulated dryer hose is available for maximum energy savings Do not shorten the return hose Make sure the hoses are not kinked Drying hopper air inlet and outlet locations vary from one drying hopper model to another but always connect the hoses so the dry process air from the dryer enters the bottom of the drying hopper and flows out the top to return to the dryer inlet 3 4 Connecting Cooling Water to the Optional Aftercooler Precooler High temperature applications 250 F to 400 F 121 C to 204 C require aftercoolers to cool moist air returning to the dryer from the drying hopper An aftercooler cools the return air by 100 F 38 C this maintains dryer efficiency and condenses unwanted plasticizers from the air stream Heat Exchangers are also required called pre coolers when processing materials that have extremely low drying temperatures typically 120 to 180 49 C to
4. 235 2 99 76 23 50 597 49 84 1266 01 20 1550 4 x 0 51 13 11 02 280 E EEES 778 15 1985 80 27 2053 96 57 2453 3 50 89 13 78 350 14 96 380 4 92 125 39 06 992 General Information 27 2 8 Silo Dehumidification System Airflow range Mid Size 50 225 cfm N In most cases 50 cfm dryer not be adequate Metal silos are affected by the weather conditions surrounding them They can become damp internally from sweat on their sidewalls caused by changes in humidity and temperature and this moisture can be transferred to the material stored in the silo Silo dehumidifiers are not intended to dry the material stored inside the silo Silo dehumidifiers operate on the simple principle of providing a blanket of dry air the space above the material to keep the material from picking up additional moisture while in storage Silo dehumidifiers are usually installed in the base of a silo One dehumidifier may serve more than one silo if sized properly depending on the location and climate conditions The process heater is usually removed from the desiccant dryer not required The process delivery air is driven to the top of the silo up the bulk material air delivery tube There is usually an air feeder tap line with a shut off valve special tube assembly kit sold with the dryer to be installed in the truck fill line Never run the silo dehumidificatio
5. 82 C Check your specific dryer model technical specifications for actual requirements Some models have a minimum low end temperature range that will determine actual requirements Installing Water Lines e Use the gt about 13 mm brass pipe nipples for water line connections Inlet and outlet line positions do not matter e Make sure you grip the nipple tightly when attaching a fitting Doing so prevents damage to the soft copper coils You should make connections with flexible hose to allow removing the coil assembly for cleaning e The aftercooler is designed to utilize either tower or city water as warm as 85 F 29 Recommended flow rates Water Flow Gallons Per Minute Liters Per MDB Model Minute 2 7 6 MDB85 3 11 4 MDB170 4 15 1 MDB255 7 26 5 MDB380 Installation 31 3 5 3 6 Optional Plasticizer Trap Plasticizer traps should be used when resins are processed in the family of acetates butyrates and or propionates They should also be used when any resin when dried is known to produce residue contaminates or volatiles This contaminate is trapped in the air stream and 15 carried back from the drying process as the air leaves the drying hopper The plasticizer trap will condense the contaminate that is in the air stream and remove it before it enters the dryer unit If this contaminant is not removed it can foul the desiccant beds and damage mechanical components in the dryer and in the d
6. ACS right away for assistance Avoid changing any parameters or settings of your sensor until you have talked with a qualified ACS Service Technician You will find phone numbers at the end of this manual in the Appendix chapter Maintenance 42 5 5 Symptoms of Worn Desiccant The moisture absorption capacity of the desiccant used in your dehumidifying dryer degrades after an indefinite period of time Useful life depends on variables such as material moisture content plasticizer vapors in the return air and number of regeneration cycles Your dehumidifying dryer may need new desiccant if it exhibits any of the following symptoms Plastic material is not being dried sufficiently high scrap reject rate Air temperature at the top of the regenerating desiccant bed rapidly climbs to 350 F 177 C or more shortly after the start of regeneration even though a saturated bed has just started heating The process air dew point measured with a portable dew point monitor 15 higher than 10 F 23 C throughout the process drying cycle Smoke or dust blows out of the process air outlet Noticeable amounts of desiccant in the beds is a medium brown color or darker If you notice any of these signs replace the desiccant in the desiccant beds Desiccant replacement kits are available from the manufacturer s parts department If you want a service technician can repack desiccant beds at your site First Aid Desiccant material cause
7. 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 the dryer with your hands while it is running Before you start the dehumidifying dryer c
8. 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 SAFETY Vil 151 Howto Use This Manual ta east Sereda cleanses vii Safety Symbols Used in this 2 7 2 00 00 600006000000 vii 1 2 Warnings and PrecautOnNS na ober dee eed emt een E ral a Ix 152 dIRESDOMSIDINNY X Generar oca emen intentio ads mti Ub Uu Tua X Operator Responso resie
9. is used in conjunction with a conveying system the dryer and all applicable drying hoppers should be placed within a reasonable distance from the other auxiliary equipment NCAUTION Use caution and observe safety rules when placing your dryer Never move your dryer when the hopper s are full of material Make sure the wheels have been locked after placing your dryer 3 2 Checking for Proper Blower Rotation Three Phase Models To check each blower for proper rotation proceed using the following steps 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 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 Installation 29 Process Blower The air connection marked Delivery should be blowing air while the Return connection has suction Return Port
10. or resistance of the dew point sensor The sensor will be destroyed MAKE SURE GASKET SUPPLIED WITH 717 10093 00 IS PLACED IN BETWEEN THE TEST CHAMBER AND DEW POINT SENSOR COIL COPPER TUBING A MINIMUM OF 5 TIMES 1 Sensor Test Chamber 4 1 0 35 HCS 5 M xl 0x16 HCS 2 Dewpoint Sensor 717 10093 00 6 M6 Lock Washer 7 6 Flat Washer 3 Clamp A0069007 Maintenance 4 8 Hex Jam Nut 10 Copper Tubing A0006071 9 6mm Hi Temp Tubing 207 00132 00 Dewpoint Monitor Troubleshooting If the DryPro Control 15 displaying erratic Dewpoint values you will want to check that your Dewpoint sensor is operating properly Keep in mind that it may take up to 6 minutes for the sensor to start operating normally after startup due to automatic calibrations within the sensor If you still suspect that there are errors in the Dewpoint readings follow the below guidelines for possible solutions 1 Check the Alarm LED on the Sensor Not lit Power off or LED functionality disabled Green Power on normal measurement Green and blinking Purge or Autocalibration in progress Red Dewpoint above limit Red and blinking Transmitter error 2 For Transmitter error try disconnecting and reconnecting the power to the Dewpoint sensor to see if the problem persists 3 Check the surrounding tubing for leaks as this could add ambient air to the airstream and throw off the Dewpoint readings If the problem persists contact
11. 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 injury are failure to follow proper operating procedures 1 e lockout tagout or failure to maintain a clean and safe working area xii Chapter 2 General Information 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for 50 100 150 and 225 cfm Dehumidifying Dryers with DryPro control Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service Our dehumidifying dryers are designed to generate heated dehumidified air at carefully controlled temperatures for use closed loop plastic drying systems 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
12. 892 04200 00 Aftercooler Precooler 892 06013 00 MDB380 Cabinet Assembly 892 03418 01 Tray Shelf Assembly 892 04317 01 Valve Assembly Upper 892 04200 01 Valve Assembly Lower 892 04200 00 Aftercooler Precooler Appendix 27 7 2 Additional Spare Parts lw pue NC CF CF CF A E W 2 5 ea 208V 230 460V A0536628 A0536628 A0534079 A0534079 gt EAR 25 0536631 208 9kW A0534093 A0534093 230V CF CF 9kW 9kW A0536632 A0536632 380V 9kW 9kW Regen Process Htr Elements A0536633 415V 9kW 0534092 40534092 00015855 W00015859 9kW 9kW 3 5kW 5kW A0535354 9kW 3 5kW W00015855 W00015855 W00015855 00015855 W00015856 W00015856 W00015856 W00015856 CF Consult Factory 575 un lt E gt D eb e Appendix 58 7 3 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 dedi
13. A certified copy of our invoice is available upon request The original Bill of Lading 15 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 MDB Dehumidifying Dryer Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For immediate assistance please contact the correct facility located in the technical assistance section of this manual Have the order number and item number available Hold the items until you receive shipping instructions 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 material purchased
14. EDIA 2 2 2 STANDARD HOSE CONNECTION DIA 25 63 5mm LENGTH ELECTRICAL MECHNICAL CONTROL CIRCUIT 120VAC 24VDC CONTROL TYPE CONTROL INTERFACE HMI TOUCH ELECTRICAL ENCLOSURE DRYER AMP DRAW LOW HEAT AND HIGH HEAT OPERATING RUNNING AMPS APPROXIMATE VALUE BASED ON TYPICAL OPERATING LOAD VALUES COULD BELESS General Information 22 255 REGENERATION AIR FLOW EXIT HMI TOUCH CONTROL INTERFACE ON OFF REGEN FILTER OR 3 5 O D PROCESS 2 SR 3 BLOWER FRONT ACCESS DOOR REMOVED HEIGHT REAR ACCESS DOORS REMOVED us ACCESS DOORS REMOVED General Information 23 150 256 AR O OO STANDARD HOLE CONNECTION DIA 35 69mm DIMENSIONS AND WEIGHT LENGTH 39in 99 mm WIDTH 37 in 940 mm HEIGHT 73 1854 mm APPROX SHIPPING WEIGHT 750 LBS 341 kg ELECTRICAL MECHNICAL CONTROL CIRCUIT 120VAC 24VDC CONTROL TYPE CONTROL INTERFACE HMI TOUCH ELECTRICAL ENCLOSURE DRYER AMP DRAW LOW HEAT AND HIGH HEAT OPERATING RUNNING AMPS 9 9V 3 60Hz 33 0 26 4 APPROXIMATE VALUE BASED ON TYPICAL OPERATING LOAD VALUES COULD BE LESS General Information 24 380 REGENERATION AIR FLOW EXIT HMI TOUCH CONTROL INTERFACE ON OFF CONTROL REGEN FILTER PROCESS RETURN FILTER RETU 35 OD N caver REGEN BLOWER PORT 35 OD PROCESS BLOWER FRONT ACCESS DOOR REMOVED REGEN
15. ER 72 APPENDIX tuaPEx Ex UpE Tc YES RuYEEE 57 57 MD BOO RAE 57 57 E 57 7I B2 6750 EE 57 7221 TAGGING Mal mea 58 753 59 Parts and Service 0 000006 59 Sales and Contracting 2 0 060000000000 nennen nena nna nns 59 Annex 60 1 9 Revisions to MANUAL pter Du mel pedro e 62 vi Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining the mid sized dehumidifying dryer The purpose 1 to assist you applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The General Information section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational p
16. ERATION AIR FLOW EXIT 2 50 O D HEIGHT REAR SIDE ACCESS DOORS REMOVED PROCESS ACCESS DOORS REMOVED deret General Information 25 225 380 m hr 160 F 400 F 71 C 204 C 70 F 21 C 5 0 hp 3 73 kw 0 5 hp 37 kw 4 5 5 0 kw 20 kw 4 HTRS 3 5 kw 14 kw DIMENSIONS AND WEIGHT NGH 89 iN 991 mm APPROX SHIPPING WEIGHT 850 LBS 386 kg ELECTRICAL ENCLOSURE 12 DRYER DRAW STANDARD VOLTAGE FULL LOAD AMPS LOW HEAT AND HIGH HEAT OPERATING RUNNING AMPS 208V 3 60Hz 95 76 6 220V 3 50Hz 90 5 72 4 230V 3 60Hz 88 6 A 69 3A 400V 3 50Hz 49 BA 39 8 460V 3 60Hz 43 34 6 9575V 3 60Hz 33 0A 28 0 APPROXIMATE VALUE BASED ON TYPICAL OPERATING LOAD VALUES COULD BE LESS General Information 26 2 7 WH Series Drying Hoppers Model 13 wo i768 i Inm Model Capacity cus ters cu Capacity cus ters liters kgs kgs WH75 2 65 75 99 21 Wut 350 100 D 11023 520 180 756535 wo 70020 Ema 7 06 200 60 2 36 90 198 42 DORSO _ 1060 300 14 13 400 23 62 600 WH600 2362 600 WH800 31 50 800 17 20 437 40 1 11 7 20 437 gos 19750 6 10 155 4 0 51 13 353 185 Er 02 280 ENE 20 31 516 1 06 916 44 33 1126 4 97 50 8 26 210 9 25
17. 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 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 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 56 Chapter 7 Appendix 7 1 Mechanical Drawings Below is a list of drawings available from ACS Group pertaining to the maintenance and construction of your MDB series dryer Contact ACS to request any of the drawings and a document will be sent to you in the format you require MDB85 Cabinet Assembly 892 03418 00 Tray Shelf Assembly 892 043 17 00 Valve Assembly Upper 892 99355 00 Valve Assembly Lower 892 04198 00 Aftercooler Precooler 892 06288 00 MDB170 Cabinet Assembly 892 03418 00 Tray Shelf Assembly 892 043 17 00 Valve Assembly Upper 892 03732 01 Valve Assembly Lower 892 03732 00 Aftercooler Precooler 892 06289 00 MDB255 Cabinet Assembly 892 03418 01 Tray Shelf Assembly 892 04317 01 Valve Assembly Upper 892 04200 01 Valve Assembly Lower
18. HOPDEIS sussa tes maneret te 27 2 8 Silo Dehumidification 5 28 CHAPTER 3 29 S21 jPOSIMIOMING Your DIV CF dE 29 3 2 Checking for Proper Blower 29 Ihree rFnase MOC CIS r du tul ones 29 3 3 Process Air Connections Between the Dryer and Drying Hopper 31 3 4 Connecting Cooling Water to the Optional Aftercooler Precooler 31 Water LINES sma es 31 do Optional PIASUCIZEN TTA da 32 9 0 Drying eae 32 Removing INC RUSE INDIO sss 32 AIF Jap ConsidefalloriSc ctetu mo T 32 3 33 EE 33 PET 34 30 DewDOIDUSSlSOL sess sta dla 35 3 9 Dirty Filter Pressure 35 3 10 Blower Pressure Switches 2 8 nnne nn nen 36 CHAPTER OPERATION 37 4 1 CICS ss gu 37 CHAPTER 5 38 o MEME NONE 38 5 2 erviclhg All Fillers uie ese ce su
19. MDB Series Dehumidifying Dryers Operation and Installation Manual Mechanical Edition 50 100 150 255 CFM 85 170 255 380 Part Number 882 99969 00 Bulletin Number DRY1 685 01 Effective August 2014 Use in Conjunction with MDB Electrical Manual 882 02900 00 CDS Mechanical Manual 882 02569 00 If Applicable an ACS company Write Down Your Serial Numbers 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 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
20. 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 actual or potential danger areas must be reported to your immediate supervisor General Responsibility No matter who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production Loss of a skilled operator temporarily or permanently Breakdown of shop morale Costly damage to equipment Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved
21. Washer M2 5 Lock Washer M2 5x0 45 Nut Dewpoint Sensor Assembly 892 20047 00 2 Bolt 2 50 Coupler 14mm Plain Washer 0 3125 Lock Washer 8 1 25 Hex Jam Nut Maintenance 51 o dim I 8 ISOR to 1 8 NPT 1 8Mx3 16C Fitting ISOR 1 8 Plug 17 Clamp 0538631 Thermocouple 0568466 High Temp Switch M3x0 5x8 SHCS M3 Lock Washer M6x1 0x16 Hex Cap Screw MDB255 amp MDB380 Regen Heater and Tray Assembly Tray Weldment Left Heater Manifold Right Heater Manifold Desiccant Can Gasket A0538024 Desiccant Can Assembly 892 04505 01 M6 Lock Washer Heater Box Cover Heater Gasket W 00012917 M6 Flat Washer Adapter Fitting 0534296 19 M8x1 25x25 Hex Cap Screw 20 8mm Plain Washer 21 0 3125 Lock washer Maintenance 52 Chapter 6 Troubleshooting Dirty filter Clean or replace filter Desiccant beds are contaminated by material or plasticizer leaking into the system Blower overload has tripped 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
22. cated to providing excellent customer service For immediate assistance please contact e North Central and South America 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 acslatinamericacustserv 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 e Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no ma
23. ce o ac eR E Red e sina 38 Recommendations for Cleaning and Replacing Filters 39 C 39 Cleaning with Compressed 1 39 VAS RECTE 39 5 3 Preventative Maintenance 40 5 4 Servicing the Dew Point 41 Dewpoint Monitor Troubleshooting 42 9 5 Symploms or vorn DESICCAI a 43 5 6 Replacing 44 MDB85 amp MDB170 Desiccant Can 45 MDB255 amp MDB380 Desiccant 46 5 7 Replacing the Process Heater ui epe Renee dec cu 48 5 8 Replacing the Regeneration 50 MDB85 amp MDB170 Regen Heater and Tray 51 MDB255 amp MDB380 Regen Heater and Tray 52 CHAPTER 6 TROUBLESHOOTING 53 Determining Temperature Controller Errors or Sensor Errors 56 CHAPT
24. d drying hoppers with process heating controls The dry air source controls two primary sub systems the process air and the regeneration circuit Each dryer has a left and a right desiccant bed so that one bed can regenerate while the other is in use The drying system can be configured for one drying hopper or for as many as 3 hoppers The process air heater can be located on the dryer single hopper only or on each individual drying hopper Heaters that are located on the drying hoppers have their own independent controls The Drying System Dehumidifying dryers force hot dry air through the resin in the drying hopper where the air picks up moisture from the material and is drawn back to the dryer In the dryer a desiccant bed strips moisture from the air The dryer then re heats dried process air and sends it back into the drying hopper to dry material again This system is a closed loop because ambient outside air is never introduced into the process air See Figure 1 Our dehumidifying dryers use the closed loop system because the process air is typically much drier than ambient air even after carrying moisture out of the plastic resin Recycling process air maintains drying efficiency at a consistently high level General Information 14 MDB Airflow Schematic SUIQN pue onpq m B DICAS USUMS WNS Did AK TH SUISOH 20 uo
25. dards Every effort has been made to incorporate these standards into the design of the MDB dehumidifying dryer however it 15 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 General Information 17 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 1 compressed air sources prior to servicing or cleaning the dehumidifying dryer Failure to do so may result in serious injury No one but the person who installed the lockout may remove it 2 4 Standard Features Mechanical Features Rugged compact frame with sturdy 4 10cm casters Dual blower dryer with dual desiccant beds and electrically actuated valves 180 F 300 F 150 C standard drying temperature range High regeneration temperature control safeties 13X desiccant molecular sieve Easy to access process and regeneration air filters High pressure centrifugal blower Dew point 55 F to 60 F 13 C to 51 1 C Dirty Filter Alarm for the Process Filter E E 2 5 Options Options tailor your dehumidifying dryer system to meet the exact requirements of the drying task being performed E E RN YW Aftercoolers and Pre coolers fo
26. ductor Incoming Power supply should include a ground connection Over current protection is supplied 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 enclosure 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 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 Color coded harmonized power cord 15 sufficient for proper installation Appendix 60 Notes Appendix 61 7 5 Revisions to Manual Revision Bulletin Number DRY 1 685 1 Revision Date Changes Made 1 Initial Release Appendix 62 1 63
27. e Date Date Date Date Cy MER B B B B B B B B B B B B B Inspect all filters for wear replace clean if dirty or worn 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 Actual inspection Next scheduled Actual inspection inspection Date By inspection Date By if brown or broken Scheduled Actual replacement Scheduled Actual replacement Every two years replacement date Date Work done by replacement date Date Work done by Photocopy this page for your maintenance records Maintenance 40 5 4 Servicing the Dew Point Monitor The accuracy of the dew point monitor on dehumidifying dryer systems depends on proper operation of the dew point sensor and the control board The dew point sensor 15 in the process air stream and is therefore susceptible to contamination Dew point sensor life depends on Air temperature and flow passing over the sensor The amount of fines dust in the process air The amount of plasticizer vapor in the process air The dryer operator should monitor the initial dew point sensor readings and establish a periodic replacement schedule as needed NCAUTION Do not attempt to check the continuity
28. e heater wiring configuration so you can properly re assemble the heaters Remove the wiring for the heater being removed or replaced Remove the bolts securing each heater mounting plate Slide out the heater LA do Re install the new heaters in reverse order Install new heater gaskets and securely tighten all fasteners Heater loops should not touch each other Hot Spots lead to premature 6 Re install the wiring based on the sketch you made earlier 7 Secure the heater access cover gt e I m n ms REGEN HEATERS MDB85 amp MDB170 MDB255 amp MDB380 Maintenance 50 DUE ee 10 11 12 14 15 16 17 19 20 MDB85 amp MDB170 Regen Heater and Tray Assembly Tray Weldment Nema 12 Element Box Nema 12 Element Box Cover Regen Heater Enclosure Insulating Tube Desiccant Can 892 04505 00 Filter Element 161 01834 01 In Housing Filter Bracket 822 05522 00 Hose Clamp M8x1 25x25 HCS Support Chain 822 9978 1 00 Heater Gasket W00012917 M6x1 0x16 HCS M6 Lock Washer M6 Flat Washer 3 16 Rivet Bushing 1 8Mx3 16C Fitting Thermocouple A0568473 High Temp Switch A0534296 21 22 23 24 25 26 27 28 M2 5x0 45 x 20mm SHC 30 31 34 amp mm Plain Washer 34 35 M3x0 5x8 SHCS Lock Washer 1 8715 to 1 8 NPT Adapter Fitting 1 8 ISOR plug Pressure Switch 733 00077 00 M2 5 Flat
29. e process airflow to the second bed and starts the regeneration cycle on the first bed During regeneration the dryer heats air to over 500 F 260 C and forces it through the desiccant bed Moisture driven off the bed bleeds to the atmosphere If you measure the temperature of the air bled to the atmosphere bleed temperature you should observe a rise after a period of time This condition bed breakthrough or bed break indicates that the bed is dry At bed breakthrough the bleed air temperature peaks between 350 F 176 C and 400 F 204 C After bed breakthrough the desiccant is hot and needs to be cooled down to avoid a temperature spike when the beds are switched The Dew Point meter measures the dew point of the process air A properly regenerated bed produces process air dew point of 40 F 40 C or lower This ultra low humidity level is more than adequate to dry plastics to as little as 003 moisture depending on the process material and ambient conditions Aftercoolers Pre Coolers and Plasticizing Traps These dehumidifying dryers force hot dry air through the resin in the drying hopper where the High temperature applications 250 F to 400 F 121 C to 204 C require aftercoolers to cool moist air returning to the dryer from the drying hopper An aftercooler cools the return air by 100 F 38 C this maintains dryer efficiency and condenses unwanted plasticizers from the air stream Heat Exchangers are also requ
30. ed interiors are clean NCAUTION You should properly dispose of any discarded desiccant Consult local disposal regulations for more information Maintenance 44 MDB85 amp MDB170 Desiccant Can Assembly 1 Hex Cap Screw M6x1 0x16 a 8 11 1 2 Gasket A0534086 2 M6 Lock Washer 9 Screen 872 03296 00 3 M6xl Hex Jam Nut 10 Hex cap Screw M6x1 0x35 4 M6x1 Hex Jam Nut 11 Thumb nut M6x1 0 5 Lock Washer 12 Rod 4822 01623 00 8 mm Plain Washer 7 Spring W00018643 Maintenance 45 MDB255 amp MDB380 Desiccant Can Assembly Desiccant Can Cover Sectional Gasket A0538024 17 Clamp A053863 1 M10x1 5 Hex Jam Nut 0 25 Lock Washer 12mm Plain Washer Spring W00015645 Screen 872 05555 00 9 8 1 25 13 Rod 822 01623 00 10 M10x1 5 Hex Jam Nut 11 0 25 Lock Washer 13 7 12 12mm Plain Washer 13 12mm Plain Washer 14 0 25 Lock Washer 15 M10x1 5 Hex Jam Nut 15 ee eS ee 14 Maintenance 46 Before re packing the beds determine the proper amount of desiccant for the dryer being serviced Desiccant can assemblies pre packed from the manufacturer are available and simply drop into the frame Pre measured desiccant kits are also available from the manufacturer 5 Carefully place half of the large bead in the bottom of the beds in an even layer on the bottom screen Place the small bead on top of it in an even layer Carefully place an even layer of the remaining large beads ov
31. een the pressure switch and the process blower and filter If you use the configuration of the switch as shown to the right as a reference the upper tubing should run to the other fitting on the process blower vacuum inlet The tubing on the bottom should run to the fitting just above the process filter inlet Refer to the airflow schematic for a detailed look Installation 35 3 10 Blower Pressure Switches The MDB Dryers contain a pressure switch connected via tubing to each blower outlet It is important that the tubing colored blue in the drawing is attached to the correct end of the switch The other end should be open to the atmosphere This is an enlarged view of the pressure switch The tubing should be connected to the HIGH pressure end which is the end with the raised connection as the arrow indicates The other end is left open to the atmosphere gt Installation 36 Chapter 4 Operation 4 1 Pre Startup Checks 1 Verify that the drying hopper is clean of rust prohibitive oil or any foreign objects 2 Verify that process and return hose connections are tight 3 Make sure that the thermocouples are attached at the inlet and outlet of each hopper in your system Failure to do so may cause damage to your drying system 4 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 t
32. er the small beads 6 Install the top screen making sure that the edge is contact with the sides of the bed all the way around Install the washers and nuts and tighten down Gently tap around the sides of the desiccant canister with a rubber mallet to settle the desiccant As settling occurs re tighten the nuts Repeat the tapping and tightening process until little additional settling occurs 7 Install the covers and gaskets on the beds making sure they are tight and sealed Replace desiccant bed gasket if necessary 8 Re connect any hoses that were disconnected Type 13X Desiccant Dryer Large bead 13X Small bead Type 13X Partno Ibs Kg Partno Ibs Kg lbs Kg rooms Ear W00018050 100 150 225 10 896 90 4086 9 0 4086 Maintenance 47 5 7 Replacing the Process Heater Our dehumidifying dryers use Calrod type heater elements mounted in a heater tube located in the top rear of the cabinet The wattage of the heater varies with model voltage temperature range etc but the replacement procedure is the same AWARNING Disconnect and lock out power before you replace heater elements Use the following procedure to replace the process heater 1 Remove the bolts securing the process heater access cover 2 Sketch the heater wiring configuration so you can properly re wire the heater 3 Remove the wires to the heater plate assembly being removed or replaced
33. heck 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 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 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 e
34. into the dryer If so replace the desiccant and remove any resin carry over Otherwise change 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 Solid State Relay Review Product for proper Process temperature was setting Train plant personnel improperly adjusted about proper temperature set point 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 Inspect for air leaks replace if necessary drying hopper air temperature Material being dried differs from material specified at the time of purchase Loss or reduction in drying Capacity Troubleshooting 53 Possible cause Corrective action Check for proper operation of ELIO ae MEE Repair or Loss or reduction in drying fango SMN replace if necessary capacity Cont d dusta contaminants Replace filter elements Insufficient power to PLC Check power supply and Power LED is off power wiring to PLC CCO NCIaON peice PLO Power light is on Run light is off and or Replace PLC
35. ired called pre coolers when processing materials that have low drying temperatures typically 120 to 180 49 C to 82 C Check your specific dryer model technical specifications for actual requirements Some models have a minimum low end temperature range that will determine actual requirements General Information 16 TIC Optional Plasticizer Trap Plasticizer traps should be used when resins are processed in the family of acetates butyrates and or propionates They should also be used when any resin when dried is known to produce residue contaminates or volatiles This contaminate is trapped in the air stream and is carried back from the drying process as the air leaves the drying hopper The plasticizer trap will condense the contaminate that is in the air stream and remove it before it enters the dryer unit If this contaminant is not removed it can foul the desiccant beds and damage mechanical components in the dryer and in the drying process Review your process and confirm with your resin supplier if this will be an issue If it is a Plasticizer trap must be used or it will void the warranty on the dryer Closed Loop and Heat Recovery Option After bed breakthrough see Process Regeneration Cycle the desiccant is hot and needs to be cooled down to avoid a temperature spike when the beds are switched Instead of using ambient air to cool down the desiccant the closed loop option recirculates a porti
36. n x Maintenance Responsibility 2 ear eoe o a pauco as eae bae teu Feb Le vaa uade XII Reporting a Safety Defect eae anra ies ae Xii CHAPTER 2 GENERAL INFORMATION 13 2 1 Models Covered in This 13 2 2 Necessary DOCUMENTS od ce nentes vos er dod oc dues uus 13 2 9 General DESCIIPUON ameet ope coke Eee ee 14 MDB Allow SChemlatic dg 15 SDECHVING DIVING 16 WaS DESIN Z a E bi Rl aUa 16 Process Regeneration Cycle 0 00 600000000000 16 Aftercoolers Pre Coolers Plasticizing 16 Closed Loop and Heat Recovery 17 Safety Circuit Standard ete tonta Moa e me betur uestis aseo sta ta a 17 2 4 Standard 18 Mecnanical Feature S Db ea 18 18 2 6 DIMENSIONS and Specifications 19 MD oe 19 MOB TO 21 MDD 299 sr ii 23 MDB O80 25 2 7 Series Drying
37. n system when you are filling material with the bulk truck fill line Isolate the dryer line with shut off valve and turn the dryer off line Run a return line back to the dryer to close loop the dryer and complete the loop to the dryer This silo dehumidified air blanketing system will blanket the silo with dehumidified air under positive pressure It will minimize moisture contamination of the resin The number of air exchanges and integrity of the blanket will depend on the size of the desiccant system the blower pressure and silo dome seals Review the silo deck for leaks prior to installation and install a PRV dome lid to prevent air from leaking Make sure the dome lid has pressure relief to allow for excess pressure build up Contact our factory application engineers for expert design and installation support General Information 28 Chapter 3 Installation 3 1 Positioning Your Dryer The dehumidifying dryer system was designed to be wheeled and locked 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 Also keep in mind all electrical and mechanical connections that have to be made If you are using the optional Aftercooler or Precooler your dryer should be positioned near your plant s water supply lines If your dryer
38. nd uoour SUISOH IFULIQ ae SOME uogcusugDox DUMAS Moe VODJO DN Did ONOG TD IOld ND 1 Pd ADD IDE DOH DUDE 15 General Information 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 1s called regeneration The Process Regeneration Cycle Our dehumidifying dryers have two desiccant beds While one bed is on line the process air loop the other is off line being regenerated When a desiccant bed is on line it absorbs moisture from the process air In time the bed becomes saturated with moisture and needs to be regenerated The dryer automatically redirects th
39. nnect 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 power supply terminals of the controller Check control power fuse for continuity Turn disconnect switch and control power switch ON Properly wire the terminals pd Negative is always red connection is wrong No compensating lead wires used for extension of the thermocouple 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 Use proper compensating lead wires and terminals Use a dedicated thermo couple connector If 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 e as possible from the origin of by noise or other induction the noise Celsius temperatures used Setup mode level 2 display instead of Fahrenheit vice d U S V display shows versa setting Use an Un Grounded Thermocouple Thermocouple and controller are connected by wires other Process value 1 abnormal or than proper lead wires not obtained Grounded Thermocouple Troubleshooting 55 Determining Temperature Controller
40. on of the dry air from the desiccant bed currently on line for the process This approach avoids introducing moisture from the ambient air normally used to cool down the desiccant also referred to as pre loading This option may be required for high humidity environments The closed loop option may use an air to air or a water to air heat exchanger to cool the air before it passes through the desiccant If a water to air heat exchanger is used then a water source 1s required The heat recovery option utilizes an air to air heat exchanger to pull heat from the exhaust of the regeneration cycle that would otherwise have been wasted The recovered heat is then used to pre heat the air in the regeneration cycle before it reaches the regeneration heaters reducing the amount of energy required to heat the air which translates to higher efficiency and lower operating costs 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 stan
41. on see the Maintenance Chapter in this manual Every month check heater elements for continuity using an ohmmeter For further information see the Maintenance Chapter this manual when using or maintaining this product 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 Prohibition Symbol Do not reach into any of the equipment while the equipment is running and or the power is on Lock out all power before performing maintenance on the machine s Vill lm N 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 S KE RN N RI Read and follow these operation and in
42. r or if oily mist is present near the intake air location Soak in a solution of FM 1400 or comparable detergent and warm water for five to ten minutes then gently agitate for several minutes Rinse thoroughly with clean water to remove all detergent NCAUTION Let the filter dry completely before returning itto service A damp filter can contaminate the closed loop system of the dryer Do not use a light bulb to dry the filter You should get satisfactory filtration after second or third washings however dirt holding capacity of the filter decreases after each washing After each cleaning Inspect the filter element Briefly hold a light bulb behind the element and look for any fatigued paper or residual dirt Inspect for holes and tears by looking though the filter toward a bright light Check for damaged gaskets or dented metal parts Do not re use a damaged filter e Inspect the end plates Any damage here can allow air to bypass the filter e Look for rust on the end plates and metal core Rust particles can flake off and contaminate the dryer and resin e Check the gasket for damage A damaged gasket allows contaminants into the process Replace as needed Maintenance 39 e Allow the filter to dry before re using Circulate warm air at less than 160 F 71 C Do not use a light bulb to dry the filter 5 3 Preventative Maintenance Checklist Dehumidifying Dryer Systems System model Everv week Date Date Dat
43. r high and low temperature applications Audible visual critical alarm Dirty Filter indicator for the Regen blower Modular hopper stands hopper banks and convey systems Closed loop regeneration and heat recovery system Insulated dryer hose Plasticizer Trap Requires Aftercooler General Information 18 2 6 Dimensions and Specifications MDB 85 REGENERATION HMI TOUCH AIR FLOW EXIT alb 2 5 ON OFF CONTROL PROCESS FILTER REGENERATION FILTER 2 25 OD REGEN BLOWER PROCESS BLOWER FRONT VIEW ACCESS DOOR REMOVED LENGTH PROCESS HEATER DESICCANT TANKS HEIGHT REGEN HEATERS REAR VIEW ACCESS DOORS REMOVED SIDE VIEW ACCESS DOORS REMOVED General Information 19 2 PROCESSMEDA AR O O O STANDARD HOSE CONNECTION DIA 2 5in 63 5mm DIMENSIONS AND WEIGHT ELECTRICAL MECHNICAL CONTROL CIRCUIT 120VAC 24VDC CONTROL TYPE CONTROL INTERFACE HMI TOUCH ELECTRICAL ENCLOSURE NEMA12 DRYER AMP DRAW STANDARD VOLTAGE FULL LOAD AMPS LOW HEAT AND HIGH HEAT OPERATING RUNNING AMPS APPROXIMATE VALUE BASED ON TYPICAL OPERATING LOAD VALUES COULD BE LESS General Information 20 MDB 170 REGENERATION AIR FLOW EXIT 2 5 O D HMI TOUCH PROCESS FILTER REGEN FILTER RETURN PORT 25 0 D REGEN BLOWER DELIVERY FRONT ACCESS DOORS RE HEIGHT REGEN HEATERS SIDE ACCESS DOORS REMOVED ACCESS DOORS REMOVED General Information 21 AIRFLOW PROCESSM
44. r the dryer to function properly it is critical to place the process air thermocouples on the drying hopper inlet and outlet These devices accurately monitor the air temperature entering and N O C E leaving the drying hopper the value of which is used by the control to maintain the process temperature set point Compression fittings are required to hold the thermocouple in place so that the tip is approximately in the center of the tube as shown Aur Inlet Air Return This photo demonstrates the proper location of the thermocouple inside the air inlet and return tubes The locations of the inlet and return will vary on different drying hoppers Compression fitting Adapter if required 1 8 NPT to BSPT 1 8 Thermocouple Se T WH Series Drying Hoppers Installation 34 3 8 3 9 Dewpoint Sensor The Dewpoint Sensor 15 a vital part of the dryer because it helps maintain the required dewpoint for your application It is easy to locate in your dryer because it is equipped with copper tubing Depending on the dryer model the copper tubing may go directly to the upper valve or plastic tubing may be required to complete the connection The other end of the sensor should be attached to the vacuum inlet of the process blower The airflow schematic located earlier in this manual will show these connections 7 Dirty Filter Pressure Switch Check for the proper tubing betw
45. rapped air from the system Make sure that the Aftercooler and Precooler has the proper supply water temperature 5 Check all companion equipment such as the sight glass loader and drying hopper loader verify that all convey tubing is in place and the loading system is ready for operation 6 Verify that all electrical connections are tight and the unit is properly grounded 7 With main power on turn the dryer on until the process blower starts verify blower rotation see section 3 3 NCAUTION Clean the rust preventing oil from inside the drying hopper Failure to clean the hopper fouls the desiccant and voids your warranty Operation 37 Chapter 5 Maintenance 5 1 Work Rules The installation operation and maintenance of this equipment is to be conducted accordance with all applicable work and safety codes for the installation location This may include but is not limited to OSHA NEC CSA and any other local national and international regulations In addition you must observe the following specific work rules Keep these operating instructions on hand and follow them when installing operating or maintaining your dryer If these instructions become damaged or unreadable you can obtain additional copies from the manufacturer Only qualified personnel familiar with this equipment should work on or with this unit M Work only with approved tools and devices gt Disconnect power before servicing
46. rocedures 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 chapter located in an accompanying manual 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 li
47. rying process Review your process and confirm with your resin supplier if this will be an issue If itis a Plasticizer trap must be used or it will void the warranty on the dryer Drying Hopper Removing the Rust Inhibitor Rust preventative may have been applied to internal unfinished surfaces Remove rust inhibitor before using the drying hopper Using a non water based degreasing agent clean all inside surfaces of the drying hopper Allow components to dry thoroughly Inspect the inside of the drying hopper for loose connections foreign objects or a blocked diffuser Air Trap Considerations The air trap assembly in the top of the drying hopper prevents ambient air from contaminating the material being dried Keep the material level at the mid point of the air trap for maximum efficiency Use a hopper loader or vacuum conveying system to maintain the proper material level Installation 22 3 7 Thermocouples the Dryer There are 3 thermocouples located inside of the MDB Dryer unit There is one located N O underneath each desiccant can and located at the exhaust of the upper valve It is very important that they are properly installed before operation Failure to do so could cause high temperatures to melt the resin in your drying hopper s Thermocouples are connected to the control and help regulate the process and regen temperatures in your system Installation 33 the Hopper Fo
48. s eye irritation Breathing in desiccant dust may be harmful and may cause skin trritation Do not get in eyes Avoid prolonged contact with skin 9 Use with adequate ventilation Wash thoroughly after handling In case of eye contact immediately flush eyes with plenty of water for at least 15 minutes If irritation persists see a physician Maintenance 43 5 6 Replacing Worn Desiccant Make sure desiccant beds are sufficiently cool before replacing worn desiccant Disconnect the electrical supply Remove the rear panels to expose the desiccant beds Access the desiccant cans in one of the following ways Remove the entire bed from the frame e Remove the hoses located at the top of the beds e Remove the thermocouple and fittings Make a note of the correct location for each Loosen the knurled nuts below the desiccant can e Loosen the couplers below the desiccant can e Ttwist the desiccant can clockwise and lift to remove Remove only the top cover then remove the screen inside by removing the single nut at the center of the can 4 Replace the desiccant in one of the following ways Replace the entire desiccant can with a pre packed desiccant can assembly available from parts and service Contact ACS for a new can assembly Drop in the new cans tighten the knurled nuts and replace the thermocouple and fittings Vacuum out the desiccant from the can and proceed to step 5 Make sure the b
49. specifically for air filter element cleaning It is non sudsing and works in hot or cold water FM 1400 contains biodegradable synthetic detergents and is non phosphate non NTA For more information contact Filter Service Corporation 2603 A West Main Farmington NM 1 505 326 1127 Maintenance 38 Recommendations for Cleaning and Replacing Filters Vacuuming Try vacuum cleaning a soiled filter first Vacuuming removes most large particles and surface contaminants and may suffice for the first time you clean a filter Use a commercial duty recommended or household vacuum cleaner Vacuum the filter from the air intake dirty side only Turn off and or lock out electrical power to the dryer Remove the threaded fastener securing the filter access cover and then remove the cover Remove the nut on the center retaining rod to remove the filter cartridge Cleaning with Compressed Blow clean dry compressed air up and down the pleats blowing out the filter from the clean side Remove loose dirt from the filter with compressed air or a water hose Compressed air should be less than 100 psi 689 5 kPa 6 89 bars Use a lg 3 mm dia nozzle at least 2 5 cm away from the filter Don t shoot the air in a crisscross motion against the grain of the pleats you may damage it Washing T As a last resort wash the filter However do so only if the pressure drop is too high from fine eS dirt embedded in the filte
50. ssential 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 you have completed the repair or maintenance procedure check your work and remove your
51. stallation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power When welding or brazing in or around this equipment make sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be nearby and ready for use if needed Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 1 3
52. sting 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 NCAUTION may result in minor or moderate injury or in property damage vil 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 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 informati
53. to generate very low dew point air heated to a controlled temperature for drying plastic pellets and regrind 70 MoBz55 MES Process air flow cfm m hr 50 85 100 170 150 250 225 380 Hose conn dia in mm 2 5 64 2 5 64 3 75 3 75 Temp range F C 140 400 60 204 140 400 60 204 185 400 85 204 160 400 71 204 Running Amps 4 9 23013160 Running Amps 37 940 2 2 Necessary Documents The documents listed below are necessary for the operation installation and maintenance of MDB Series dehumidifying dryers You can obtain additional copies from the manufacturer Make sure that the appropriate personnel are familiar with these documents This manual MDB Electrical Manual 882 02900 00 The schematic and assembly drawings included in the customer information packet The Customer Parts List included in the information packet E EN RN RI Operation and installation manuals for any optional controls or auxiliary equipment in the drying system Large Dehumidifying Dryers General Information 13 2 3 General Description Moisture removal from hygroscopic moisture attracting plastic pellets 15 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 15 heated to a controlled temperature for drying plastic pellets and regrind The drying system consists of a dry air source an
54. tter where you are located For more information please visit us at www acscorporate com United States Asia Australia ACS Schaumburg ACS Suzhou 1100 E Woodfield Road 109 Xingpu Road SIP Suite 588 Suzhou China 215126 Schaumburg IL 60173 Phone 86 8717 1919 Phone 1 847 273 7700 Fax 86 512 8717 1916 Fax 1 847 273 7804 gt Europe Middle East Africa ACS New Berlin 2900 S 160 Street ACS Warsaw New Berlin WI 53151 Ul Dzialkowa 115 Phone 1 262 641 8600 02 234 Warszawa Fax 1 262 641 8653 Phone 48 22 390 9720 Fax 48 22 390 9724 Appendix 59 7 4 Annex Information The following design information is provided for your reference E 2 e cU Am 12 13 14 13 16 17 18 19 Two hand control is not required or provided 21 22 23 The machine is not equipped with cableless controls 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 fs 2 Nominal supply voltage Verify on serial number tag 11 Earth ground type TN system has one point directly earthed through a protective con
55. your dryer If the disconnect switch you installed has a D lockout lock it in the OFF position before you perform any maintenance or service 5 2 Servicing Air Filters Operating the dryer without the process air filter installed voids your ACAUTION warranty Filter cleaning is an important part of your dryer maintenance program Our dehumidifying dryers have a single cartridge canister type filter in the process and regen air loop Refer to the individual model schematics in the General Information section to locate your machine s filters These filters protect the blowers from plastic fines drawn in from the drying hopper Regular filter cleaning is essential to keep your dryer operating at peak efficiency You can wash or blow out the filters but remember you reduce dirt holding capacity with each washing The risk of dirt reaching the clean side of the filter during cleaning plus possible filter damage from high pressure washing or blowing makes washing a gamble You can carefully clean or wash the filter when airflow becomes restricted Do not wash filters more than six 6 times or use them for more than a year whichever comes first Use a detergent that won t damage filter media Such a detergent permits easy removal of dirt particles through flushing and rinsing An effective detergent removes the fine particles from the pores of the filter media The filter manufacturer recommends FM 1400 washing compound It is formulated
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