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ACS A0570882 User's Manual

1. na Bav X aNo2z voz wav EEES YITOYSINOO LSL i MAASIO e QNyOB a TOHLNOD INIOd Mad l MIN O SVAH N393H 4 7 dag 1H Aviad 193738 038 Wdlv3H N3O3H e 038 1331 E Z NI YIMOSINOO nivM3dWL 5539044 ell 6l 1 SLON 33S T qadt THE 14 Flectrical Drawing Figure ANO LVH H S3 4W01 77 Add E Vudiv3H Siz SIH ALIAS SIH ALIIS CAI zl siu Y e TalaH N AVISM ASNO Walv3H NAY 33 80 e m ZINO Aydl SX 9 o YIMOd 330 Ey vein el zi n ol 7 3 Spare Parts List Figure 17 Spare Parts List Mechanical MINI DRYER SPARE PARTS LIST 15 30 60 cfm Models LEVEL 1 Mechanical Components W00015435 DewPointSensorInsertCable_____ A0548556 Dew PointSensor jA0566467 Valve switch j jA0572319 Process Air Filter UPTO55CFM A0566531 Process Air Filter UP TO 100 CFM jW00018051 13X molecular Sieve Desiccant 8 X 12 Beads
2. niente nnns 29 Setting the High Dew Point Alarm r 29 Restoring the Process Air Dew Point Meter E5CK to Factory Setup 29 4 3 Dryer Operation Procedures a r 30 Controller Operation a eas Peu PURA YR sas 30 Alarm Display Messages 32 4 4 Auto T ning the Dryer eise eerte ipic eid eR AREE S EO FERA RR EN ett 33 4 5 Shutting Down the Dryer ooooocccccccccoooconocccnnnnncnnnnnnncnnnnnnncnnnnnnnncnnnnnnncnnnnnnnnnnnnnnnnnnnnnnnss 33 CHAPTER 5 MAINTENANCGE 34 5 1 Preventative Maintenance Schedule a 34 5 2 Preventative Maintenancoe nennen nnne nnns nennen nenne 35 Servicing Process Air Filt rs cccccccccccnseeeeeeeeeeeeecceaneeseeeeeeeseseaaaeeeseeeeeseeeeaas 35 Servicing the Dew Point Monitor eise enne 36 5 3 Corrective Maintenance a 37 Symptoms of Worn Desiccant a nnn nna 37 Replacing Worn Desiccant eese hne nnns 38 Replacing the Process Regeneration Heater
3. 40 Replacing Cleaning the Regeneration Cooling Coils 41 CHAPTER 6 TROUBLESHOOTING 42 0 1 Introductionis a ee a UE a ue d aa ee a 42 6 2 Determining Temperature Controller Errors or Sensor Errors 45 Using a ThermogoutlDIe u u n unun hun yala ayam aaah asia ai 45 Using a Platinum Resistance Thermometer sse 45 CHAPTER APPENDIX iasoer ordi eere eiu 2 u cis 46 JEUNE C pL 46 Warranty Specifications Error Bookmark not defined Warranty Restrictions Error Bookmark not defined Warranty Liabilities Error Bookmark not defined Customer Responsibilities Error Bookmark not defined 7 2 Drawings and Diagrams 0 ccccceeeeeeeeeeeeee eee eeeeeeaeeeeeeeaeaeeeeeeaaeeeeesaaaeeeessaneeeessaaes 47 Aftercooler Design Specifications esses eene 48 Spare Parts Lidia 50 7 4 Dryer Identification Serial Number Tag 51 T Technical Assistance uii esent ie tL Eee t bebisieebotes iet Hefe siodae cien 51 Parts Department ii t oit n ata 51 Service BL 6 1 6101 f ee 51 Sales Department odas e lr 51 Contract Departmeht u u e RYE RE
4. Indicator Name Description ALARMI ALARM 1 LED Lights in the Operation Indicator Section when the output function assigned to auxiliary output 1 turns on The ALARMI indicator lights when the process temperature exceeds the set point temperature by more than the alarm deviation value Alarm output de energizes the heaters Heaters re energize when the temperature falls within the acceptable range Identifying Temperature Controller Keys Indicator Name Description CO Mode Key Press the Mode key to shift the display to the next set of parameters The menu screen displays xz Down Key Press the Down arrow key to lower the process air set point temperature During setup it lets you decrease the value of the parameter displayed on the set point LED readout A Up Key Press the Up arrow key to raise the process air set point temperature During setup it lets you increase the value of the parameter displayed on the set point LED readout Setting the Process Air Temperature When setting the process air temperature consult with the resin manufacture for the recommended drying temperature To change the process air temperature set point with the dryer running Press the Up Key to raise the set point to the temperature you want Press Down Key to lower the set point to the temperature you want 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 25 of 51
5. W00013983 High Temperature Gasket I A0566839 j DesiccantTankGasket U A0566676 High Temperature Snap Switch LEVEL 2 Mechanical Components 40568483 500 Watts Heater element 115 Volts A0568484 500 Watts Heater element 208 220 Volts A0568485 500 Watts Heater element 230 Volts A0568486 500 Watts Heater element 400 Volts A0568487 500 Watts Heater element 460 Volts A0568488 500 Watts Heater element 575 Volts A0570287 1000 Watts Heater element 115 Volts A0570288 1000 Watts Heater Element 208 220 Volts A0570289 1000 Watts Heater Element 230 Volts A0570290 1000 Watts Heater Element 400 Volts 40570291 1000 Watts Heater Element 460 Volts A0570292 1000 Watts Heater Element 575 Volts A0572359 1500 Watts Heater Element 208 220 Volts 40572360 1500 Watts Heater Element 230 Volts 40572361 1500 Watts Heater Element 400 Volts 40572362 1500 Watts Heater Element 460 Volts A0572363 1500 Watts Heater Element 575 Volts A0566682 t 4 ODTeflonTube LEVEL 3 Mechanical Components A0572358 t O D byi2FtLongHiTempHose 40534060 2 1 2 O D by 12 Ft Long Hi Temp Hose A0566535 Return AirCoolingColl 40570437 115VoltProcess Blower jA0570294 115VoltProcessBlower
6. 40534282 208 460 Volt Process Blower jA0535350 575 Volt Process Blower A0552439 208 460 Volt Process Blower A0552440 b75VoltProcessBlower woo015335 Dew Point Sensor Manifold A0548558 ___ GasketfortheDewPoitSensor W00015436 Plastic Nut for the Dew Point Sensor A0568022 Rubber Bumper for the bottom ofDryer 0420001600 SwivlCasters 0420001700 RigidCasters j 132 00007 00 HandleforThePanels j A0566466 Valve Motor 0 A0547006 Knob forthe Filter Housing 0570444 Valve Shaft 220V 50 HZ 3PH SCFM 400V 50 HZ 3PH SCFM 575V 60 HZ 3PH screw 2 LI IL faq Ll l T 15 30 amp 60 cfm Compact Dryers Chapter 7 Appendix 30CFM 208V 3PH 30CFM 220V 50 HZ 3PH 30CFM 230V 3PH OCFM 400V 50 HZ 3PH 30CFM im 9 75 Lbs 50 of 51 OCFM 575V 60 HZ 3PH 7 4 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
7. Restoring the Process Air Temperature Controller E5CN to Factory Settings If the preset parameters on the controller have been tampered with and it no longer properly controls temperature and displays dew point you can restore the controllers to the factory setup Call the Service Department for detailed instructions ESCN Operating Parameters The ESCN controller has several mode selections Within each mode are numerous parameters that can be set The factory has set the security level to protect the critical parameters from being accidentally changed Below is an explanation of the operating modes you will have access to and on the following page are the manufacturers default settings Available ESCN Modes Operation Level Indicator Name Description Run Stop Mode When RUN is selected the control is running ro 5 r S When STOP is selected the control is stopped When the control is stopped the STOP display lights The default is set to RUN Alarm Value 1 This setting is used to indicate how many degrees Al l Mode AL 1 the process temperature will be allowed to exceed the set point temperature An alarm output will de energize the heaters 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 26 of 51 Adjustment Level Indicator Name Description Auto Tune Mode Ht At See Page 19 of Chapter 3 for instructions on how to Auto Tune your dryer Note Althoug
8. Absorbed water is driven from saturated desiccant by heating it to a high temperature reducing desiccant capacity to hold water and forcing air through it This moisture removal process is called regeneration 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 air and forces it through the desiccant bed The moisture driven off the bed bleeds to the atmosphere 2 3 Standard Features Mechanical Features Dual desiccant beds Electrically actuated air valve 13X Molecular Sieve Single regenerative process blower Drying temperature range of 180 F to 250 F Electrical Features Process thermocouple to be connected to drying hopper air inlet Nema 12 control enclosure NFPA79 machinery electrical standards Non fused electrical disconnect Branch fusing Mercury process heater contactor Regeneration temperature control Process high temperature alarm light Process regeneration heater box High temperature safety system Process Regeneration Controller Features Mitsubishi progra
9. Keep body parts tools clothing and debris away from dryer 15 30 amp 60 cfm Compact Dryers Chapter 1 Safety 7 of 51 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 Vl 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 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be obse
10. OMRON Note No field adjustment is required The dew point meter is meant for moisture indication only Setting the High Dew Point Alarm The high dew point alarm setting is changed by pressing the up and down keys to input the alarm value The factory setting for Alarm Value 1 AL 1 is 10 F 23 C Restoring the Process Air Dew Point Meter E5CK to Factory Setup If the preset parameters on the controller have been tampered with and it no longer functions properly call the Service Department This controller is not meant to be modified Note The dew point alarm monitors and indicates a deviation from the set point 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 29 of 51 4 3 Dryer Operation Procedures Controller Operation 1 Turn the disconnect if applicable on the control panel to the ON position Power is applied to the voltage line fuses line side of the control power switch 2 Turn the control power switch to the ON position Power is applied to the temperature control programmable relay and dew point controller The valve will move to the start position as follows a The valve motor rotates until the cam switch makes 2 transitions b Ifthe cam switch does not make a transition within 10 seconds a valve motor fault is generated VALVE MTR is displayed on the relay screen the alarm light is activated The valve motor heaters and blower shut off To restart the dryer cycle control power t
11. 8 Allen wrench remove the 10 24 button head screws holding the top back and side panels to the frame and back of the dryer Disconnect the three 3 plugs for the valve motor switch and blower 15 cfm only Remove four 4 nuts at each corner of the top casting Disconnect all hoses and dew point air lines Pickup and place the top casting in a safe place Using a 1 8 Allen wrench remove the four 4 10 32 button screws holding the desiccant cover to the canister Remove the cover Pickup the desiccant can and turn it upside down over an empty container to remove all desiccant 10 Dispose of properly using MSDS sheet 15 30 amp 60 cfm Compact Dryers Chapter 5 Maintenance 38 of 51 Figure 10 Desiccant Bed Location and Disassembly Valve amp Air Manifold Casting Hollow Desiccant Tank Wire Conduit Assemb Lower Air Manifold Casting Caution You should properly dispose of any discarded desiccant Consult local disposal regulations for more information 11 Inspect each desiccant screen for tears or holes where desiccant burned through Replace desiccant can if needed 12 After cleaning each chamber add the full amount of bead desiccant specified per bed Amounts are listed in the Desiccant Amounts Table below Tap on side of tank to settle desiccant Smooth the top level and finally add another layer of the remaining bead desiccant to the top Make sure
12. Read Operation and Installation Manual High Voltage Earth Ground Inside Enclosure Protected Earth Lifting Point Ground 1 2 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 XK KK KR NAN Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power Use EXTEREME CAUTION when working with dryer HIGH HEAT can be dangerous
13. The AT screen will show with the setting OFF 2 Press the UP arrow to change the setting to ON 3 Press the beige button again to go back to the Temperature Screen Your actual temperature will start to flash for about 10 20 minutes with the temperature fluctuating up and down during that period After the flashing stops it means auto tuning has finished 4 5 Soukting Down the Dryer When processing is complete close the hopper slide gate and shut down any in line companion equipment such as the aftercooler Turn the Dryer ON OFF selector switch to OFF Turn the system ON OFF switch to OFF If needed empty the drying hopper Uno mo A po For maintenance or a long term shutdown open de energize the electrical disconnects at the dryer and at the power drop 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 33 of 51 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule The checklist below contains a list of items which should be inspected and or replaced to keep your Dehumidifying Dryer 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 week Ty Inspect all filters for wear replace clean if dirty or worn Check to make sure that all hose conections are air tight Lock out electrical power and inspect electrical wiring for int
14. 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 Dehumidifying Dryer Bill of lading Packing list Operating and Installation packet XK KR KR 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 1 414 354 0970 for all other countries call our international desk at 414 354 0970 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 15 30 amp 60 cfm Compact Dryers ii 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 wil
15. controller for maintaining process air temperature The controller is a modular self contained unit you can remove from the mounting housing All parameters except for the process air set point are factory set and adjusted normally no field adjustment to the internal controls is necessary Figure 6 Typical Process Air Temperature Controller Temperature mmm e indicators Identifying Process Air Temperature Controller LED Indicators Indicator Name Description PV Process Value During normal operation the process value PV ona Numeric LED numeric LED indicator displays the process SO temperature at the To Process thermocouple It also lists parameters during setup and error messages if any errors occur SV Set Value During normal operation the set value SV anoa Numeric LED numeric LED indicator displays the process set D D point temperature selected for the dryer The dryer then maintains this set point temperature This LED indicator also displays parameter and pre set function values during configuration setup OUT1 Out 1 LED Lit when Control Output 1 is on The Outl indicator lights when the controller signals the process heaters to be energized OUT2 Out 2 LED Lit when Control Output 2 is on Not used in this application AT AT LED Flashes during auto tuning in process value PV screen 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 24 of 51
16. fins filled with dust or side plate clean baffles replace contaminants Replace filter elements Check resin manufacturer s data sheet for proper drying Process temperature set too high temperature Make sure plant due to operator error personnel are aware of the correct process temperature set point High temperature alarm not set y aa Reset high temperature alarm Material in drying hopper cakes properly or meltdown occurs Process set point is out of Restore temperature controller acceptable range to factory pre sets Function set for degrees Celsius C set point at degrees Fahrenheit F Loss or reduction of process air temperature Material being dried differs from material specified at the time of purchase Loss or reduction in drying capacity Verify correct Celsius or Fahrenheit settings Verify that the thermocouple is properly installed in the inlet tube Process thermocouple not in airflow 15 30 amp 60 cfm Compact Dryers Chapter 6 Troubleshooting 43 of 51 Burned out regeneration heater Repair or replace Contaminated or worn out desiccant Leaking process air hoses Repair or replace Poor dew point performance Piven operates Beyond ts Check dryer and drying hopper capacity sizing Bad dew point sensor Replace Fouled dew point sensor Clear obstruction Air should manifold flow freely through sensor Dirty filter Clean or replace filter element The
17. is displayed on the relay screen The alarm light is activated The process heater regen heater and process regen blower are turned off 5 Ifthe process temperature controller faults or the process heater safety switch opens a heater fault is generated HIGH TEMP is displayed on the relay screen The alarm light is activated The process heater regen heater and process regen blower are turned off 6 Ifthe process blower overload trips a process blower fault is generated PROC BLWR is displayed on the relay screen The alarm light is activated The process heater regen heater and process regen blower are turned off 3 phase only 7 The valve position limit switch enables the right bed heater and provides an input signal to the programmable relay when actuated by the cam lobe When the cam lobe position is high the right bed is activated When the cam lobe position is low the left bed is activated Each heater is ON OFF controlled 8 Upon completion of the HEAT portion of the regeneration sequence the regen heaters are disabled by the programmable relay and the COOL time begins 9 Once the Cool time has expired the valve motor is turned on until the cam switch makes a transition Upon making a transition the timing sequence is restarted for the new bed 10 When no fault conditions exist the display reads SYSTEM NORMAL 11 The top 2 lines of the display show the HEAT and COOL times in minutes for the regene
18. level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk on your dryer use it The work platform should have secure footing and a place for tools and parts DO NOT climb on dryers 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 dryer until all persons are clear of the area DO NOT start and run the dryer until you are sure all parts are functioning correctly BEFORE you turn the dryer over to the operator for production verify all dryer enclosure panels guards and safety devices are in place and functioning properly Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use
19. meet the specific requirements stated by the Customer at the time of purchase 2 2 General Description Dehumidifying dryers are used to generate very low dew point air heated to a controlled temperature for drying plastic pellets and regrind Our dryers force hot dry air through resin in a drying hopper where air picks up moisture from the material and draws it back to the dryer In the dryer a desiccant bed strips moisture from the air The dried process air is then re heated and delivered back into the drying hopper for more moisture removal A small amount of ambient air is introduced into the process air stream to make up for the air lost during the bed regeneration Because the process air is typically much drier than the ambient air the air mixture maintains drying efficiency at a consistently high level To compensate for the humidity content in the air this dryer is supplied with the proper amount of desiccant Figure 1 Typical Dryer Air Flow Schematic High Pressure Moisture Peripheral Blower Exhaust Filter Separates Dust Drying Hopper vM ORT Make Up Air fA ao 15 30 amp 60 cfm Compact Dryers Chapter 2 Functional Description 12 of 51 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
20. 15 30 amp 60 cfm Compact Dehumidifying Dryers Part Number A0570882 Bulletin Number SM1 690 1 Effective 8 05 04 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 O Copyright 2004 All rights reserved Shipping Information Unpacking and Inspection You should inspect your dryer for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance
21. 7 5 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 414 354 0970 Fax 414 354 6421 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 800 657 4679 or call 414 354 0970 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most of our products Sales Department Call 414 354 0970 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 414 354 0970 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 15 30 amp 60 cfm Compact Dryers Ch
22. E h L4 Wed teem oOmmoou pr 15 30 amp 60 cfm Compact Dryers 34 7 16 46 7 8 35 5 16 27 7 2 5 5 5 Chapter 7 Appendix 38 7 16 72 35 5 16 27 7 2 5 5 5 Hopper Size 0 85 ft_ 24 1 7 ft_ 48 liters 1 7 ft_ 48 liters 3 0 ft 85 liters 3 0 ft 85 liters 9 0 ft 255 liters liters Dimension m cm m om m om m om In Cm In 38 7 16 49 7 8 35 5 16 27 7 2 5 5 5 38 7 16 79 35 5 16 27 7 2 5 5 5 47 of 51 Cm Figure 15 Cart Mount Dryer Dimensions A FF TT c T op T E T T S m em m em m 6m m om mom m om 27 69 9 23 58 4 36 914 36546 922 0 29 2 27 13 16 70 6 33 83 8 Aftercooler Design Specifications Entering water temp 15 30 amp 60 cfm Compact Dryers Chapter 7 Appendix 48 of 51 AMolsIH NOISIA38 NOILdIHOS 3d Nod ay uondosd OI 03573138 Y LZ91 S0V A un ZELF arva ON u3gSo C Tw 38 S IE OVAOT TL HUE we 4B Net 43140 ds xr v0 91 10 dnoi5 adea AE aia di Ss 38NSOTNZ 4o 30ISINO dilvool OILVW3HOS Tv ra V S018 TwNINYAL C MEA N BHM SIZ OL elf 3M l JN3531 S3LON
23. TE YR EY CR P AER Rae PARS 51 15 30 amp 60 cfm Compact Dryers v Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your dehumidifying dryer The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the dehumidifying dryer We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the dehumidifying dryer These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the dryer safely and efficiently The Maintenance chapter is intended to serve as a sou
24. afety Defect nennen 10 1 4 Techn ical SpeGifiGati nS u n uu uu s uuu ashaku ashaku nennen 11 Annex B Information ix eoe ei E edt Ee eR TEE gu Basanta 11 CHAPTER 2 FUNCTIONAL DESCRIPTION 12 2 1 Models Covered in This Manual cccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaaaaeeeeeeeeesesaaaaees 12 2 2 General D s ripti6ly au na aa aski am ener nnne apasaq 12 Whatis desiccant i a irre erre e re e ee n T 13 The Process Regeneration Cycle 13 2 3 Standard Features Terrae e de aquya ta ces ERR BEEN ERA id TER Te Ne ERROR Eye eR 13 Mechanical Features eiit tido 13 Electrical Features iiis et e tue bates e eee eae 13 Controller Features uu ied tie a Eo diua eaa Pru e aa bi 13 2 4 SOPUONS ARAM 14 2 5 Safety Devices and Interlocks a a 14 CHAPTER 3 INSTALLATION 16 3 1 Uncrating the Equipment nnne rh n enne 16 3 2 Rigging and Placing the Dryer sssssssssssseememmeeme nenne 16 Recommended Dryer Lifting Hardware oooooocccnnnncccccocconccccononoconononnnnnnnnnnnnnnnnnnos 17 3 3 Electrical CONNEeCtiONS ooooooocccnnnncccconnnnncnnnnnnncnonnnnnncnnnnnnnnnnnnnnnncnnnnnnnnnonnnnnnn
25. and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment 15 30 amp 60 cfm Compact Dryers Chapter 1 Safety 10 of 51 1 4 Technical Specifications Annex B Information The following design information is provided for your reference l O ON CUN Es G2 SES 12 13 14 15 16 17 18 19 20 2 22 23 24 25 26 No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature 0 degrees Celsius Maximum 104 degrees Fahrenheit Humidity range 50 relative humidity Altitude Sea level Environment Clean dust free and non explosive Radiation None Vibration Minimal i e machine mounting Allowable voltage fluctuation 10 Allowable frequency fluctuation Continuous 1 Intermittent 2 Nominal supply voltage 115 1 60 Verify on serial number tag 11 Earth ground type TN system has one point directly earthed through a protective conductor Power supply should include a ground connection Over current protection is supplied in the dryer but additional protection should be supplied by the user The door mounted disconnect serves as the electrical disconnect device for 3 phase units Dryer is not equipped with local lighting Functional identification Dryer is supplied with an op
26. and may cause damage to the Dryer and or injury to personnel Recommended Dryer Lifting Hardware ltem Quantity Description________ Vendor Vendor part no 2 Existing hopper lifting bracket_ Figure 3 Suggested Lift Rigging for Floor Mounted Dryers Note Floor Mounted Dryers can be lifted by hoist or fork lift 15 30 amp 60 cfm Compact Dryers Chapter 3 Installation 17 of 51 Figure 4 Suggested Lift Rigging for Machine Mounted Dryers 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 dryer ensure that you take into consideration and make arrangements for the following A qualified electrician should make all electrical connections Fulfill all national state and local safety and electrical code requirements The serial tag lists voltage phase and amp draw information Line voltage must be within plus or minus ten percent 21096 of the voltage listed on the serial tag or damage m
27. apter 7 Appendix 51 of 51
28. ation is not only unsafe but will void the warranty on your equipment When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting Report the following occurrences IMMEDIATELY unsafe operation or condition unusual dryer action leakage improper maintenance NEVER stand or sit where you could slip or stumble into the dryer while working on it DO NOT wear loose clothing or jewelry which can be caught while working on a dryer In addition cover or tie back long hair 15 30 amp 60 cfm Compact Dryers Chapter 1 Safety 9 of 51 Clean the dryer and surrounding area DAILY and inspect the machine for loose missing or broken parts Shut off power to the dryer when it is not in use Turn the switch to the OFF position or unplug it from the power source Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning tags to the disconnect switch When you need to perform maintenance or repair work on a dryer above floor
29. ay occur Phase imbalance must be less than two percent 2 Connect main power to the dryer at the disconnect or terminals in the upper right corner of the control enclosure Install a fused disconnect with a lockout feature in the power main leading to the dryer The power drop must include a ground wire Make sure all electrical connections are tight 15 30 amp 60 cfm Compact Dryers Chapter 3 Installation 18 of 51 3 4 Setup Procedures This section provides the procedures necessary for configuring your Dehumidifying Dryer Configuration of your dryer includes checking for proper blower rotation making dryer drying hopper process air connections and the optional aftercooler on 15 and 30 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 If the three phase blower rotates improperly reverse any two wires at the fused disconnec
30. cuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards into the design of the dryer however it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch 15 30 amp 60 cfm Compact Dryers Chapter 2 Functional Description 14 of 51 must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue For example if a safety switch is guarding a motor and the safety switch fails the motor should not be able to run Saf
31. e use a damaged filter Check the gasket for damage A damaged gasket allows contaminants into the process Replace as needed Servicing the Dew Point Monitor The accuracy of the dew point monitor on mini dryer systems depends on proper operation of the dew point sensor and the control board The dew point sensor is in the process air stream and is therefore susceptible to contamination Dew point sensor life depends on Air temperature and flow passing over the sensor The amount of fines dust in the process air The amount of plasticizer vapor in the process air Once every six months the dryer operator should monitor the initial dew point sensor readings and establish a periodic replacement schedule as needed Caution Do not attempt to check the continuity or resistance of the dew point sensor The sensor will be destroyed 15 30 amp 60 cfm Compact Dryers Chapter 5 Maintenance 36 of 51 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 variabl
32. ed air but remember it could become damaged from high pressure blowing Recommendations for Cleaning and Replacing Filters Turn off and or lock out electrical power to the dryer Remove the threaded fastener securing the filter access cover then remove the cover Remove the nut on the center retaining rod to remove the filter cartridge Figure 9 Air Filter Location and Disassembly Process Air Fi 1 Wide x 1 8 Thick Temperature 15 30 amp 60 cfm Compact Dryers Chapter 5 Maintenance 35 of 51 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 Cleaning with Compressed Air Blow clean dry compressed air up and down the pleats blowing out the filter from the inside out Remove loose dirt from the filter with compressed air or vaccum from the outside Caution DO NOT clean wash filter with water After each cleaning nspect 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 r
33. egrity 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 15 30 amp 60 cfm Compact Dryers Chapter 5 Maintenance 34 of 51 5 2 Preventative Maintenance This section describes maintenance procedures which will increase the longevity and efficiency of your dehumidifying dryer Perform them at the regular intervals listed on the dryer checklist on the previous page Servicing Process Air Filters Caution Operating the dryer without the process air filter installed voids your warranty Filter cleaning is an important part of your dryer maintenance program Dehumidifying dryers have a single cartridge canister type filter in the process air loop The filter protects blowers from plastic fines drawn in from the drying hopper and prevents the desiccant from being contaminated Regular filter cleaning is essential to keep your dryer operating at peak efficiency You can blow or vacuum the dirt out of the filter with compress
34. emove the four 4 nuts at each corner of the top casting Pickup and place the top casting in a safe place Pickup the desiccant can to reveal the heater Using a 1 8 Allen wrench remove the four 4 10 32 screws on the heater plate Remove the wires to the heater plate assembly being removed or replaced SOP Coo OW mw Um bx ces Remove the two 2 4 40 screws for the temperature switch 10 Inspect temperature switch with voltmeter Normally closed ohms Replace if faulty 11 Re install the heater 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 p p Replacing Cleaning the Regeneration Cooling Coils Figure 13 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 il Head Screws using y any oily residue on the coil Allen Wrench 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 15 30 amp 60 cfm Compact Dryers Chapter 5 Maintenance 41 of 51 Chapter 6 Troubleshooting 6 1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble sh
35. emperature control has been configured for your specified scale F or C 15 30 amp 60 cfm Compact Dryers Chapter 3 Installation 20 of 51 Starting Up the Dryer l Turn on energize the disconnect switch in your power drop then turn on the disconnect switch on the dryer 3 phase only Turn the system ON OFF switch to ON to start the dryer Close the slidegate at the bottom of the drying hopper Make sure that the blowers turn in the right direction Fill the drying hopper with material Dryer performance is compromised if hopper is not full 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 Make sure the aftercooler has the proper supply water temperature Set the process set point on the temperature controller 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 l For Auto tuning press the beige button once The AT screen will show with the setting OFF Press the UP arrow to change the setting to ON Press the beige button again to go back to the Temperature Screen Your actual temperature will start to flash for about 10 20 min
36. erating manual in the language of the destination country Cable support may be required for power cord depending on final installation No one is required to be in the interior of the electrical enclosure during the normal operation of the unit Only skilled electricians should be inside the enclosure for maintenance Doors can be opened with a screwdriver but no keys are required Two hand control is not required or provided All dryers should be moved around and set in a place with a lift truck or equivalent There are no frequent repetitive cycles that require manual control repetitive functions are automatic while the dryer is operating An inspection report detailing the functional test is included with the dryer The machine is not equipped with cableless controls Color coded harmonized power cord is sufficient for proper installation 15 30 amp 60 cfm Compact Dryers Chapter 1 Safety 11 of 51 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for 15 30 and 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 carefully controlled temperatures for use in plastic drying systems Drying systems are sized to
37. es such as material moisture content plasticizer vapors in the return air and number of regeneration cycles Your dryer may need new desiccant if it exhibits any of the following symptoms The process air dew point measured with a portable dew point monitor is higher than 10 F 23 C throughout the process drying cycle Noticeable amounts of desiccant in the beds is a medium brown color or darker If you notice any of these signs replace the desiccant in the desiccant beds Desiccant replacement kits are available from the Parts Department If you want a technician can repack desiccant beds at your site WARNING Handling desiccant material is HAZARDOUS Wear an N 100 type safety filter mask or equivalent to avoid prolonged breathing of desiccant dust Wear safety goggles and gloves to avoid contact with eyes and skin Handle with adequate ventilation Wash hands thoroughly after handling FIRST AID In case of eye contact immediately flush eyes with plenty of water for at least 15 minutes SEE A PHYSICIAN IMMEDIATELY IF IRRITATION PERSISTS 15 30 amp 60 cfm Compact Dryers Chapter 5 Maintenance 37 of 51 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 l ot gv Me cp OS oo Disconnect electrical power to the dryer Using a 1
38. ety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used on these dryers 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 the dryer Failure to do so may result in serious injury No one but the person who installed the lockout may remove it 15 30 amp 60 cfm Compact Dryers Chapter 2 Functional Description 15 of 51 Chapter 3 Installation 3 1 Uncrating the Equipment Dehumidifying Dryers are shipped mounted on a skid enclosed in a plastic wrapper and contained in a cardboard box 1 Pry the c
39. fles replace Stop the dryer If the dryer was connected to the drying hopper check to see if the desiccant and process air Phase is reversed on power drop heater has been contaminated coming into the dryer Only on with resin 3 phase units If so replace the desiccant and remove any resin carry over Otherwise change the phase of two legs of the three phase power drop Wrong delivery and return Reverse hoses See air flow connections diagram on Page 12 Suction in delivery tube pressure from the return tube 15 30 amp 60 cfm Compact Dryers Chapter 6 Troubleshooting 42 of 51 Problem Possible cause Corrective action Process heaters are faulty Chee Qu pes Replace if required Solid state temperature Z51362 controller faulty Pese Make sure that plant personnel Process temperature was are aware of the proper adjusted in error by plant temperature set point Post an personnel appropriate sign next to the controller Process heaters are faulty Desiccant beds are Replace desiccant contaminated Drying systems are designed for the material which was originally specified Different materials may need a longer residence time or a different ing temperature Break in flex hose to from Inspect for air leaks replace as drying hopper needed Airflow valve sticking or failing check dor properap SAOR 9r valve actuators Repair or to shift replace if necessary Remove blower si lat Blower
40. h the controller is calibrated at the factory the manufacturer recommends that the unit be Auto Tuned prior to dryer startup Temperature Input E n 5 Shift Mode TnS This setting is used to offset an error between the set point and the actual temperature The entire input range is shifted by a set figure preprogrammed by the operator Proportional Band Mode P This setting controls the amount in which the manipulated variable MV is proportionate to the deviated value or controller error Integral Time Mode I bl E Setting this feature gives the control an action that is proportionate to the time integral of the control error By using this setting proportional action is used in combination with integral action to offset the control error and the set point will begin to match the control temperature PV or process value Derivative Time Mode d Setting the derivative control provides the controller with the ability to correct for a future error in the previously set process output 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 27 of 51 Entering Operating Parameters to Select Modes To enter the display 1 Press the Mode Display key to view the Run Stop amp Alarm 1 Modes 2 Press the Up Key and the Down Key to set the higher or lower the values of the parameter or turn that function On or Off The SV readout displays the different values for the parameter withi
41. internal mechanism is not inserted properly into the housing connected supply Nothing displays when the No power is supplied or the Supply a voltage of 85 to 125 controller is turned on supplied power is not within the VAC to the power supply specified range terminals of the controller Check control power fuse for continuity Turn disconnect switch and control power switch ON Input polarity on thermo couple ee y D P Properly wire the terminals is wrong or connection is wrong No compensating lead wires used for extension of the thermocouple Replace Properly insert the internal mechanism into the housing Disconnect switch or Control Power switch not set to ON Control Power fuse blown Use proper compensating lead wires and terminals Use a dedicated thermocouple Thermocouple and controller are connector If a connector is a connected by wires other than metal different from the proper lead wires thermocouple and controller a temperature error may result Verify that the thermocouple is properly installed in the inlet tube Sensor is broken or short P Replace with a good sensor circuited Separate input wires as far as possible from the origin of the noise Process value is abnormal or not obtained Process thermocouple not in airflow The controller is influenced by noise or other induction Celsius temperatures used instead of Fahrenheit or vice Contact Service Department
42. l be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty terms 15 30 amp 60 cfm Compact Dryers iii Table of Contents CHAPTER 1 SAFETY o 222 tonada aa 6 1 1 How to Use This Manual a nennen eh hrn nnne hn nennen nennen 6 Safety Symbols Used in this Manual 6 Dryer Safety TAg u a n a Kak rA aaa 7 1 2 Warnings and Precautions r eene enne rhe enne rene 7 Ertrag 8 General Responsibility lisse Ea a E iia nnna 8 Operator Responsibility oooooooooncnncccccnncccnnnncnnnncnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 9 Maintenance Responsibility aei 10 Reporting a S
43. mmable relay controller 15 30 amp 60 cfm Compact Dryers Chapter 2 Functional Description 13 of 51 Display of process temperature set point and actual settings 2 4 Options Options marked with field 663699 indicate options that can be factory installed or retrofitted in the Process temperature up to 400 F or below 180 F including aftercooler on back of dryer and silicone insulated delivery hose Note For below 160 F cooler needs to be outside between dryer and drying hopper Machine mount adapter to accommodate a dryer and corresponding hopper Drawer magnet stainless steel construction Casters two 2 fixed and two 2 swivel Portable carts Dew point monitor High temperature operation up to 400 F Insulated process air delivery hose 2 5 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the Dryer This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment At the completion of this section the operator and maintenance personnel will be able to do the following Identify and locate specific safety devices Understand the proper use of the safety devices provided Describe the function of the safety device Safety Cir
44. n a mode 3 Toswitch modes within a level press and hold the Level Display key for one 1 second The PV readout will display the different parameters within each mode 4 Use short presses on the Mode Display key to display each parameter within a mode The SV readout displays the different values for the parameter within a mode 5 Press the Up Key and the Down Key to set the higher or lower the values of a parameter or turn that function On or Off 6 Press the Level Key once to return to the Process Temperature Setting Figure 7 Settings for Process Temperature Controller ESCN Part No A0567917 Mode Parameter Settingrange Default Manuf setting Run Stop Run Stop Run AT execute cancel ON OFF Adjustment Proportional Band 0 1 to 999 9 8 0 Various x 40 Integral Time 0 to 3999 Various Derivative Time 0 to 3999 Various 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 28 of 51 Process Air Dew Point Display Optional The Process Air Dew Point meter indicates the current process air delivery moisture content Standard dryers use a microprocessor based controller for displaying dew point air temperature The controller is a modular self contained unit removable from the mounting housing All parameters are factory set and adjusted normally no field adjustment to the internal controls are necessary Figure 8 Typical Dew Point Display Monitor Part No A0555757
45. nnnincnnns 18 3 4 gt Setup Proced res ieie eee A a ees ede deg en eg Deva eer dere E lens 19 Checking for Proper Blower Rotation sse 19 Making Dryer Drying Hopper Process Air Connections 19 Drying Hopper Air Trap Considerations essen 20 Optional Aftercooler d eR t RE e ct E C RE I 20 3 57 Initial Start up tae teo te e ti s te eiua 20 Pre Startup GhecKs c n ve VA E eR REI A i EPA EE ENS 20 Starting Up th Dryer ie di 21 Auto Tuning the Dryer oooconioconconnccnncconannnnnonacnnnncnna narco ona h ns hah na nns nna nara n rca rin r anna nnns 21 Shutting Down the Dryer r 21 CHAPTER 4 OPERATION 22 4 1 Start up ice ete oe e Ge REPRE ERR CARNET desde CERE EUR sasa yaaa yasa Sasu CERE VN quna 22 4 2 Controller Description and Operation enne 23 15 30 amp 60 cfm Compact Dryers iv Identifying Control Panel Indicator Lights and Switches for the Standard Controller i ate Moin Nas 23 Process Air Temperature Controller 24 Setting the Process Air Temperature a 25 Restoring the Process Air Temperature Controller E5CN to Factory Settings 26 Process Air Dew Point Display
46. nt 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 The company is not liable for any incidental consequential or special damages or expenses 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 Any sales use excise or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser 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 Many types of the manufacturer s equipment carry an additional one year service policy Consult your sales representative for specific details 15 30 amp 60 cfm Compact Dryers Chapter 7 Appendix 46 of 51 7 2 Drawings and Diagrams Figure 14 Machine Mount Dryer Dimensions Mounting flange d azas E TOU h Eo FT Y iL Y E Diameter hole J F
47. o deactivate the alarm light and restart the valve motor sequence Note The relay screen which contains the Alarm Display Messages is located inside the controller enclosure For a list of Alarm Display Messages see Page 32 WARNING Do not attempt to check the Alarms on the Controller located within the unit enclosure unless you are a qualified electrician c The valve will normally complete one full cycle revolution If the drying process shuts down due to an alarm the dryer has been setup to have the following operational features The bed in process at power down will remain in process The bed in regeneration at power down will remain in regeneration The regeneration timing cycle will restart from the beginning 3 Once the control power is on and no fault conditions exist start the dryer as follows a The process regen blower is started b The process heater is turned on and controlled by the ESCN controller c The regen heater is turned on and the regeneration timing sequence is initiated For default timing settings for regeneration see the table below Model Heating Cooling 15 cfm 30 cfm 18 45 60 cfm N A N A Note In a humid environment you may change the setting to 20 45 for better dew point management 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 30 of 51 4 Ifeither the left or right bed safety temperature switch opens a regen heater fault is generated HIGH TEMP
48. on the top of the drying hopper prevents ambient air from contaminating the material being dried To ensure that your unit will operate at peak efficiency do the following Keep the material level at the mid point of the air trap This can be achieved by utilizing a hopper loader or vacuum conveying system to supply material to the drying system Optional Aftercooler Water cooled 15 and 30 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 up to 85 F 29 C Recommended flow rate is three 3 gpm gallons per minute 11 liters per minute 3 5 Initial Start up Pre Startup Checks M Check the process and 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 Caution Clean the rust preventing oil from inside the drying hopper Failure to clean the hopper fouls the desiccant and voids your warranty M Verify that the dryer s thermocouple is properly connected in the center of the drying hopper s delivery tube M Verify that the t
49. ooting 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 Dirty filter Clean or replace filter Desiccant beds are contaminated by material or plasticizer leaking into the system Replace desiccant See Page 38 for more information Little or no air coming from the process delivery tube Fix the problem and reset the Blower overload has tripped overload Possible open fuse loose wire contaminants clean baf
50. rating away from the skid Note Remove the nails holding the box to the skid and lift the box off carefully avoiding staples in the 1 x 4 wood supports Cut the steel banding 2 Use a pry bar to remove the blocks securing the unit to the skid 3 Lift unit from sides Use a pry bar if necessary to carefully remove the skid from the unit 4 Lower slowly 3 2 Rigging and Placing the Dryer Take care when rigging and placing the dryer Figures 1 2 and 3 on the following pages show a suggested safe rigging diagram It lets you lift the dryer hopper unit vertically for installation on the machine throat Adjust chain lengths at the center sling bracket before you lift the unit Your dryer has built in lifting lugs 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 Use caution and observe safety rules when lifting and placing your dryer 15 30 amp 60 cfm Compact Dryers Chapter 3 Installation 16 of 51 Figure 2 Suggested Lift Rigging for Cart Mounted Dryers Caution Do not use a hoist to move or rig your Dryer when it is mounted on a cart Moving the Dryer with a hoist will cause it to become unstable
51. ration sequence Changes to these times can be made by the operator as follows a Press the up or down arrow until the cursor is positioned at the number to be changed 66 b Press the key to increment the number or the number key to decrement the c Press the OK key to accept the value and write to the relay memory OR d Press the ESC key to cancel the changes Note A change will NOT take effect until step 11 c is done 12 The dryer is shut off by turning the control power switch to the OFF position 13 Refer to Schematic drawing enclosed in the control enclosure 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 31 of 51 Alarm Display Messages Note The relay screen which contains the Alarm Display Messages is located inside the controller enclosure WARNING Do not attempt to check the Alarms on the Controller located within the unit enclosure unless you are a qualified electrician The following is a list of Alarm Display Messages which can be found on the relay screen Temperature Controller Alarm and or Regen Heater Temp Switch and or HIGH TEMP Process Heater Temp Switch and or Redundant Temp Safety Valve Motor Time Out VALVE MTR PROC BLWR Multiple Alarms HIGH TEMP VALVE MTR HEAT 15 COOL 50 No Alarms SYSTEM NORMAL 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 32 of 51 4 4 auto Tunng the Dryer For Auto tuning press the beige button once
52. rce of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your dehumidifying dryer provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage 15 30 amp 60 cfm Compact Dryers Chapter 1 Safety 6 of 51 Dryer Safety Tags Hot
53. rved and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No mater who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production Loss of a skilled operator temporarily or permanently Breakdown of shop morale Costly damage to equipment Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation 15 30 amp 60 cfm Compact Dryers Chapter 1 Safety 8 of 51 Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact
54. 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 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 22 of 51 4 2 Controller Description and Operation Identifying Control Panel Indicator Lights and Switches for the Standard Controller Switches Main Power This switch allows the dryer to receive power from the main power supply 3 phase only Dryer Control ON OFF Switch This switch energizes or de energizes control power to the indicator panel and starts the dryer The controller can be energized without the dryer running Indicator Lights Alarm Light This feature warns the operator of a high bed safety temperature a regeneration heater fault or a blower failure Power On This light illuminates when the main power switch is on telling the user the dryer is energized Dryer Operating Indicates the process air blower is on Figure 5 Dryer Control Panels Standard Controller Standard Single Phase Control Panel shown with Optional Dew Point Monitor PROCESS TET TEMPERATURE DEW POINT DRYER CONTROL Pv ON sv om gt EL s MEA FAMA or omron E5CK POWER ON T PROCESS TEMPERATURE POWER ON ALARM N TN 15 30 amp 60 cfm Compact Dryers Chapter 4 Operation 23 of 51 Process Air Temperature Controller Our dryers use a microprocessor based PID temperature
55. t outside the dryer or at the disconnect terminal in the control enclosure This assures that the blower rotates in the proper direction Making Dryer Drying Hopper Process Air Connections Floor Mount Models When making process air connections to your floor mounted dryer ensure that you take into consideration and make arrangements for the following Use high temperature flexible dryer hose or rigid tubing to connect the dryer to the drying hopper Keep the delivery hose to the drying hopper as short as possible to minimize heat loss We strongly recommend insulated hose for maximum energy savings Do not use insulated hose on the return from the drying hopper The return air to the blower must be 150 F 66 C or below If the return air temperature is not below this point you should purchase and install the optional aftercooler to remove excessive heat Consult the manufacturer for more information Aftercooler considerations also apply to machine mount models Make sure that hoses are not kinked or collapsed Drying hopper air inlet and outlet locations vary but always connect hoses so the dry process air from the dryer enters the bottom of the drying hopper and flows out the top to return to the dryer inlet Thermocouple is to be installed at drying hopper s delivery tube 15 30 amp 60 cfm Compact Dryers Chapter 3 Installation 19 of 51 Drying Hopper Air Trap Considerations Our exclusive air trap assembly
56. this layer is level and smooth 13 Repeat the previous step for the other bed 14 Inspect the gaskets Replace if necessary 15 Re install all components and reconnect all of the wiring and hoses Figure 11 Required Desiccant Amounts 13X Type Dryer 8 x 12 bead Total Model ds Wo0018051 15 30 amp 60 cfm Compact Dryers Chapter 5 Maintenance 39 of 51 Replacing the Process Regeneration Heater The dehumidifying dryers utilize a single phase Calrod type heater element This heater element is mounted in the center compartment in 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 oo Figure 12 Process Regeneration Heater Location and Disassembly Valve amp Air Manifold Casting Hollow Desiccant Tank Desiccant Assembly Rod Regeneration Heater n a Wire Conduit Assembl Lower Air Manifold Casting 15 30 amp 60 cfm Compact Dryers Chapter 5 Maintenance 40 of 51 Procedures 1 Disconnect electrical power to the dryer 2 Usinga 1 8 Allen wrench remove the 10 24 button head screws holding the top back and side panels to the dryer frame Disconnect the plug for the valve motor valve switch and blower 15 only R
57. utes with the temperature fluctuating up and down during that period After the flashing stops it means auto tuning has finished Shutting Down the Dryer l VIE MA or When processing is complete close the hopper slide gate and shut down any in line companion equipment such as the aftercooler Turn the Dryer ON OFF power switch to OFF Turn the system ON OFF switch to OFF If needed empty the drying hopper For maintenance or a long term shutdown open de energize the electrical disconnects at the dryer and at the power drop 15 30 amp 60 cfm Compact Dryers Chapter 3 Installation 21 of 51 Chapter 4 Operation 4 1 Start up 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 The process blower starts 3 Close the slidegate at the bottom of the drying hopper Make sure that the blowers turn in the right direction 4 Fillthe drying hopper with material 5 Ifyour 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 Make sure the aftercooler has the proper supply water temperature 6 Set the process set point on the temperature controller 7 After the proper pre drying time for the initial hopper fill has elapsed fully open the drying hopper
58. versa 15 30 amp 60 cfm Compact Dryers Chapter 6 Troubleshooting 44 of 51 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 Using a Platinum Resistance Thermometer If the controller displays a temperature of about 0 0 C 32 F when you insert a 100 ohm resistor between terminals A and B of the controller and you short circuit controller terminals B and B the controller is normal and the sensor is probably broken short circuited or incorrectly wired Other service problems or questions can be answered by contacting the Service Department 15 30 amp 60 cfm Compact Dryers Chapter 6 Troubleshooting 45 of 51 Chapter 7 Appendix 7 1 Warranty The manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions 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 This parts warranty does not cover any labor charges for replaceme
59. with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person REMEMBER NEVER place your hands or any part of your body in any dangerous location NEVER operate service or adjust the dryer without appropriate training and first reading and understanding this manual NEVER try to pull material out of the dryer with your hands while it is running Before you start the dryer check the following Remove all tools from the dryer Be sure no objects tools nuts bolts clamps bars are laying in the hopper area f your dryer has been inoperative or unattended check all settings before starting the unit Atthe beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alter

ACS A0570882 User's Manual

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