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Sterling DH1-610-2 User's Manual

1. sure the blower is functioning correctly a a S High pressure peripheral K regenerative blower Dryer valve 2 i Hose 4 2 Hose Utilizing 40F dew aces Process Regeneration a Return Air desiccant Air Filter Temperature Thermocouple c Position 13X Molecular l Make U Sieve 8x12 L SEN TEREF Air E be ads Na Bs SS ZSIR wenn T 2 TTT RSRSRS T T L U A E Low watt density 2 1 2 Hose Se reset ba Insulated Double wall S A Sn T heaters can stainless steel constructed heater operate safely ania hous d th mini rying hopper ousing an with minimum air desiccant flow container High L temperature Process Air Regeneration snap Salis Temperature thermocouple monitor t ae e regeneration L temperature k 2 1 2 Hose x TS l Portable Drying Conveying Systems Chapter 7 Appendix 57 of 63 Figure 13 High Heat Model 180 F to 400 F Air Flow Schematic Pressure switch makes sure the blower is add functioning correctly k F _ High pressure peripheral ee regenerative blower Dryer valve 9 Hose Optional Return lt 7 Air Cooler K N N K 7 b 5 y N h 2 Hose Utilizing 40F dew point air to regenerate 2 Proce
2. thermocouple monitors and controls the High pressure peripheral regenerative blower a N b Process d Regeneration Air Filter Low watt density heaters can minimum air flow housings regeneration temperature Optional Pre Cooler for lt Low Temperature T Operation 120F to 180F Portable Drying Conveying Systems Chapter 7 Appendix operate safely with High temperature snap switches monitor the heat status of the heater 2 Hose 2 1 2 Hose Return Air Temperature Thermocouple Position Insulated stainless steel drying hopper 59 of 63 7 5 Spare Parts List Figure 15 Level 1 Spare Parts List Electrical amp Mechanical DRYER SPARE PARTS LIST AD15 AD30 AD60 CFM CFM 3 3 gt gt 2 2 2 2 2 2 2 2 Zl 2 2 2 L u J L Wey LL l UL l Wy Wy UL UL l Wy Wy Wy LL O JO JO JO Ol OIOI O OF OF O O O O OF O LO lLO lLO JL LO oi Of OI OI OI OI OI OI Cl GO Ol O O w m m m m i COL MO v C2 CLO l L t L L L L C3 C3 C3 m C3 m C3 C3 C3 E 2 PEDE SES C3 LO C3 LO C3 C3 LO C3 LO C3 oO C3 LO C3 LO C3 oO gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt o Jo lG JO LO 1 0 O O O OF O OT O O O O LO LEV
3. 19 Cable support may be required for power cord depending on final installation 20 No one is required to be in the interior of the electrical enclosure during the normal operation of the unit Only skilled electricians should be inside the enclosure for maintenance ZA Doors can be opened with a screwdriver but no keys are required Portable Drying Conveying Systems Chapter 7 Appendix 56 of 63 22 Two hand control is not required or provided 2D All dryers and conveying equipment should be moved around and set in a place with a lift truck or equivalent 24 There are no frequent repetitive cycles that require manual control tepetitive functions are automatic while the drying and conveying system is operating 23 An inspection report detailing the functional test is included with the dryer and conveying system 26 The machine is not equipped with cable less controls 27 Color coded harmonized power cord is sufficient for proper installation Aftercooler Design Specifications Entering water temp 85 F 29 C 50 F If used as Plasticizer trap 10 C If used as Plasticizer trap 7 4 Drawings and Diagrams Figure 12 Standard Model 180 F to 250 F Air Flow Schematic Pressure switch makes
4. 2 gt 2 gt 8 gt 8 gt gt gt gt gt gt gt gt gt S191815 EIS S 81 S 81 81 S E C E E DT E RS a LE ee a HR R EE EE H S CE H RH S titi ti ES ee BES i i 61 of 63 7 6 Returned Material Policy Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from the manufacturer returned is subject to 15 75 00 minimum restocking charge ALL returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty t
5. DRYER SPARE PARTS LIST AD15 AD30 AD60 LEVEL 2 Electrical Components PART SIZE A0558000 Motor Starter S O a ee A0548555 Dew Point Circuit Board S S O LEVEL 2 Mechanical Components A0548621 Ceramic Cap for the End of Heater Elements A0566478 750 Watts Heater element 208 220 Volts A0566479 750 Watts Heater element 230 Volts __ A0566480 750 Watts Heater element 400 Volts A0566481 750 Watts Heater element 460 Volts _ __ A0566482 750 Watts Heater element 575 Vois A0566483 1250 Watts Heater Element 208 220 Volts A0566484 1250 Watts Heater Element 230 Volts __ _ A0566485 1250 Watts Heater Element 400 Volts A0566486 1250 Watts Heater Element 460 Volts A0566487 1250 Watts Heater Element 575 Volts ____ A0566601 2500 Watts Heater Element 208 220 Volts A0566602_ 2500 Watts Heater Element 230 Volts A0566603 2500 Watts Heater Element 400 Volts _ A0566604_ 2500 Watts Heater Element 460 Volts A0566605_ 2500 Watts Heater Element 575 Volts A0568139 Screen Cover for the DesiccantTanks A0568140 Screen Cover for the DesiccantTanks A0568141 T Screen Cover for the Desiccant Tanks ___ A0566682 1 4 OD Teflon Tube _ _ A0566415 Washer Gasket for the Heater Elements DRYER SPARE PARTS LIST AD15 AD30 AD60 LEVEL 3 Electrical Components PART SIZE A0567921 mna prena M A0568961 P TEE SE Redundant Temperature Safety Controller LEVEL 3
6. At this point the operator can return back to the DRYER MENU or MAIN MENU by touching the appropriate button on the screen Alarm Screen Example VALVE POSITION FAULT ALARM SILENCE This is an example of what a typical Alarm screen looks like The user will see the message causing the alarm in the top half of the display with an ALARM SILENCE button in the lower half To turn off the alarm the user must press the ALARM SILENCE button This will cancel the alarm Redundant Safety Controller Display Optional The Redundant Safety Controller limits the process air temperature from exceeding specific temperatures in case of a catastrophic failure of the primary PLC process air temperature control system The controller is a modular self contained unit removable from the mounting housing All parameters are factory set and adjusted normally no field adjustment to the internal controls are necessary Figure5 Typical Redundant Safety Controller Display Setting the Redundant Safety Controller The Redundant Safety Controller alarm setting is changed by pressing the up and down keys to input the alarm value The upper display reading indicates the Process Value while the Portable Drying Conveying Systems Chapter 4 Operation 36 of 63 lower display indicates the High Point Setting alarm value The factory setting for the High Point Alarm Value Ll hi is 150 F 23 C Restoring the WATLOW Redundant Safety Controller to Fa
7. Mechanical Components A0534059 2 O D by 12 Ft Long Hi Temp Hose A0534060 2 1 2 O D by 12 Ft Long Hi Temp Hose A0566535_ Return Air Cooling Coil A0536628 208 460 Volt Process Blower A0536629 575 Volt Process Blower A0534079 208 460 Volt Process Blower _ A0535351_ 575 Volt Process Blower A0552439 208 460 Volt Process Blower A0552440 575 Volt Process Blower W00015335_ Dew Point Sensor Manifold _ _ _ A0548558 Gasket for the Dew Point Sensor Chapter 7 Appendix Figure 16 Level 2 amp 3 Spare Parts List Electrical amp Mechanical 15C 5 15CFM 230V 3PH socFm 400V 50 HZ 3PH 30CFM 460V 3PH lsocFm 575V 60 HZ 3PH ocr 15CFM 208V 3PH 30CFM 220V 50 HZ 3PH 30CFM 1 O O o O O o O O o L L 1 Oo O SS 5 p2t2 l 0 o O0 o tej J f 0 LH o f Jel J 0 LH LST 0 O O0 S SJ J J J 0 o 0 2 2 W55 khalal Ji a A le ee ee a a E ee ee oe Sa aa Mes TS y ay ECEE ee 23 S a ee ar ee 0 i Ec J l I E a 0 A s l a 0 S T si po 0 ft ls 0 A I l I8 LR L L 2 eS O 5 Feet O 8 10 d ld ld lo lo ol SI S S S SI S S S ST dal dal 5 O IO IO IO IO GQ G o O OI o o O O OF OY O jejeje 2 el Sl Sl Sl sl s S Sl SI 3 3 8 8 E E I T T E I T E Q D Q A D Q Q D D T 109 lT 19 r l ail T j Tl mi Tl ol Tl ol ct Flee je e eye Sial SiS sal se a se als gt l2 gt 2 gt Sis 2 gt 8 gt
8. Operator ReESDONSIDIIY ss esrrict sca toceer a died a a a e ai 9 Maintenance ResponsiDiiiy eee ee ee eee 10 Reporing a Safety DTCC ii eveeseeeesaididcdentotewetckvetesenueeedeieldecsieeiehtalobtacsbekdetkaedebedd 10 CHAPTER 2 FUNCTIONAL DESCRIPTION sss sss sss see e 11 2 1 Models Covered in This Manual sss eee 11 22 General DESCPNOM T 11 TASDAN SY SUC I st tee teen tases E ale ih cet E ae ee td 11 WV NETS Ree T easa a E E 11 The Process Regeneration CVCle cs ee 11 2 3 Olanda Features eiai E ttn dundee aE eotadenceee ants 12 Mechanical CALUINCS sussen keee aee EERI EE E a E ETE AA 12 El cticalFeatir GSi aaea a a A a wentiieun ts 12 COmUoller REAU ES anni a E ee eae atieGe 12 2A ODIOM S esio a en ene ee eee eee 13 2 5 Safety Devices and lInterlocks sese 13 Salely Circuit Standardo seerne r 13 Fail Sate Operan erresen a e a a e A 14 TNT Device LOCK OUTS TTT 14 CHAPTER 3 INSTALLATION sss sss ss sevene eee 15 O 1 WACKATING the Equipment TT 15 32 Rigging and Placing the DIV TTT 15 39 IESG Cal COMMS CHOINS TTT 17 O24 SClUD Procedure S essea T E R E E ous 18 Checking for Proper Blower Rotation sse ee ee ee ee ee 18 Drying Hopper Air Trap Considerations If Equipped sss esse sees eee 18 Installing the Optional AfterCooler ccccceccccccseeeeeecseeeeeeseeeeeeseeeeeeesaeeeeesaaees 18 29 Tarz Een T G eee ewe mine a reer tane ie nem ret er eet ree ee ees en ee 19 Pre Slant e Le icteric tess asia
9. Portable Drying Conveying Systems 4 Replacing the Process Heater eee ee eee 45 Replacing Cleaning the Cooling Cols eee eee eee 46 CHAPTER 6 TROUBLESHOOTING sss ss sss e s eee esen 48 6l te s1s 5 CHOP sssr see oe dente teas E E E E 48 6 2 Determining Temperature Controller Errors or Sensor Errors eee ee e e e e 54 Using a He yace hla Ernis a titel binatess 54 CHAPTER 7 APPENDIX ssssssssssesesrrrrrnessssnnnnneersnnnnneeeennnnnnnnns 55 ZA Waran aienea a E Na e A E E E yoiaweds 55 Waranty SD CCINCAIONSigic5 5 TTT 55 VV CIBER IAC SUM CUOINS casis check aiantn vata tian Sntwnaleh a 55 Waranty LiaDilil Six teccsess cates ee etnatadies acldnte deh acta acu ds ces een tact A 55 Customer R SPONSIDILtieS T 56 Yea OpionaiComponeNiS srren a aN 56 Fae S R lt e nae TT ae ese 56 PATIO EIT cece Seca HEE 56 Aftercooler Design SpeCifiCationS cccccseccccsseeeceeeeecceeseeceeeeeseueeesseueeesaeeeesaaes 57 1A Drawings and DIAGFAINS T 57 Pa Tee Te Te ion veces adeaduadeeubineutoeciiadisie nied beietncb aren 60 7 6 Returned Maternal le e 62 Re d ETT 62 Warranty FeqUINS euas a a Radedousiad events enlundncse ede Wiaiadehiaeenasielaels 62 7 7 Dryer Identification Serial Number Tad sss sse eee ee 62 7 0 TECMMICAIASSIS TANG TTT 63 Pans DCDANIMEN cay ccadsorasanntisunsssnmnatehacgnagdoawas OEE 63 Service RTT nen 63 Sales Departmen eee eee oer re anaes nea een E 63 Coniract DED AMM GI 422s vette ns asscrorat ene sadn sheet
10. OF ALL OTHER WARRANTIES GUARANTIEES AGREEMENTS AND SIMILAR OBLIGATIONS OF THE COMPANY AND OR MANUFACTURER UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE PAGE OR LIMITED BY THE MANUFACTURERS WARRANTY FOR PARTS The Company s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty Warranty Restrictions This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the Company s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the Company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned immediately without any further use or handling Warranty Liabilities THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT RESULT FROM THE USE OF THIS PRODUCT Some states do not allow the exclusion or limitation of special consequential or incidental damages so the above limitatio
11. aT HT 30 SV SILOM MENU as cce cee csstenccssacnaendeeceas beaudasoneteutaawnemndaanenupadapacdeusnee NEEESE 31 YE AE 1 eRe ee H E Re ee acre 31 elel TT 32 Te Hene GIOCK Sassi eect canes cect a ates eee dt rotnis 32 Ten Fie OCW arra A RENE 33 HOU WIGTOYS ache seitdostinc vaacoredasntashewasbewau stated de gut des anetb snc saviontusmenstedine guste sash N 33 Tien St AUS set cacao sce Poeun ngt tana ade o a e eet cede 34 CUD UT SUNS 1 Shieikan acetal nol ere aa ese ecanieticen ested has 34 U e SGUN TTT 34 SENICE ETT 35 an TT ne Tn TET 35 Redundant Safety Controller Display esse eee 36 Setting the Redundant Safety Controller see eee eee eee 36 Restoring the WATLOW Redundant Safety Controller to Factory Setup 37 4 2 System Operation Procedures ccccccccsecccccssececceessceeeseseceeeseeeeeseegeeeessageeeessegeeees 38 4 3 lt SnUttING DOWN The DIV EF siise a aaa 39 CHAPTER 5 MAINTENANCE cccccccecceeeeeceeeneeneeneeneenes 40 5 1 Preventative Maintenance Schedule see eee ee 40 5 2 Preventative Maintenance eee eee ee e e ee eee eee 41 Servicing Process Air Fites renin a a A eOe 41 Servicing the Dew Point Monitor sss eee ee ee ee 42 53 C recve Mantenan E minirao a dita tat teed teete elit 43 SYMpltoms Or WOrn R Te eT 43 Replacing Worn DOSICC AM aictiicres set deacatsas touinieatiahownnsoctceryinerainctasanatsceetaaaeeestand 43 Replacing the Regeneration Heater eee ee eee 45
12. horn is ON The process temperature thermocouple is damaged Replace the thermocouple The regeneration temperature thermocouple is not connected to the temperature controller Make sure the connections are correct and tight The regeneration temperature thermocouple is damaged Replace the thermocouple Dryer Shuts Down Process blower OFF Process heaters OFF Regen heaters OFF Alarm light is ON Alarm horn is ON Make sure the process filter is clean Clean or replace if necessary Double check the alarm set point 35 F Check the positioning of the thermocouple inside the air inlet of the drying hopper The tip of the thermocouple should be centered to the tube and not touching any metal part of the tube The drying temperature set point is lower than dryer capabilities Check the dryer specs Make sure all the hose connections are tight Make sure the regeneration timing cycle matches the specs If not contact Service department Dryer Shuts Down Process blower OFF Process heaters OFF Regen heaters OFF Alarm light is ON Alarm horn is ON 49 of 63 Alarm Message PROCESS SENSOR FAIL The process temperature thermocouple is open REGEN SENSOR FAIL The Regeneration temperature thermocouple is open PROCESS HIGH TEMP The process temperature has exceeded the alarm set point Portable Drying Conveying Systems Chapter 6 Troubleshooting Correc
13. in the screen by pressing the number keys Press ENT Enter when you are finished to set the new values or CLR Clear to erase the current values and reenter new ones To set the values in the next field press ENT Enter to close the screen shown above Then select the next number field to enter new values Dryer Menu Pressing this button will take the user to another screen where more machine parameters can be viewed and adjusted Portable Drying Conveying Systems Chapter 4 Operation 24 of 63 Dryer Menu Screen DRYER MENU FRYER DRYER OVERDRY Ea STATUS Ea SETUP E PROTECT HLARMS SE Cae PT AUTO Be Sa E I R The screen SIE above will allow the c allow the operator to ennaa operating parameters for the following e DRYER STATUS e DRYER SETUP requires supervisory password e OVERDRY PROTECT requires supervisory password e ALARMS e AUTO TUNE requires supervisory password e DEW PT SETUP Dew Point Setup e AUTO START requires supervisory password e MAIN MENU DRYER STATUS Pressing the STATUS button will take the operator back to the original status screen shown on page 27 Pressing MENU will return you back to the menu screen DRYER SETUP SETUP 1 of 3 DRYER D E BSR HIF at iat i RE TION ALARM By pressing the LOW or HIGH alarm buttons the operator can enter the desired values to enable the alarm to go off at a specific deviation from set point on the high or low side When these settings ha
14. is generated The alarm horn and light are activated The process heater regen heater and process regen blower are turned off Pressing the ALARM SILENCE pushbutton will deactivate the alarm horn and light 7 Turn the Off On switch to the ON position and push the START button to restart the dryer If the fault condition still exists the dryer will not restart 8 If the process blower overloads trips a PROCESS BLOWER FAIL is generated The alarm horn and light are activated The process heater regen heater and process regen blower are turned off Pressing the ALARM SILENCE button will deactivate the alarm horn and light 9 Reset the motor overload and turn the Off On switch to the ON position and push the START button on the touch screen to restart the dryer 10 The valve position limit switch enables the right bed heater and provides an input signal to the PLC when actuated by the cam lobe Each heater is controlled by the PLC 11 Upon completion of the HEAT portion of the regeneration sequence the regen heaters are disabled by the PLC and the COOL time begins 12 Once the COOL time has expired the valve motor is turned on until the cam switch makes a transition Upon making a transition the timing sequence 19 restarted for the new bed 13 When a HIGH DEW POINT alarm is generated by the dew point controller the alarm horn and light will activate Press ALARM SILENCE to deactivate the alarm until the next HIGH DEW POINT alarm o
15. operation of the dryer and the optional conveying system This section of the manual will address those parameters that allow the user to optimize the drying conveying system for specific applications Figure 4 Dryer Status Screen on Touch Screen Controller RIGHT BED IM PROCESS LEFT BEC HEAT 25 Startup Screen DEGREE F ER PLC Y DISPLAY VER The screen shown above provides the operator with the following information e Dryer Model Number e Temperature view In Celsius or Fahrenheit e Copyright Information e PLC Version e Display Version After approximately 10 12 seconds the controller will flash to the Dryer Status Screen shown in Figure 10 above Portable Drying Conveying Systems Chapter 4 Operation 22 of 63 Main Menu Screen MATIN MENU ALARH HEND HISTORY SYSTEM MEND The MAIN MENU provides information on the following drying conveying system parameters e DRYER MENU some submenus are password protected e ALARM HISTORY e HELP MENU e SYSTEM MENU e NO USERS LOGGED ON This section of the manual will focus on the dryer features portion of the controller at this time Press the DRYER MENU button to return to the next section of dryer functions Dryer Status Screen Shown at Controller Power Up Note Looking at the screen from Left to Right Dryer Process The SETPOINT button allows the operator to set the process air temperature The ACTUAL button will give you a reading of what t
16. tags to the disconnect switch When you need to perform maintenance or repair work on equipment above floor level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk on your equipment use it The work platform should have secure footing and a place for tools and parts DO NOT climb on machines or work from ladders If you need to repair a large component use appropriate handling equipment Before you use handling equipment portable A frames electric boom trucks fork trucks overhead cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable Carefully test the condition of lifting cables chains ropes slings and hooks before using them to lift a load Be sure that all non current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you have completed the repair or maintenance procedure check your work and remove your tools rigging and handling equipment Do not restore power to the equipment until all persons are clear of the area DO NOT start and run the machine until you are sure all parts are functioning correctly BEFORE you turn the machine to the operator for production verify all equipment enclosure panels guards and safety devices are in place and functioning properly Reporting a Safety Defect If y
17. with a rubber melet gently for one or two minutes to make sure the desiccant is packed tight Add more desiccant if required 2 Repeat the previous step for the other bed 3 Inspect the gaskets and replace if necessary Place the screen in between the desiccant tank and the cap 4 Reconnect all the hoses and panels when done Portable Drying Conveying Systems Chapter 5 Maintenance 44 of 63 Figure 9 Required Desiccant Amounts Dryer 8 x 12 bead Total model Part no lbs Kg W00018051 Replacing the regeneration heaters Procedures see figure 8 1 Sketch the heater wiring configuration so you can properly re wire the heater 5 Remove the ceramic nuts and wires to the heater plate assembly being removed or replaced 6 Remove the six 6 10 32 button head screws securing the process heater plate using a 1 8 Allen wrench and slide out the assembly 7 Remove the heater s from the mounting plate by removing the large brass nuts and washers 8 Re install the heater s and heater plate assemblies in reverse order Install new heater gaskets and securely tighten all fasteners Caution Heater loops should not touch each other Hot spots lead to premature heater failure 2 Reinstall the wires based on the sketch you made earlier Reinstall the ceramic nuts to each heater terminal Replacing the Process Heater The dehumidifying dryers utilize a single phase Calrod type heater element This heater element is mou
18. CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 630 595 1060 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations Portable Drying Conveying Systems Chapter 7 Appendix 63 of 63
19. EL 1 Electrical Components SIA RIS Wee RT ce ea ed l l l ll E te a a a a HOHHH HOHHH ee eee 2 5 O T sis S ee ee TSTST Ta TSS STS SaS STTTS ee S TST TS TS T TST TTT sflsfa TT tT tT tT Tat tT tT tT tT A0534042_ 6 Fuseforthe Heater Elements JIA T TJs J TJ T3 TT 3 TS s S Taas T STT TTT A0534044 8 Fuseforthe Heater Elements JINA T Js 33a J TJ JTI f TSS TSS TST TT Ts TSS TS TSS TST T3 sist TT sat T T T333 eS ee ee TTI ee ee ee ee ee ee a E EA E ET ECT EN 1 125 TSTS TSS STTTS 1 25 S TST S TS TS TTTS CASE I O E E a E Si SJs ST TTI TITI TIITII TSTST TSTS TST TITT 3 2 TSS TS SaS S TTT STS ee SS TST Tal T A0538062 6 Fusefor the Process Blower CT CT T T J TJ TJ JTI T3 6 25 TSS S TSS TST TTT TSTST S TST TST TT rene TSS ee TTT STTS STTS TS e 1 25 Jei JTT TATT STel TS TSAA TS TT To Te TST T aA TST TTA eje T tata T T at at f 2 TT CCTS SST aA tT tT TT 2 8 1 ALL ee aa a a ae TTT tT tT tT tT tty tT tT tT tT tat tT tT pT ee HHOH a af a 1 6 5 STTTS aaa ee ST LEVEL 1 Mechanical Components W00015435 T Dew Point Sensor InsertCable _A0548556 DewPointSensor S A0566467 Valve switch SS O W0005247 Process Air Filter S W00018051__ 13X molecular Sieve Desiccant 8 X 12 Beads W00013983_ High Temperature Gasket A0566676 High Temperature Snap Switch Portable Drying Conveying Systems Chapter 7 Appendix 60 of 63 Portable Drying Conveying Systems
20. Enter to close the screen shown above Then select the next number field to enter new values Over Drying Protection FROCESS RE TURN HATER IAL ma AIR PFG PEU TEC T Oh Portable Drying Conveying Systems Chapter 4 Operation 26 of 63 The PROCESS RETURN AIR TEMPERATURE displays the air temperature as it leaves the drying hopper If this temperature is above 150 F an aftercooler is required By pressing the DISABLE or ENABLE the operator disable or enable this feature of the dryer This feature is used to prevent the over drying of the plastic resin in the drying hopper At this point the operator has the choice of pressing MAIN MENU DRYER MENU or MORE to access the screen 2 of 2 of the OVERDY PROTECTION for adjusting values OVERDRY PROTECTION 2 of 2 SET BACK VALUES 74 SET UP ETPOIMT TEMP DELAY TEMP SET BACK VALUES The SETPOINT is the secondary drying temperature set point This is the temperature at which the drying temperature will be reduced to after a certain delay time and when the return air temperature has exceeded its set point The TEMP is the set point for the return air temperature of the drying hopper When the return air temperature exceeds this value after a certain delay time the process temperature will be reduced to its secondary value SETPOINT to eliminate over drying of the plastic material The DELAY is the time which will take for the dryer to switch the drying temperature set point
21. L UCK METERS HISTORY EO service HE The screen shown above will allow the operator to set review operating parameters for the following The above screen will allow the operator to set review operating parameters e SYSTEM SETUP e SET CLOCK e HOUR METERS e ALARM HISTORY e I OSTATUTUS Input and output status e SYSTEM BACKUP e SERVICE e MAIN MENU SYSTEM SETUP SYSTEM SETUP This screen allows the operator to set alarm and password features ALARM OFF DUR is the amount of time 0 99 minutes that the alarm and horn will stay off after the alarm silence button is pushed When this function is set to O this feature will never turn off When it is set to 99 it will stay off until another alarm occurs OPER PW is the four 4 digit number that allows access to the station and pump status screen and the station operator screen When this feature is set to OOOO these screens are not password protected OPER PW DUR is the amount of time 5 99 minutes the password will allow access to the associated screens The screen changes to the station status screen when the time expires SETUP PW is the four 4 digit number that allows access to the setup screens When this is set to OOOO there is no password protection Store password in a secure location SETUP PW DUR is the amount of time 5 99 the password will allow access to the associated screens When the time expires the screen changes to the station status sc
22. Sterling SDAA 25 100 Small Dryer With AP 1 Controls Part Number 882 00294 00 Bulletin Number DH1 610 2 Effective 05 15 06 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2006 All rights reserved Shipping Information Unpacking and Inspection You should inspect your portable drying conveying system for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading 19 attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise cu
23. ad Operation and Installation Manual High Voltage b Earth Ground _ Inside Enclosure Protected Earth Lifting Point Ground 1 3 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 M 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 S R R K S S Operate this equipment within design specifications M OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you M Make sure the equipment and components are properly GROUNDED before you switch on power M Use EXTEREME CAUTION when working with dryer HIGH HEAT can
24. be dangerous Keep body parts tools clothing and debris away from dryer Portable Drying Conveying Systems Chapter 1 Safety 7 of 63 M When welding or brazing in or around this equipment make sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed M Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled M Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 1 4 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must
25. be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No mater who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production e Loss of a skilled operator temporarily or permanently e Breakdown of shop morale e Costly damage to equipment e Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Portable Drying Conveying Systems Chapter 1 Safety 8 of 63 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 c
26. ccant bed strips moisture from the air The dried process air is then re heated and delivered back into the drying hopper for more moisture removal Portion of the low dew point process air is directed to the desiccant tank that is off process This air is heated to approximately 450 F 232 C before entering the bed that is in regeneration The moisture is then forced from the desiccant before being exhausted into the atmosphere A small amount of ambient air is introduced into the process return air filter to make up for the air lost during the bed regeneration To compensate for the humidity content in the air this dryer is supplied with the proper amount of desiccant What is desiccant Desiccant is a material that attracts and holds absorbs water from the air The desiccant our dryers use is a synthetic crystalline metal aluminosilicate blended with a clay binder and formed into beads The Process Regeneration Cycle Our dryers have two desiccant beds While one bed is on line in the process air loop the other is off line being regenerated When a desiccant bed is on line it absorbs moisture from the process air In time the bed becomes saturated with moisture and needs to be regenerated The dryer automatically redirects the process airflow to the second bed and starts the regeneration cycle on the first bed During regeneration the dryer system heats the very low dew point air and forces it through the desiccant bed The moi
27. ccurs 14 The dryer is shut off by pushing the SHUTDOWN button on the PLC or turning the control power On Off switch to the OFF position 15 Refer to the schematic drawing enclosed in the control enclosure 4 3 Shutting Down the Dryer 1 Turn off the conveying system supplying the drying hopper and or machine Press the SHUTDOWN button for the dryer to complete its cycle 2 When processing is complete close the hopper slide gate and shut down any in line companion equipment such as the aftercooler 3 If the dryer is shut down using the SHUTDOWN button on the dryer status screen the process heater will shut off and the bed regeneration process will be completed When the dryer is started at a later date the process air will be directed through the bed that was regenerated last 4 If the dryer control switch is turned off without using the dryer shutdown feature the dryer and the on board conveying system will stop immediately When the dryer is started at a later date the process air will be directed through the last bed that was being used when the dryer control switch was turned off If a bed was being regenerated when the dryer control switch was turned off the regeneration process would begin over again on that same bed Portable Drying Conveying Systems Chapter 4 Operation 39 of 63 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule The checklist below contains a list of items which should be inspected and or rep
28. ch on of the regeneration heater boxes has tripped Corrective Action Check the pressure setting of the filter pressure differential switch against the print Adjust accordingly Check the filter pressure differential switch to make sure it is functioning Replace is necessary The switch is indicating the incorrect desiccant tank is in regeneration Check the wiring of the switch against the wiring diagram Make sure all the wire connections are tight The return air temperature thermocouple is not connected to the temperature controller Make sure the connections are correct and tight The return air temperature thermocouple is damaged Replace the thermocouple Make sure the process air filter is clean Clean or replace if necessary Make sure all the hose connections are tight The process heater contactor has failed in the closed position Check heater contactor replace if necessary Check the high temperature snap switch replace if necessary Make sure the process air filter is clean Clean or replace if necessary Make sure all the hose connections are tight The Regeneration heater contactor has failed in the closed position Check heater contactor replace if necessary Check the high temperature snap switches replace if necessary Chapter 6 Troubleshooting Dryer Status Dryer Normal Process blower ON Process heaters ON Regen heaters ON Alarm Message ON Alarm ho
29. ctory Setup If the preset parameters on the controller have been tampered with and it no longer functions properly call the Service Department Note This controller is not meant to be modified WATLOW Operating Parameters The WATLOW controller has only one mode selection ALARM The factory has set the security level to protect the critical parameters from being accidentally changed Below is an explanation of the modes you will have access to and the manufacturer default settings Entering Operating Parameters to Select Modes To enter the display 1 Press both the Up and Down J keys for three seconds from the home page The word SEE will appear in the upper display and PAGE will appear in the lower display 2 Press the Advance Key l H to move through the parameter prompts 3 Press the Up D or Down J keys to change the parameter value 4 Press the RESET Key at any time to return to the Home Page display Figure 6 Setting List for Redundant Safety Controller WATLOW Part No A0568961 Mode Parameter Setting range Default Manuf Sensor Type Thermocouple Linearization Temperature Units S dEC Temp Decimal Places INFOSENSE Process Scale Low Process Scale High Calibration Offset Ot 1 Output 1 Function Limit 2 2 hyS1 Limit 1 Hysteresis 0 0 to 999 0 1 0 2 Output 2 Function Off Process Alarm Limit 2 OFF f LSd2 Output 2 Sides Both high low Both Portable Drying Conveyin
30. dboard box 1 Pry the crating away from the skid Note Remove the nails holding the box to the skid and lift the box off carefully avoiding staples in the I x 4 wood supports Cut the steel banding 2 Use a pry bar to remove the blocks securing the unit to the skid 3 Lift unit from sides Use a pry bar if necessary to carefully remove the skid from the unit 4 Lower slowly 3 2 Rigging and Placing the Dryer Take care when rigging and placing the drying and conveying system Figure 1 below shows a suggested safe rigging diagram It lets you lift the dryer hopper unit vertically using a fork truck Caution If you are mounting a machine mount dryer with a magnet or transition adaptor on the machine throat you must provide additional support to hold the dryer securely on the machine Be aware that off center static and dynamic hopper loading can occur with machine vibration Again provide additional support to hold the dryer securely on the machine For 60 cfm dryer units you must provide additional support to stabilize these units and to protect personnel when installing on machine throats Use caution and observe safety rules when lifting and placing your dryer Portable Drying Conveying Systems Chapter 3 Installation 15 of 63 Figure 1 Suggested Lift Rigging for Cart Mount Dryers Caution Do not use a hoist to move or rig your Drying Conveying System when it is mounted on a cart Moving the un
31. e blower rotates improperly reverse any two wires at the fused disconnect outside the dryer or at the disconnect terminal in the control enclosure This assures that the blower rotates in the proper direction Drying Hopper Air Trap Considerations If Equipped Our exclusive air trap assembly on the top of the drying hopper prevents ambient air from contaminating the material being dried To ensure that your unit will operate at peak efficiency do the following e Keep the material level at the mid point of the air trap This can be achieved by utilizing a hopper loader or vacuum conveying system to supply material to the drying system Installing the Optional Aftercooler Water cooled 15 30 60 cfm models use a water to air heat exchanger as an aftercooler Cooling water is required for this design 3 gpm at 85 F or lower Return air from the hopper passes through the air filter to trap fines and dust before entering the heat exchanger Installing Water Lines Hose and Hose Clamp When installing the water lines ensure that the aftercooler utilizes either tower chilled or city water as warm as 85 F 29 C Recommended flow rate is three 3 gpm gallons per minute 11 liters per minute Portable Drying Conveying Systems Chapter 3 Installation 18 of 63 NOTE If the Aftercooler is used as a plasticizer trap the water temperature of 50 F or lower is recommended 3 5 Initial Start up Pre Startup Checks M Check the process a
32. ed ies Serna ee nie yntanes 63 Portable Drying Conveying Systems 5 Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your drying system The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the drying system We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the drying system These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the dryer safely and efficiently The Maintenance chapter is intended to serve as a source of detailed ass
33. embly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your drying system provides excellent long Service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Portable Drying Conveying Systems Chapter 1 Safety 6 of 63 1 2 Safety Tag Information Dryer Safety Tags Hot Re
34. epair NEVER attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment e 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 e Report the following occurrences IMMEDIATELY e unsafe operation or condition e unusual dryer conveying system action e leakage e improper maintenance Portable Drying Conveying Systems Chapter 1 Safety 9 of 63 e NEVER stand or sit where you could slip or stumble into the equipment while working on it e DO NOT wear loose clothing or jewelry which can be caught while working on the equipment In addition cover or tie back long hair e Clean the equipment and surrounding area DAILY and inspect the machine for loose missing or broken parts e Shut off power to the equipment when it is not in use Turn the switch to the OFF position or unplug it from the power source Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning
35. equipment maintenance periods Press the DRYER RESET button MB RESET button and or DB RESET button to reset the counters When and if the counters have been reset on the controller the operator can return back to the MAIN MENU or SYSTEM MENU by touching the appropriate button on the screen Portable Drying Conveying Systems Chapter 4 Operation 33 of 63 Input Status UPDATE L NEU T STATUS oururs HTR_SFTY O Ld SWITCH O aaa FILTER O SEM VERIFY O ae BLW SFTY O HTA SFTY O This screen allows the operator to view the status of the variables contributing to the input of material into the drying system It also is useful in troubleshooting system issues 1 e a dirty filter or low material level in a hopper At this point the operator may choose the SYSTEM MENU button to go back to the system menu or MAIN MENU to return to main menu or press OUTPUTS to access the output screen Output Status UPDATE OUTPUT STATUS as PROCESS ENABLED IMPUTS VALVE MOTOR O l ALARM G oscar REGEN ENABLE O SGT CLOSED LOOP O ae This screen allows the operator to view the status of variables contributing to the disbursement of material from the drying system to the molding machine At this point the operator may choose the SYSTEM MENU button to go back to the system menu or MAIN MENU to return to main menu or press OUTPUTS to access the output screen SYSTEM SETTINGS The SAVE SETTING button will save the curre
36. erms 7 7 Dryer Identification Serial Number Tag Located on back of Dryer Company Logo C XXX Series Dryer Model Number XXX 15 Max Drying Capacity HR 460V Serial Number 060701R 1 Date of Manufacture 06 2003 4 5A Over current Protection Device s 4 5A Total Frequency 50 60Hz Compressed air supply None Dryer Mass 400 Ibs 180 KG Electrical Diagrams amp Street Address City State Zip Code Telephone Number Portable Drying Conveying Systems Chapter 7 Appendix 62 of 63 7 8 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 630 595 1060 Fax 630 475 7005 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 233 4819 or call 630 595 1060 Emergencies after 50m CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Sales Department Call 630 595 1060 Monday Friday 8am 5pm
37. from primary drying temperature to secondary drying temperature or back to the primary drying temperature set point SET UP TEMP The SETUP TEMP is the secondary temperature setting for the return air temperature When the return air temperature of the drying is lower than this set point after a certain delay time the process temperature set point will switch back to the primary drying temperature set point Once the parameters have been set for the drying process the operator can return to the DRYER MENU MAIN MENU or BACK to the screen 1 of 2 of the OVERDRY PROTECTION Setting Values By pressing and holding the numbers in the SET BACK DELAY button the following screen will be displayed Portable Drying Conveying Systems Chapter 4 Operation 27 of 63 Enter the values you would like to set in the screen by pressing the number keys Press ENT Enter when you are finished to set the new values or CLR Clear to erase the current values and reenter new ones The next feature in the DRYER MENU is the ALARMS button screen Alarms Retains 100 of the most recent alarms This screen allows the operator to review the number and type of issues that the Dryer has encountered during its operation The Alarm History screen is NOT reset able Problems can be viewed by Date Hour and Comment Because of the size of the screen only three 3 comments alarms can be viewed at a time To view alarms not visible on the screen p
38. g Systems Chapter 4 Operation 37 of 63 None Process Value Limit 1 Low Set Limit 1 High Set Limit 2 Low Set Limit Upper Display Look 2 High Set Alarm 2 Low Set Alarm 2 Process High Set Limit 3 Low Set Limit 3 High Set Alarm 3 Low Set Alarm 3 High Set None Process Value Limit 1 Low Set Limit 1 High Set Limit 2 Low Set Limit Limi imit 1 High Set Lower Display Look 2 High Set Alarm 2 Low Set Alarm 2 High Set Limit 3 Low Set Limit 3 High Set Alarm 3 Low Set Alarm 3 High Set 0 no lockout 1 Programming and Setup Page Locked 2 Limit Set Points are the only Operation Page parameters accesible 3 Full Lockout LOC Lockout 4 2 System Operation Procedures 1 Turn the disconnect switch on the control panel to the ON position Power is applied to the voltage line fuses and line side of the control power switch 2 Turn the control power switch to the ON position Power is applied to the PLC and touch screen Push the start button on the PLC and the valve will move to the start position as follows The valve motor rotates until the cam switch makes 2 transitions b If the cam switch does not make a transition within 10 seconds a valve motor fault alarm is generated The alarm horn and light are activated The valve motor heaters and blower shut off Pressing the ALARM SILENCE pushbutton will deactivate the alarm horn and light Note Cycle control power to restart the dryer c The valve will normally com
39. he actual process air temperature is entering the drying hopper Portable Drying Conveying Systems Chapter 4 Operation 23 of 63 Machine Status The area in the lower left portion of the touch screen conveys two lines of information relating to the overall operation of the dryer The following is a list of typical machine dryer summary status line text messages 1 Left Bed In Process 8 Left Bed Heat 2 Right Bed In Process 9 Left Bed Cool 3 Process Offline 10 Left Bed Ready 4 Valve Changing Position 11 Right Bed Heat 5 Auto start Timer Enabled 12 Right Bed Cool 6 Autotune in Progress 13 Right Bed Ready T Dryer Offline 14 Over dry Protect Active Start Button The START BUTTON allows the user to stop and start the dryer manually When the start button is pressed the dryer begins to operate The text in the button will change from START to SHUTDOWN The next time the button is pressed the dryer will go into a sequence shutdown and the button text will change to RESTART The process heater will shut off the current bed regeneration will be completed and then the blower will stop If sequence shutdown is not desired turning the POWER SWITCH off will turn off all components of the dryer immediately and the optional conveying system will be turned off also Setting Values By pressing and holding the numbers in the SETPOINT button the following screen will be displayed 0 HS Enter the values you would like to set
40. ious page Servicing Process Air Filters Caution Operating the dryer without the process air filter installed voids your warranty Filter cleaning is an important part of your dryer maintenance program Dehumidifying dryers have a single cartridge canister type filter in the process air loop The filter protects blowers from plastic fines drawn in from the drying hopper and prevents the desiccant from being contaminated Regular filter cleaning is essential to keep your dryer operating at peak efficiency You can blow or vacuum the dirt out of the filter with compressed air but remember it could become damaged from high pressure blowing Recommendations for Cleaning and Replacing Filters e Turn off and or lock out electrical power to the dryer e Remove the threaded fastener securing the filter access cover then remove the cover e Remove the nut on the center retaining rod to remove the filter cartridge Figure Air Filter Location and Disassembly Thumb Nut Pa Clamp N v N j d 4 Dust Can Filter l Filter Housing Cartridge Portable Drying Conveying Systems Chapter 5 Maintenance 41 of 63 Vacuuming Try vacuum cleaning a soiled filter first Vacuuming removes most large particles and surface contaminants and may suffice for the first time you clean a filter Use a commercial duty recommended or household vacuum cleaner Vacuum the filter from the air intake dirty side only C
41. it with a hoist will cause it to become unstable and may cause damage to the equipment and or injury to personnel Figure 2 Suggested Lift Rigging for Cart Mounted Dryers Note Floor Mounted Dryers can be lifted by hoist or fork lift USE Overhead Crane Portable Drying Conveying Systems Chapter 3 Installation 16 of 63 Figure 3 Suggested Lift Rigging for Cart Mounted Dryers Mounting flange l N Diameter hole Notes Hopper mounting flanges on 0 75 and and 1 5 cu ft 20 amp 40 liter hoppers are supplied blank so the customer can drill to match existing machine throat 3 0 cu ft 80 liter hoppers and larger are not supplied with a cast flange as shown Caution When using a hoist to move a machine mounted dryer ALWAYS attach chains to the three 3 locations lifting points on the unit Moving the Dryer without the chains attached to all of the lifting points will cause the unit to become unstable and may cause damage to the Dryer and or injury to personnel 3 3 Electrical Connections When making electrical connections to your unit ensure that you take into consideration and make arrangements for the following A qualified electrician should make all electrical connections Fulfill all national state and local safety and electrical code requirements The serial tag lists voltage phase and amp draw information e Line voltage must be within p
42. itch was turned off the regeneration process would begin over again on that same bed Portable Drying Conveying Systems Chapter 3 Installation 20 of 63 Chapter 4 Operation 4 1 Controller Description and Operation Identifying Control Panel Components for the AP 1 Controller Disconnect Switch The Disconnect Switch is located in the front upper right hand corner of the control enclosure It allows the user to disconnect power to the dryer for emergency shutdown service or long periods of inactivity Control Power Switch The Control Power Switch is located on the front of the control enclosure below the touch screen The switch energizes the control circuit PLC touch screen relays etc within the control enclosure Touch Screen The Touch Screen is located in the center of the control enclosure Once the disconnect is on and the control circuit is energized the machine can be started and parameters can be adjusted through the touch screen Alarm Horn amp Light The Alarm Horn is located in the center of the control enclosure next to the Control Power Switch The Alarm Light is located on the top of the enclosure These devices give an audible and visual indication that there is a malfunction with the system Figure 3 Typical Control Panel Portable Drying Conveying Systems Chapter 4 Operation 21 of 63 Process Air Temperature Controller Control package use a PLC with a touch screen interface to control the
43. laced to keep your Portable Drying Conveying System operating at peak efficiency Perform each inspection at the regular intervals listed below System model Date Date Date Date Date Date Date Date Date Date Date Date Date Every Day Inspect all filters for wear tall fiters for if dirty or worn Check to make sure that all hose connections are air tight _Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec_ Lock out electrical power and inspect electrical wiring for integrity Lock out electrical power and check heater elements for continuity using an ohmmeter Check dew point and temperature tracking with an external dew point monitor and pyrometer Visually inspect the shifting of the airflow valve during one cycle Next scheduled Actual inspection Next scheduled Actual inspection Inspect desiccant Replace 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 Portable Drying Conveying Systems Chapter 5 Maintenance 40 of 63 5 2 Preventative Maintenance This section describes maintenance procedures which will increase the longevity and efficiency of your Portable Drying Conveying System Perform them at the regular intervals listed on the checklist on the prev
44. leaning with Compressed Air Blow clean dry compressed air up and down the pleats blowing out the filter from the inside out Remove loose dirt from the filter with compressed air or vacuum from the outside Caution DO NOT clean wash filter with water After each cleaning e 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 Check the gasket for damage A damaged gasket allows contaminants into the process Replace as needed Servicing the Dew Point Monitor The accuracy of the dew point monitor on mini dryer systems depends on proper operation of the dew point sensor and the control board The dew point sensor is in the process air stream and is therefore susceptible to contamination Dew point sensor life depends on e Air temperature and flow passing over the sensor e The amount of fines dust in the process air e The amount of plasticizer vapor in the process air Once every six months the dryer operator should monitor the initial dew point sensor readings and establish a periodic replacement schedule as needed Caution Do not attempt to check the continuity or resistance of the dew point sensor The sensor will be destroyed Portable Drying Conveying Systems Chapter 5 Maintenance 42
45. lus or minus ten percent 410 of the voltage listed on the serial tag or damage may occur Phase imbalance must be less than two percent 2 e Connect main power to the dryer at the disconnect or terminals in the upper right corner of the control enclosure Install a fused disconnect with a lockout feature in the power main leading to the dryer The power drop must include a ground wire e Make sure all electrical connections are tight Portable Drying Conveying Systems Chapter 3 Installation 17 of 63 3 4 Setup Procedures This section provides the procedures necessary for configuring your portable drying conveying system Configuration of your unit includes checking for proper blower rotation and installing the optional aftercooler on 60 cfm models We recommend that you carry out these procedures in the order given here Note Before carrying out these procedures install all equipment as described in this section Checking for Proper Blower Rotation Three Phase Models Caution In three phase models incorrect phasing of power leads can cause backward rotation of blower motors and CONTAMINATION OF THE DESICCANT Always check blower rotation before putting material in the drying hopper The blower is rotating properly when air flows from the delivery outlet Note Holding your hand in front of the air return will also indicate if the blower rotates in the proper direction by feeling suction If the three phas
46. n a ube Shamed dacs eae Naot teh 19 Stann UDANE OM aesa aai a a steer melee 19 Auto Tunng the DIVET serur A 19 SHUTING DOWNING Dry resposes ae AEN EES ANE NE EEMS REEERE SRN 20 CHAPTER 4 OPERA TION sss ss sss se seene neee 21 4 1 Controller Description ANd Operation eee ee eee 21 Identifying Control Panel Components for the AP 1 Controller sese eee ee 21 Portable Drying Conveying Systems 3 Discon el WGN arsssaecscclonns lccwnizcranntonsctcncs deus verledsetaderteldosnitasinlscaessteensvewst 21 Control POWE OWIE T 21 B Re lere TET 21 PUAN lt eiee SLON T 21 Process Air Temperature Controller eee ee ee eee 22 SAUD eT 22 Man Menu e TT 23 Dryer Status Scree ensenen iaa ai uae Aad abel coe obeh a 23 Sa UE e TTT 24 Dryer IE T 25 Daa 5 gee te 0 cement er an ree ete ees an eee nen AO Sere ma ene Ree tears era nee ee eee 25 BIO T 25 Dryer Setup Screen 1 of 3 Process Temperature High amp Low ALarm 25 Dryer Setup Screen 2 of 3 Choosing Degree F or Degree C e ee eee 26 Dryer Setup Screen 3 of 3 Process return air temperature 26 OVerdry Protection Seletan te ash eats len eee ta eeu heeds 26 Screen 1 of 2 Enable or Disable the feature esse eee e eee 26 Screen 2 of 2 Overdry Protection Parameter Settings sese eee ee 27 TT nT 28 AWO TOUNO renege ener Sm Ie go oe 28 DEW PE SOUS TT 29 PUTO T TTT 29 van WAS UND iea hae tase hottest eat aetna ad eee duet ate eects E Mate 30 Ie
47. n be set for degrees Fahrenheit between 40 through 15 degrees and degrees Celsius between 40 through 10 degrees Setting Values By pressing and holding the numbers in the HIGH DEW PT ALARM the ALARM STARTUP DELAY or the ALARM BED SW DELAY buttons the following screen will be displayed Enter the values you would like to set in the screen by pressing the number keys Press ENT Enter when you are finished to set the new values or CLR Clear to erase the current values and reenter new ones To set the values in the next field press ENT Enter to close the screen shown above Then select the next number field to enter new values Once this feature has been set the operator can return back to the DRYER MENU or MAIN MENU by touching the appropriate button on the screen Auto Start AUTOSTART TIMER IE loura OFF T BALITOSTARTE l TIHER This screen allows the operator to set the time and day that the dryer will start automatically Reference page 32 Make sure the clock is set to current date ant time Pressing NEXT DAY allows the operator to scroll forward through the days of the week to select the day they desire the dryer to start Pressing PREV DAY allows the operator to scroll backward through the days of the week to select the day they desire the dryer to start Portable Drying Conveying Systems Chapter 4 Operation 29 of 63 By touching the ON TIME and OFF TIME sections on the screen the operator can e
48. n may not apply to you The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty No person agent manufacturer distributor dealer installer or company is authorized to change modify or extend the terms of this warranty in any manner whatsoever The time within which an action must be commenced to enforce any obligation of the Company s arising under this warranty or under any statute or law of the United States or any state thereof is hereby limited to the duration of this warranty Some states do not permit this limitation so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For transactions involving the potential applicability of international law or that of a foreign country this warranty policy and the procedures hereunder shall be governed by Portable Drying Conveying Systems Chapter 7 Appendix 55 of 63 applicable federal and state law but not by the United Nations Convention on Contracts for the Sale of Goods Customer Responsibilities Any sales use or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser 7 2 Op
49. nd return hoses for tight connections M Check all companion equipment such as the drying hopper verify that the loading system is ready for operation M Verify that all dryer electrical connections are tight M Verify that the thermocouple is properly installed at the hopper inlet Starting Up the Dryer 1 Turn on energize the disconnect switch in your power drop then turn on the disconnect switch on the dryer 2 Turn the system ON OFF switch to ON to energize the display panel 3 Check the display for the proper temperature scale F or C 4 Close the slide gate at the bottom of the drying hopper Make sure that the blowers turn in the right direction 5 Fill the drying hopper with material 6 Press the START button on the Touch Screen to start the dryer The process blower starts 7 If your dryer has a water cooled aftercooler make sure that sufficient cooling water 3gpm at 85 F or lower flows properly through the coil and that you have bled any trapped air from the system 8 Set the process set point on the touch screen 9 After the proper pre drying time for the initial hopper fill has elapsed fully open the drying hopper slide gate Note To allow proper residence time during continuous processing maintain the material level in the hopper at the midpoint of the air trap assembly Auto Tuning the Dryer Requires Supervisory Password From the Dryer Status screen press D Menu and select A
50. nk is in Process blower OFF FAULT been wired correctly regeneration Check the Process heaters OFF wiring of the switch against Regen heaters OFF the wiring diagram Make Alarm light is ON sure all the wire connections Alarm horn is ON are tight VALVE MOTOR The valve has made Limit switch may be out of Dryer Shuts down OVERIDE enough rotations and position Re adjust the Process blower OFF the correct position of switch to make sure it trips Process heaters OFF the valve was not when it is at the high Regen heaters OFF detected position and it does not Alarm light is ON touch the cam when it is at Alarm horn is ON the low position Limit switch may be faulty Replace the switch and make sure the wires are connected correctly Portable Drying Conveying SystemsChapter 6 Troubleshooting 48 of 63 Alarm Message PROCESS SENSOR FAIL The process temperature thermocouple is open REGEN SENSOR FAIL The Regeneration temperature thermocouple is open PROCESS HIGH TEMP The process temperature has exceeded the alarm set point Portable Drying Conveying Systems Chapter 6 Troubleshooting Corrective Action Dryer Status The process temperature thermocouple is not connected to the temperature controller Make sure the connections are correct and tight Dryer Shuts Down Process blower OFF Process heaters OFF Regen heaters OFF Alarm light is ON Alarm
51. nt dryer parameter settings The RESTORE SETTINGS button will restore the dryer parameter settings that were saved previously The RESTOR FACTORY DEFAULTS button will restore the initial dryer parameter settings as the dryer was shipped from the factory Portable Drying Conveying Systems Chapter 4 Operation 34 of 63 At this point the operator may choose to return to the SYSTEM MENU or MAIN MENU by pressing the appropriate buttons Service Menu RETURN This service menu screen is PASSWORD PROTECTED and meant for manufacturer personnel use only Press the RETURN key to go back to the SYSTEM MENU ST STEM MENU CLOCE METERS MEM STATUS MEM MEH Touching the MAIN MENU button in the SYSTEM MENU screen will return the operator back to the overall menu screen Alarm Screens This screen allows the operator to review the number and type of issues that the Drying Conveying System has encountered during its operation Problems can be viewed by Date Hour and Comment Portable Drying Conveying Systems Chapter 4 Operation 35 of 63 Because of the size of the screen only three 3 comments alarms can be viewed at a time To view alarms not visible on the screen press the DOWN button To return to a particular alarm press the UP button to scroll upward in the alarm history Pressing CNV Convey in this screen will take the operator to the CONVEY STATUS of the system You will only get CNV alarms with a Nomad dryer
52. nted in the center compartment below the desiccant beds Although the replacement procedure is the same for each heater the wattage varies by model voltage temperature range etc WARNING Hazardous electrical current present Disconnect and lock out power before you replace heater elements Figure 10 Process Heater Location and Disassembly Undo 6 10 32 Button Head Screws using 1 8 Allen Wrench 1 Wide x 1 8 Thick High Temperature Gasket L 4 40 screws B Hi Temperature Snap Switch Portable Drying Conveying Systems Chapter 5 Maintenance 45 of 63 Procedures 1 Sketch the heater wiring configuration so you can properly re wire the heater 2 Remove the ceramic nuts and wires to the heater plate assembly being removed or replaced 3 Remove the six 6 10 32 button head screws securing the process heater plate using a 1 8 Allen wrench and slide out the assembly 4 Remove the heater s from the mounting plate by removing the large brass nuts and washers 5 Re install the heater s and heater plate assemblies in reverse order Install new heater gaskets and securely tighten all fasteners Caution Heater loops should not touch each other Hot spots lead to premature heater failure 6 Reinstall the wires based on the sketch you made earlier 7 Reinstall the ceramic nuts to each heater terminal Replacing Cleaning
53. nter the values for the time they wish the dryer to turn on and off See the next page for instructions on setting values for this feature Pressing the AUTOSTART TIMER DISABLED button will activate this dryer feature Pressing AUTOSTART TIMER ENABLED will deactivate this feature Once this feature has been set the operator can return back to the DRYER MENU or MAIN MENU by touching the appropriate button on the screen Setting Values 0 ICRA Enter the values you would like to set in the screen by pressing the number keys Press ENT Enter when you are finished to set the new values or CLR Clear to erase the current values and reenter new ones To set the values in the next field press ENT Enter to close the screen shown above Then select the next number field to enter new values Main Menu MATA MENU This screen allows you to jump to the different areas of the controller to set monitor and operate different features of the Drying Conveying System Conveying screens are used only with Nomad dryers NO USER LOGGED ON indicates that the password to access certain features of the dryer is not entered USER LOGGED ON indicates that the password to access certain features of the dryer is still active and these features can be accessed and changed SYSTEM H Help Menu EMU MA I N HENO Portable Drying Conveying Systems Chapter 4 Operation 30 of 63 System Menu oT oTEM MENU SYSTEH SET HOJA ALARH SETUP L
54. of 63 5 3 Corrective Maintenance This section provides you with the information necessary to correct or repair any issues which might appear during the normal operation of your dehumidifying dryer Although we have listed how to perform these procedures it is recommended that you call the Service Department to have any in depth maintenance performed Symptoms of Worn Desiccant The moisture absorption capacity of the desiccant used in your dehumidifying dryer degrades after an indefinite period of time Useful life depends on variables such as the condition of the process filter how much dust and fines have been passed through the filter and got into the desiccant chamber and plasticizer vapors in the return air WARNING Handling desiccant material is HAZARDOUS Wear an N 100 type safety filter mask or equivalent to avoid prolonged breathing of desiccant dust Wear safety goggles and gloves to avoid contact with eyes and skin Handle with adequate ventilation e Wash hands thoroughly after handling In case of eye contact immediately flush eyes with plenty of water for at least 15 minutes SEE A PHYSICIAN IMMEDIATELY IF IRRITATION PERSISTS Replacing Worn Desiccant Caution DESICCANT BEDS ARE HOT DURING OPERATION To avoid burn hazard make sure desiccant beds are sufficiently cool before replacing worn desiccant To access the Desiccant Bed 1 Disconnect electrical power to the dryer 2 Using a 1 8 Allen w
55. omponents of the dryer Alarm horn is OFF have proper seals on them desiccant tanks heater box filters after cooler Tighten the connections and replace any damaged seals Make sure the regeneration timing cycle matches the specs If not contact Service department Desiccant may be contaminated and blocking the air flow Check desiccant replace if necessary Portable Drying Conveying Systems Chapter 6 Troubleshooting 51 of 63 PROCESS LOOP BREAK Alarm Message Corrective Action Dryer Status PROCESS The process blower Make sure the process air Dryer Shuts Down BLOWER FAIL pressure switch did not filter is clean Clean or Process blower OFF detect enough replace if necessary Process heaters OFF pressure Check the rotation of the Regen heaters OFF blower Alarm Message ON Check the pressure switch Alarm horn is ON Process blower hose connection Replace hoses or the pressure has failed Check the over load rating against the wiring diagram Adjust accordingly Check the wiring of the blower Make sure it is wired for the proper voltage Check the process blower fuses for any fault Replace if necessary Check the blower motor starter Replace if necessary Check the blower motor Replace if necessary Check the incoming voltage against the name plate of the dryer PROCESS The process heater Check the heater fuses Dryer Shuts Down HEATER FAIL safety contactor is not
56. ontact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person REMEMBER e NEVER place your hands or any part of your body in any dangerous location e NEVER operate service or adjust the equipment without appropriate training and first reading and understanding this manual e NEVER try to pull material out of the equipment with your hands while it is running e Before you start the portable drying conveying system check the following e Remove all tools from the equipment e Be sure no objects tools nuts bolts clamps bars are laying in the hopper area e If your portable drying conveying system has been inoperative or unattended check all settings before starting the unit e At the beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly e Keep all safety guards in place and in good r
57. ooting 6 1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshooting is indicated Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to provide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destroy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necessary refer to the parts catalog section Alarm Message Cause Corrective Action Dryer Status VALVE The limit switch on the The switch is indicating the Dryer Shuts down POSITION valve may not have incorrect desiccant ta
58. ou believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tag out or failure to maintain a clean and safe working environment Portable Drying Conveying Systems Chapter 1 Safety 10 of 63 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for 15 30 or 60 cfm dehumidifying dryers Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service Our dehumidifying mini dryers are designed to generate heated dehumidified air at a very low dew point at carefully controlled temperatures for use in plastic drying systems The dryer circulates hot dehumidified air through a column of plastic resin in the large drying hopper The resin in the hopper is discharged through a slide gate in a first in first out manner 2 2 General Description The Drying System Dehumidifying dryers are used to generate very low dew point air heated to a controlled temperature for drying plastic pellets and regrind Our dryers force hot dry air through resin in a drying hopper where air picks up moisture from the material and draws it back to the dryer In the dryer a desi
59. plete one full cycle revolution If sequence shutdown is not initiated in 10 Seconds and control power switch or disconnect are turned off 1 The bed in process at power down will remain in process 2 The bed in regeneration at power down will remain in regeneration 3 The regeneration timing cycle will restart from the beginning 3 Once the control power is on and no fault conditions exist turning the Off On switch to the ON position and pressing the START button on the touch screen will start the dryer as follows The process heater is turned on and controlled by the PLC b The process regen blower is started c The regen heater is turned on and the regeneration timing sequence is initiated The regen heater is controlled by the PLC Portable Drying Conveying Systems Chapter 4 Operation 38 of 63 4 If either the left or right bed safety temperature switch opens a REGEN TEM SAFETY is generated The alarm horn and light are activated The process heater regen heater and process regen blower are turned off Pressing the ALARM SILENCE button on the touch screen will deactivate the alarm horn and light 5 Turn the Off On switch to the ON position and push the touch screen START button to restart the dryer If the switch is still open the dryer will not restart 6 If the PLC touch screen faults the optional redundant high temperature safety device opens or the process heater safety switch opens a process heater fault
60. rcuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Portable Drying Conveying Systems Chapter 2 Functional Description 13 of 63 Every effort has been made to incorporate these standards into the design of the drying system however it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue For example if a safety switch is guarding a motor and the safety switch fails the motor should not be able to
61. reen Portable Drying Conveying Systems Chapter 4 Operation 31 of 63 Note If password s feature is enabled please write down your passwords and file them in a secure location At this point the operator can return back to the MAIN MENU or SYSTEM MENU by touching the appropriate button on the screen Set Clock SET AUTOSTART LLL This menu allows the operator to set the AUTOSTART CLOCK and the ALARM CLOCK Press the SET AUTOSTART CLOCK or the SET ALARM CLOCK buttons to set the times and dates on these features Set Auto Start Clock SET CLOCK 08 02 03 l2 39 SYSTEM SET TIME MENL This screen allows the user to set the 7 day timer which can be programmed for daily or weekly over midnight on off operation An internal battery backup holds the settings in memory when the dryer is de energized Setting Values By pressing the numbers Month Day Year Hours and Minutes under Set Clock on the previous screen shown above the following screen will appear DE aR IB Enter the values you would like to set in the screen by pressing the number keys Press ENT Enter when you are finished to set the new values or CLR Clear to erase the current values and reenter new ones To set the values in the next field press ENT Enter to close the screen shown above Then select the next number field to enter new values Pressing the SET TIME button will enter the new information into the controller When the new info
62. rench remove the four 4 10 32 button head screws holding the Desiccant Cap to the Regeneration Heater 3 Remove the Desiccant Cap 4 With a shop vacuum carefully remove all desiccant from each tower Portable Drying Conveying Systems Chapter 5 Maintenance 43 of 63 Figure 8 Desiccant Bed Location and Disassembly Undo 4 10 32 Button Desiccant Cap Head Screws using 1 8 Allen Wrench 13X Molecular Sieve ares 8x12 Beads pe a Regeneration Heater 1 Wide x 1 8 Thick Silicon Strip and Stick Gasket y ATA aa Ta IO yyy y S OO S B L Regeneration Thermocouple 16 Mesh 0 028 Diameter Wire 2 4 4 2 4 40 screws Stainless Steel Screen Hi Temperature Snap Switch m 1 Wide x 1 8 Thick High Temperature Gasket Caution You should properly dispose of any discarded desiccant Consult local disposal regulations for more information Inspect each lower desiccant screen for tears or holes where desiccant burned through Replace as needed 1 After cleaning each chamber add the full amount of bead desiccant specified per bed Amounts are listed in the Desiccant Amounts Table below Smooth the top level and finally add another layer of the remaining bead desiccant to the top Make sure this layer is level and smooth Tap the chambers
63. replace if necessary Process blower OFF responding Make sure the wiring is Process heaters OFF correct and wire connections Regen heaters OFF are tight Alarm Message ON Check the process heater Alarm horn is ON safety contactor Replace if necessary DIRTY FILTER The filter pressure Make sure the process air Dryer Normal differential switch has filter is clean Clean or Process blower ON tripped replace if necessary Process heaters ON Make sure the filter housing Regen heaters ON is installed correctly and the Alarm Message ON connections are tight Alarm horn is OFF Check the hoses to the filter pressure differential switch is connected correctly are not damaged and all the connections are tight Replace the hoses if necessary Check the wiring connections to filter pressure differential switch against the print Tighten the connections Portable Drying Conveying Systems Chapter 6 Troubleshooting 52 of 63 Alarm Message DIRTY FILTER VALVE MOTOR FAIL P RETURN SENSOR FAIL PROCESS TEMP SAFETY REGEN TEMP SAFETY Portable Drying Conveying Systems Cause The filter pressure differential switch has tripped The limit switch on the valve may not have been wired correctly The return air temperature thermocouple is open or failed The high temperature Snap switch of the process heater box has tripped The high temperature snap swit
64. ress the DOWN button To return to a particular alarm press the UP button to scroll upward in the alarm history Pressing CNV Convey in this screen will take the operator to the CONVEY STATUS of the system You will only get CNV alarms when conveying options are enabled Nomad only At this point the operator can return back to the DRYER MENU or MAIN MENU by touching the appropriate button on the screen Auto Tune This screen allows the operator to automatically tune the process air temperature control algorithm to a specific drying application The autotune sequence should be initiated if the user feels there are unacceptable fluctuations in the process air temperature The calculated P I and D variables will be shown in the lower left hand portion of the screen for reference purposes The autotune feature can be enabled by pressing the PUSH TO START PROCESS AUTOTUNE button AUTOTUNE IN PROGRESS or PROCESS NOT ACTIVE will inform the operator of the current status of this feature At this point the operator can return back to the DRYER MENU or MAIN MENU by touching the appropriate button on the screen Portable Drying Conveying Systems Chapter 4 Operation 28 of 63 Dew Pt Setup DEW POINT SETUP HIGH LIALT ALARM VALUE This screen allows the operator to set the dew point alarm value The HIGH LIMIT ALARM VALUE is an audible visual alarm which will sound when the process air dew point rises to this value Values ca
65. rmation has been entered into the controller the operator can return back to the MAIN MENU or SYSTEM MENU by touching the appropriate button on the screen Portable Drying Conveying Systems Chapter 4 Operation 32 of 63 Set Alarm Clock TC SET CLOCK TCS Cea os In this screen the user can set the variables which are used to time and date stamp alarms This feature works in conjunction with the ALARM screen See page 31 to notify the user of issues which the Dryer had encountered during its operation Setting Values Pressing the individual numbers in the second row of the screen shown above the operator can select the field Month Day Year Hours and Minutes he wishes to change Enter the values you would like to set by pressing the number keys Press ENT Enter when you are finished to set the new values or CLR Clear to erase the current values and reenter new ones Press END to return back to the CLOCK MENU screen Press the SYSTEM MENU button in the CLOCK MENU SCREEN to return back to the system menu screen and the next set of programmable features Hour Meters MO RESET RESETHBLE RESETS HHA A HT Tian This screen monitors the number of hours that the dryer machine blower and dryer blower have operated In addition to monitoring the total number of hours of equipment operation it also has reset table fields which allow the operator to set the counter back to zero This is useful for monitoring hours between
66. rn is OFF Dryer Shuts Down Process blower OFF Process heaters OFF Regen heaters OFF Alarm Message ON Alarm horn is ON Dryer Normal Process blower ON Process heaters ON Regen heaters ON Alarm Message ON Alarm horn is OFF Dryer Shuts Down Process blower OFF Process heaters OFF Regen heaters OFF Alarm Message ON Alarm horn is ON Dryer Shuts Down Process blower OFF Process heaters OFF Regen heaters OFF Alarm Message ON Alarm horn is ON 53 of 63 6 2 Determining Temperature Controller Errors or Sensor Errors Using a Thermocouple If the controller displays a temperature that is close to room temperature 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 Other service problems or questions can be answered by contacting the Service Department Portable Drying Conveying Systems Chapter 6 Troubleshooting 54 of 63 Chapter 7 Appendix 7 41 Warranty Unless otherwise specified this product includes a Standard ONE YEAR PARTS Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions as set forth in the operating manuals for such equipment THE FOREGOING EXPRESS WARRANTY IS EXCLUSIVE AND IN LIEU
67. run Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used on this equipment are primarily concerned with electrical power disconnection and the disabling of moving parts that may need to be accessed during the normal operation of the machine Some of the safety devices utilize a manual activator This is the method of initiating the safety lock out This may be in the form of a plug lever or a handle Within this lockable handle there may be a location for a padlock Personnel servicing the equipment should place a padlock in the lockout handle In addition to the safety devices listed above these dryers are equipped with a line cord plug This allows the operator or maintenance personnel to unplug the dryer from its power source and tag it out The plug can then be tagged with any number of approved electrical lockout tags available at most electrical supply stores WARNING Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing or cleaning this equipment Failure to do so may result in serious injury No one but the person who installed the lockout may remove it Portable Drying Conveying Systems Chapter 2 Functional Description 14 of 63 Chapter 3 Installation 3 1 Uncrating the Equipment Portable Drying Conveying Systems are shipped mounted on a skid enclosed in a plastic wrapper and contained in a car
68. ss and cool the Hose Regeneration i Return Air desiccant Air Filter Temperature Thermocouple Position 13X Molecular Sieve 8x12 K Low watt density beads A heaters can operate safely 2 1 2 Hose with minimum air Insulated Double wall l flow tainl constructed heater T l rhe arene lt drying hopper housing and Cad ee desiccant container High E l temperature Process Air Regeneration snap switches Temperature thermocouple 3 monitor the heat Thermocouple monitors and 2 Hose status of the gai coniro the heater housings L 5 regeneration E temperature 9 2 1 2 Insulated Delivery Air Hose N Z L Portable Drying Conveying Systems Chapter 7 Appendix 58 of 63 Figure 14 Low Heat Model 120 F to 250 F Air Flow Schematic Pressure switch makes sure the blower is functioning correctly Dryer valve Utilizing 40F dew point air to regenerate and cool the desiccant Ra MICS CO CERT E See pee docs N 13X Molecular N nnn S 8 1 2 T S N E A beads Double wall constructed _ heater housing and desiccant y container Regeneration
69. stomer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on it You should have M Portable drying conveying system 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 shipments in the United States and Canada call 1 800 233 4819 for all other countries call our international desk at 630 475 7491 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Portable Drying Conveying Systems 2 Table of Contents CHAPTER 15 SAFETY TTT 6 lei lt eud TO WSe TIS Manual seen e cae eae Ics a eae 2 6 Safety Symbols Used in this Manual ee eee 6 122 Satety Tag Teta ele 7 Dryer Satety TAGS T 7 1 5 Wamngsand i FECAUTONS Accietaaicielavnetariuccnutrideas tetuhioiaidonindavtetehenmuctmcidenaabianetion 7 Tet FARES OOMS IDI cesarean teach cach anand E ud ntcsaniomerou Guus Mauer oie 8 General Sele cI 8
70. sture driven off the bed bleeds to the atmosphere Portable Drying Conveying Systems Chapter 2 Functional Description 11 of 63 2 3 Standard Features Mechanical Features e Rugged compact cart with handles and sturdy 4 10 cm casters e Dual desiccant beds e Electrically motorized air valve e 13X Molecular Sieve e Single regenerative process blower e Drying temperature range of 180 F to 250 F 82 C to 121 C e 2 5 hose connections Electrical Features e Process thermocouple to be connected to drying hopper air inlet e Nema 12 control enclosure e NEPA79 machinery electrical standards e Non fused electrical disconnect e Branch fusing e Solid State process heater contactor e Regeneration temperature control e Process high temperature alarm light e Dirty filter indicator e Process regeneration heater box e Dew Point Monitor e Material saver over dry protection e High temperature safety system Process Regeneration e 7 day timer auto start Controller Features e Mitsubishi programmable relay controller e Display of process temperature set point and actual settings e Display of process air dew point Portable Drying Conveying Systems Chapter 2 Functional Description 12 of 63 2 4 Options Options marked with indicate options that can be factory installed or retrofitted in the field e Process temperature up to 400 F 204 C including aftercooler with dryer and silicone insulated deli
71. the Cooling Coils WARNING Hazardous electrical current present Disconnect and lock out power before you replace heater elements Figure 11 Cooling Coil Location and Disassembly 1 Wide x 1 8 Thick High Temperature Gasket Use compressed air or a steam cleaner to blow the dust off or clean Undo 4 10 32 Button l l Head Screws using 1 8 any oily residue on the coil Allen Wrench lR 9888999981 CR RR 198988881 Water flow requirement If used as an After Cooler 3 to 4 GPM 80F If used as a Plasticizer Trap 3 to 4 GPM 40F to 45F Note To clean the cooling coil use compressed air or a steam cleaner to blow the dust off or clean any oily residue on the coil Portable Drying Conveying Systems Chapter 5 Maintenance 46 of 63 Replacement Procedures l O N A na A W N Shut down the dryer tag out and lock out the controls if necessary Shut the water off to the cooling coil Remove the four 10 32 bolts Gently slide the cooling coil out Visually inspect the coil for leaks dirt and ant sign of volatiles Blow the dust out or if the coil is covered with plasticizer steam clean it Place the coil back in its housing Make sure the gasket is OK replace if necessary Inset the four 10 32 bolts back in place Turn the water to the cooling coil back on Portable Drying Conveying Systems Chapter 5 Maintenance 47 of 63 Chapter 6 Troublesh
72. tional Components The following is a list of options which your Portable Drying Conveying System may have been equipped with e High Temperature Option with Aftercooler e Casters 7 3 Technical Specifications Annex B Information The following design information is provided for your reference 1 No modifications are allowed to this equipment that could alter the CE compliance 2 Ambient temperature 40 degrees Celsius Maximum 104 degrees Fahrenheit 3 Humidity range 50 relative humidity 4 Altitude Sea level 5 Environment Clean dust free and non explosive 6 Radiation None 7 Vibration Minimal i e machine mounting 8 Allowable voltage fluctuation 10 9 Allowable frequency fluctuation Continuous 1 Intermittent 2 10 Nominal supply voltage 460 3 60 Verify on serial number tag 11 Earth ground type TN system has one point directly earthed through a protective conductor 12 Power supply should include a ground connection 13 Over current protection is supplied in the dryer and conveying system but additional protection should be supplied by the user 14 The door mounted disconnect serves as the electrical disconnect device 15 Dryer and conveying system are not equipped with local lighting 16 Functional identification 17 Dryer and conveying system are equipped with a CE mark 18 Dryer and conveying system are supplied with an operating manual in the language of the destination country
73. tive Action Dryer Status The process temperature thermocouple is not connected to the temperature controller Make sure the connections are correct and tight Dryer Shuts Down Process blower OFF Process heaters OFF Regen heaters OFF Alarm light is ON Alarm horn is ON The process temperature thermocouple is damaged Replace the thermocouple The regeneration temperature thermocouple is not connected to the temperature controller Make sure the connections are correct and tight The regeneration temperature thermocouple is damaged Replace the thermocouple Dryer Shuts Down Process blower OFF Process heaters OFF Regen heaters OFF Alarm light is ON Alarm horn is ON Make sure the process filter is clean Clean or replace if necessary Double check the alarm set point 35 F Check the positioning of the thermocouple inside the air inlet of the drying hopper The tip of the thermocouple should be centered to the tube and not touching any metal part of the tube The drying temperature set point is lower than dryer capabilities Check the dryer specs Make sure all the hose connections are tight Make sure the regeneration timing cycle matches the specs If not contact Service department Dryer Shuts Down Process blower OFF Process heaters OFF Regen heaters OFF Alarm light is ON Alarm horn is ON 50 of 63 Alarm Message Corrective Action Dryer Stat
74. us REGEN LOW The regeneration Make sure all the hose Dryer Normal TEMP temperature did not connections inside the dryer Process blower ON get within the alarm set are tight Process heaters ON point Check the regeneration Regen heaters ON heater fuses Replace if Alarm Message ON necessary Alarm horn is OFF Replace if necessary Check the heaters Replace if necessary Check incoming voltage to the dryer specs The process drying air Check the positioning of the Dryer Shuts Down temperature has not thermocouple inside the air Process blower OFF made any inlet of the drying hopper Process heaters OFF improvement toward The tip of the thermocouple Regen heaters OFF the drying temperature should be centered to the Alarm Message ON set point for more than tube and not touching any Alarm horn is ON 480 seconds metal part of the tube Make sure all the hose connections are tight For drying temperature of 250 F or higher delivery air hose should be insulated Check the heater contactors Replace if necessary if necessary Check incoming voltage to the dryer specs HIGH DEW The dew point reading Make sure the process air Dryer Normal POINT has exceeded the dew filter is clean Clean or Process blower ON point alarm set point replace if necessary Process heaters ON Make sure all the hose Regen heaters ON connections and all the Alarm Message ON c
75. uto Tune to gain access to this screen Portable Drying Conveying Systems Chapter 3 Installation 19 of 63 Figure 2 Process Autotune Screen PUSH TO START PROCESS AUTOTUNE f 1 The autotune feature can be enabled by pressing the START STOP button located in the center of the screen 2 AUTOTUNE IN PROGRESS or PROCESS NOT ACTIVE will inform the operator of the current status of this feature 3 At this point the operator can return back to the DRYER MENU or MAIN MENU by touching the appropriate button on the screen Shutting Down the Dryer 1 Turn off the conveying system supplying the drying hopper and or machine Press the shutdown button for the dryer to complete its cycle 2 When processing is complete close the hopper slide gate and shut down any in line companion equipment such as the aftercooler 3 If the dryer is shut down using the shutdown button on the dryer status screen the process heater will shut off and the bed regeneration process will be completed When the dryer is started at a later date the process air will be directed through the bed that was regenerated last 4 If the dryer control switch is turned off without using the dryer shutdown feature the dryer will stop immediately When the dryer is started at a later date the process air will be directed through the last bed that was being used when the dryer control switch was turned off If a bed was being regenerated when the dryer control sw
76. ve been made the operator now has a choice of returning to the DRYER MENU BACK takes you back to the DRYER MENU or pressing MORE to take you to screen 2 of 3 of the DRYER SETUP screen Portable Drying Conveying Systems Chapter 4 Operation 25 of 63 Buy pressing the MORE screen you can choose for the temperatures to display in degrees F or degree C Note Changing the temperature scale requires adjusting the alarm values DRYER SETUP 2 of 3 MORE DRYER TEMPERATURE UNITS When these settings have been made the operator now has a choice of returning to the DRYER MENU BACK takes you back to the DRYER SETUP 1 of 3 or pressing MORE to take you to screen 3 of 3 of the DRYER SETUP screen DRYER SETUP 3 of 3 PROCESS AHIR RE TURN AIR ACTU L NOTE At this display before you change any of the settings you need to test the thermocouple readings in Ice water 32 F at sea level and boiling water 212 F at sea level Then you may change these settings accordingly to make sure the controller is displaying the correct temperature Setting Values By pressing and holding the numbers in the LOW TEMP ALARM or the HIGH TEMP ALARM buttons the following screen will be S Enter the values you would like to set in the screen by pressing the number keys Press ENT Enter when you are finished to set the new values or CLR Clear to erase the current values and reenter new ones To set the values in the next field press ENT
77. very hose Note For below 180 F 82 C cooler needs to cool the air coming out of the desiccant tank prior to entering the process heater box e Ifthe dryer is a central dry air generator it will not have a process heater box e Plasticizer trap with cooling coil in lieu of standard aftercooler mounts outside on back of dryer e Drawer magnet stainless steel construction e Casters two 2 fixed and two 2 swivels e Machine mount adapter to accommodate a dryer and corresponding hopper e Low temperature operation below 180 F 82 C includes an internal cooler e Redundant high temperature safety circuit e Cart with caster with hopper mounting place e Low level indicator s e Insulated air hose for air delivery e RPV for drying hopper 2 5 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the drying system This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment At the completion of this section the operator and maintenance personnel will be able to do the following Identify and locate specific safety devices Understand the proper use of the safety devices provided Describe the function of the safety device Safety Ci

Sterling DH1-610-2 User's Manual

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