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Sterling 350-2100 CFM Dehumidifier User Manual

1. Error Bookmark not defined Sales Department Error Bookmark not defined Contract Error Bookmark not defined 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
2. A REGEN BLOWER AND FILTER 09 as BS EEA D E i REAR VIEW PROCESS AIR ERAS PROCESS RETURN 15 of 58 Chapter 2 Functional Description Figure 4 Dryer Dimensions SUGGESTED 24 MINIMUM VERTICAL CLEARANCE LEFT n SIDE VIEW TEM PI MAINTENANCE H CLEARANCE Model A B C D E F G H I 850 84 88 56 34 12 90 87 12 84 12 74 83 1000 84 88 56 34 90 87 12 84 12 74 83 1250 84 88 56 34 90 87 12 84 12 74 83 1500 100 90 2 82 12 44 12 90 2 88 70 2 91 83 1800 100 90 2 8212 44 16 90 2 88 70 2 91 2 83 2100 100 90 2 82 1 2 44 12 90 2 88 70 1 91 83 350 2100 cfm Dryers Chapter 2 Functional Description 16 of 58 Chapter 3 Installation 3 1 Work Rules The installation operation and maintenance of this equipment must be conducted in accordance with all applicable work and safety codes for the installation location This may include but not limited to OSHA NEC CSA and any other local national and international regulations 1 Read and follow these operating instructions when installing operating and maintaining this equipment If the instructions become damaged or unreadable additional copies are available from the manufacturer 2 Only qualified personnel familiar with this equipment should work on or with this dryer Work with approved tools
3. 8 T Responsibly cm 9 General Hesponsibilily e tet ei HR Feo Ene due Eua cpu baden pads ck 9 Operator 5 a teet etae aditus 9 Maintenance 5 a aeq uo e rd ro Doa Blue to bate oben 10 Reporting a Safety Defect a d ouod 11 iN eeip ileji e E 11 CHAPTER 2 FUNCTIONAL DESCRIPTION 12 2 1 Models Covered in This Manual rr 12 252 General 12 2 3 Typical Features and Components essere nennen 12 2 4 Optional Features eim eret ente rk at Ded ito re ba Fo Ie ku er ane Lega 12 2 5 Closed Loop Drying 5 sr 13 26 AMhaLis DESICCANT siio rou tette Poe a Sa niae pietas e e 13 2 7 Process Regeneration Cvcle eene 13 2 8 Specifying Drying SyStetTi otras eer oet Rer Ro Ride Dope adenine 14 CHAPTER 3 INSTALLATION eeeee ee 17 RUGS eT 17 3 2 Electrical COHRSGLOTIS sco soa ahaha eee GR 17 3 3 Check For Proper Blower Rotation sa 17 3 4 Dryer Drying Hopper Process Air Hose Connection 17 3 5 X Aftercooler Cooling Water Connection nn 18 3 6 Drying Hopper Air Trapa on me ot OE a 18 CHAPTER 4 CONTROL PANEL 20 4 1 Gontr
4. Press m once The hour and minute display will return to zeroes and the hour indicator should be blinking Set the days of the week for automatic operation MODE Press le The Dav of the Week indicator will appear and the Sundav indicator should be flashing Press to automatically operate the dryer on Sunday press __ to prevent the dryer from automatically operating on Sunday Reverse video white characters on a black background UN indicates the day s selected for automatic operation For example Ml Press to store Sunday in the timer s memory Proceed until all desired days of the week are set Put the timer into Run mode MODE Press until the current time appears The colon between the hours and minute should be blinking The timer is now in run mode and automatic operation will begin as programmed 350 2100 cfm Dryers Chapter 5 Startup Shutdown amp Operation 34 of 58 Chapter 6 Maintenance 6 1 Servicing the Process Air Filters Models 350 700 WARNING Operating the dryer without the process air fillers installed will void the warranty Filter Cleaning is an important part of dryer maintenance Dryer models 350 through 700 have single high temperature up to 350 F cartridge cannister type filter in the process air loop It s mounted above the process blower on the rear of the dryer This filter protects the centrifugal blowers from plastic fines being drawn in from the drying h
5. OPERATIONANDINSTALLATIONMANUAL SDA SERIES 350 2100 LARGE DEHUMIDIFYING DRYERS IMPORTANT PLEASE READ CAREFULLY BEFORE ATTEMPTING TO INSTALL OR OPERATE EQUIPMENT Bulletin No DH1 655 1 Part No 882 00225 00 Effective 4 28 08 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 2008 All rights reserved DH1 655 1 il Shipping Info DH1 655 1 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
6. action temperature operating range by more than 70 C 158 F Whena platinum RTD sensor is used this message is displayed when the temperature has fallen to 99 9 C 147 82 F 350 2100 cfm Dryers 4 mA during reverse heating action 20 mA during normal cooling action 20 mA during reverse heating action 4 mA during normal cooling action Approximately 1 mA Approximately 1 mA Chapter 6 Maintenance Alarm Output Issues alarm outputs in accordance with the set alarm mode Issues alarm outputs in accordance with the set alarm mode Issues alarm outputs in accordance with the set alarm mode Proportional alarm output is OFF 46 of 58 Figure 9 Regeneration Monitor Signal Processor Error Messages lye D uo Status Condition Error Corrective Message BCD Linear Commun Action tive Output Output ications Outputs CPU RAM error external memory error Device memory Failure data error Turn the power OFF and then ON again Corrupted once If the error Data persists press the mode key and set all parameters again Turn the power OFF and then ON again once If the error persists call Service Breakage or short circuit of sensor When the Sensor thermocouple Error is used terminals 11 and 13 are not short circuited Input value Overflow or display Display Continues Continues Keep the input value Underflow value Blinks Continues OVER Continu
7. 2 6 Whatis Desiccant Desiccant 1s a material which attracts and holds absorbs water from the air The desiccant ACS dryers use is a synthetic crystalline metal aluminosilicate that is blended with a clay binder and formed into beads Absorbed water is driven from saturated desiccant by heating it to a high temperature reducing the desiccant s capacity to hold water and forcing air through it This moisture removal process is called regeneration 2 7 The Process Regeneration Cycle ACS dryers have two desiccant beds While one bed is on line in the process air loop the other is off line being regenerated 350 2100 cfm Dryers Chapter 2 Functional Description 13 of 58 Process Return Air From Drying Hopper When a desiccant bed is on line it absorbs moisture U Upper from the process air In dl Vas M Um time the bed becomes saturated with moisture and needs to be regenerated The dryer automatically redirects the process airflow to the second EEE o Jm and starts the regeneration WA IMI 2 Eee cycle on the first bed Wa i i During regeneration air is Fi Two heated to approximately l igure l we 550 F and forced through Airflow Diagram the desiccant bed The moisture driven off the bed is bled to the atmosphere If the temperature of the air bled to atmosphere bleed temperature is measured a rise can be observed after a period of time This condition called bed breakthrough indicate
8. Comparative output settings when security is enabled Output hysteresis Process temperature Input shift value Comparative output settings when security is disabled Linear output range Sensor type Display unit F C Display refresh time Communication unit Securitv protection Present Value PV LEVEL 0 Regen Bleed Air Temp In this the default level the present regeneration bleed air temperature is displayed plus the monitor s four setpoints can be viewed and changed HH Set Value Heater Cut Off Temp If security is enabled the setpoints cannot be changed They may be reviewed by pressing If security is disabled the setpoints can be A H Set Value changed on this level bv using and A Closed Loop Regen Cool Down Temp When the desired setpoint is displayed press to move to the digit you want to change and use A M GE to change the digit Then press to save L Set Value the new setting to memory and to move on to the y Regen Blower Shutdown Temp next setpoint LL Set Value Low Regen Temp Alarm 350 2100 cfm Dryers Chapter 6 Maintenance 48 of 58 LEVEL 1 In this level the four setpoints can be n changed plus Hysteresis Input Shift ka Setpoints and Security Protection can be set L l l Use to move from one parameter to the next Rem _ Hysteresis When the desired paramete
9. aL m RC AMPERES Sequence Shutdown Start Stop Control Power Switch Redundant High Temperature Alarn Redundant High Temperature Rese Redundant High Temperature Safel Heater Burn Out Indicator Amp Met DES E Day Timer OPTIONAL EQUIPMENT SHOWN Chapter 3 Installation 19 of 58 Chapter 4 Control Panel 4 1 Control Panel Indicator Lights PROCESS BLOWER ON This indicator lights when the process blower is energized PROCESS HEATER ON This indicator lights when the process air heaters are energized HIGH PROCESS AIR TEMPERATURE ALARM M This indicator lights when the temperature at the process air thermocouple is above the set high alarm value When the indicator lights the alarm relay is energized and all the heaters turn off while the blowers remain on The alarm mode and value are factory set to track 25 F above the process setpoint The alarm value is a deviation above the process setpoint When the temperature at the process thermocouple returns to within the acceptable range the alarm output is de energized and all the heaters turn on again automatically The alarm range may be altered See Section 5 5 REGEN BLOWER ON This indicator lights when the regeneration blower is energized REGEN HEATER ON This indicator lights when the regeneration heater is on LEFT BED REGENERATING amp RIGHT BED REGENERATING The indicator lit shows which bed is currently being regenerated
10. you won t end up with a clean filter and you might damage it Washing As a last resort wash the filter This is only necessary when the pressure drop is too high due to fine dirt embedded in the filter or there s been oily mist near the intake air location Use a mild low sudsing detergent and warm water Soak the filter 5 10 minutes then gently agitate for several minutes Rinse thoroughly with clean water to remove all detergent Let the filter dry completely before returning it to 350 2100 cfm Dryers Chapter 6 Maintenance 36 of 58 service Satisfactory filtration should be obtained through the second or third washing however the dirt holding capacity of the filter decreases after each washing After Each Cleaning e Inspect the filter element hold a light bulb behind the element to find fatigued paper or residual dirt e Inspect the end plates damage here could allow air to bypass the filter e Look for rust on the end plates and metal core rust particles could flake off and contaminate the dryer and resin e Check the gasket for damage a damaged gasket will allow contaminants into the process Replace if needed 6 4 Servicing the Regeneration Filter WARNING Operating the dryer without the regeneration air filters installed will void the warranty Filter Cleaning is an important part of dryer maintenance These dryers are equipped with a filter in the regeneration air loop Regular filter clea
11. 7 Inspect the gasketing on each of the covers Replace if necessary 8 Re install the covers 350 2100 cfm Dryers Chapter 6 Maintenance 39 of 58 Figure 6 Desiccant Amounts Required 600 re TE 1 9 p 120 6 9 Process Heater Replacement Procedure ACS dryers have a number of single phase Calrod type heater elements wired in a delta formation They are mounted in the vertical compartment behind the right hand desiccant tower The number and wattage of the heaters varies with model voltage temperature range etc but the replacement procedure is the same WARNING Disconnect and lock out power before heater replacement 1 Remove the bolts securing the process heater access cover 2 Sketch the heater wiring configuration so the heaters may be re wired properly Heaters are mounted on a common plate of three or six for easy maintenance Remove the jumper bars and wires for the heater plate assembly ies being removed or replaced 4 Remove the bolts securing the heater plate assembly and slide out the assembly Avoid damaging the gasketing 5 Remove individual heaters for replacement by removing the large brass nuts and washers 6 Re install the heaters and heater plate assemblies in reverse order replacing gaskets if necessary Caution Heater loops should not touch each other Hot spots will lead to premature heater failure 7 Re install the jumper wires and bars according to the sketch made ear
12. and devices 4 Disconnect the electricity before maintenance or service If the dryer is installed with a power cord that can be unplugged unplug it If the dryer is permanently wired to a power main a fused power disconnect must be installed to allow the disconnect to be locked in the OFF position Open and lock out the disconnect installed in the control enclosure 3 2 Electrical Connections The voltage phase and amp draw information is listed on the serial tag Line voltage must be within 10 of the voltage listed on the serial tag or damage may occur Phase imbalance must be less than 5 Fulfill all national state and local safety and electrical code requirements Connection should be made by a qualified electrician 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 M The power drop must include a ground wire 3 3 Check For Proper Blower Rotation The blowers are rotating properly when air flows from the delivery outlet e Incorrect phasing of power leads will cause backward rotation of blower motors and contamination of the desiccant If both blowers are rotating improperly reverse any two wires at the fused disconnect outside the dryer or at the disconnect terminal in the control enclosure This assures that both blowers will be rotating in t
13. filter a damaged filter should not be washed or reused e Remove loose dirt from the filter with compressed air or a water hose Compressed air should be less than 100 psi use a 1 8 diameter nozzle at least 2 away from the filter Water should be less than 40 psi don t use a nozzle e Soak the filter in FM 1400 or comparable detergent solution for at least 15 minutes Never soak more than 24 hours e Swish the filter around in the solution to agitate loosen dirt particles and put them in suspension e Rinse the filter from the clean side to the dirty side with a gentle stream of water 350 2100 cfm Dryers Chapter 6 Maintenance 35 of 58 to remove all dirt and suds less than 40 psi no nozzle If the clean or downstream side of the filter has been contaminated with dirty water during the soak cycle rinse from both sides e Dry the filter before re using Circulate warm air at less than 160 F Do not use a light bulb to dry the filter e 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 6 3 Servicing the Process Air Filters Models 850 through 2100 On 850 through 2100 cfm dryers the multiple high temperature up to 350 F process filters are located in the housing under the blower platform on the left rear corner of the dryer These filters protect the centrifugal blowers from plastic fines being d
14. from the signal processor depending on the part of the regeneration process currently underway The signal processor s setpoints are factory set for efficient operation in most situations The manufacturer does not recommend changing the setpoints indiscriminately but persons knowledgeable of the processing system may fine tune the setpoints for decreased energy consumption LL Setpoint Low Regeneration Alarm Setpoint 130 F This setpoint alerts the PLC and operator to possible regeneration heater problems If this bleed air temperature is not reached within 30 minutes of the regeneration heaters being energized the Low Regen Air Temp Alarm lights The light will go out automatically when the setpoint is reached The alarm can indicate burnt out regeneration heaters or an extremely moist desiccant bed L Setpoint Regeneration Blower Shutdown Temp 160 F After a desiccant tower has been regenerated the regeneration blower continues to cool the desiccant until this setpoint is reached The signal processor informs the PLC and the PLC shuts down the regeneration blower to prevent loading the regenerated bed with ambient moisture H Setpoint Optional Closed Loop Regeneration Cool Down Temp 250 F This setpoint output is used on dryers equipped with optional closed loop regeneration cool down When this setpoint is reached the output signals the PLC to shift the Wye valve in this device s aftercooler and the cooling water valve to
15. in addition to information for operating the dryer safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that 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 moder
16. is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on it You should have Dehumidifying Dryer Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the parts and service department immediately at 262 641 8610 Have the item and order numbers ready to expedite your return 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 iii Table of Contents CHAPTER 1 SAFER Xi i e fk 6 14 Howto Use This Manual rti e Tenere e eret ip Ra di Fe Ee ERR EH Uer HE 6 Safety Symbols Used in this Manual sse 6 1 2 Safety Tag Information oes ax ieee cece Aes echo eo tutu Ga NUR ER D EE 7 Driver saret Tags tetendit E 7 185 Warnings and Precablioris nuce rut eee ese Po Du vada Dodge tex a o
17. off line HIGH DEW POINT ALARM This indicator lights when the process air delivery dew point exceeds the dew point shift point as set by the adjustment pot on the control enclosure graphic panel See Section 5 6 DIRTY FILTER ALARM M This indicator lights if the pressure differential across either the process air return filter or the regeneration inlet filter exceeds the pressure switch setting This indicates a filter in need of service The light resets automatically when the filter is serviced The pressure switch is adjustable See Section 6 4 LOW PROCESS AIR TEMPERATURE ALARM M This indicator lights when the temperature at the process air thermocouple is below the set low alarm value 350 2100 cfm Dryers Chapter 4 Control Panel 20 of 58 The alarm mode and value are factory set to track 25 F below the process setpoint The alarm value is a deviation above the process setpoint This alarm is informational If the alarm light stays lit for an extended period of time check for blown fuses or possible burnt out heaters M When the temperature at the thermocouple returns within limits the alarm clears automatically This alarm is delayed on initial start up to avoid nuisance alarms The alarm range may be altered See Section 5 5 PROCESS BLOWER FAILURE ALARM This indicator lights if pressure switch 2PS detects a loss of process blower air pressure All heaters are shut off until the a
18. operator s responsibility does not end with efficient production The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment 350 2100 cfm Dryers Chapter 1 Safety 9 of 58 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 e Remove all tools from the dryer Be sure no objects tools nuts bolts clamps bars are laying in the hopper area If your dryer has been inoperative or unattended check all settings before starting the unit At the beginning of your shift and after breaks verify that the controls and other auxiliary eq
19. properly set These are listed below 350 2100 cfm Dryers Chapter 6 Maintenance 42 of 58 Display Sensor Type Switch Temp Characters Position Range _ Thermocouple poe 0 1 700 0 3 000 amp P Thermocouple Type S 0 1 700 0 3 000 Thermocouple Type K 2 200 to 300 to 1 300 2 300 Thermocouple Type J 3 100 to 100 to 900 1 600 ki AR d 400 700 E nec DEN lil 1981 450 0 800 0 pe g meme TR 450 0 800 0 NotUsed 8 S A NtUsed 9 f 9 Set both transmission output selector DIP switches OFF They are marked SW207 TRANSFER and are on the right circuit board on controls equipped with optional communications See the Communications Manual part number A0535959 ON eel 1 2 3 4 5 6 10 The function selector DIP switch SW201 FUNCTION selects 6 control modes It is on the right circuit board Put this switch in the set up configuration at right while inputting the initial control parameters SW201 Set up Configuration 1 OFF Control Mode 2 OFF Normal Reverse Output OFF Input Shift Temperature Sensor Standard Scale Indication PID Constant Indication 350 2100 cfm Dryers Chapter 6 Maintenance 43 of 58 11 Slide the control chassis back into the control housing The remaining parameters are set with the keypad 12 Ready the dryer for startup with a real or simulated load Restore the electrical power 13 Turn the control po
20. the readings on the dewpoint meter on the dryer s control panel The readings should correspond within a degree or two across the entire range 4 If the readings agree the control board is OK Dewpoint sensor replacement is recommended If the readings do not agree replace the control board and run the test again to rule out the possibility of a bad sensor Do not attempt to make any adjustments to the components on the dewpoint control board 5 When testing is finished re connect the control cable to the sensor adapter 6 7 Symptoms of Worn Out Desiccant The moisture adsorption capacity of the desiccant used in ACS dryers degrades after an indefinite period of time Useful life depends on variables such as material moisture content plasticizer vapors in the return air and number of regeneration cycles Your dryer may need new desiccant if it exhibits any of the following symptoms e The plastic material is not being dried sufficiently high scrap reject rate e The air temperature at the top of the regenerating desiccant bed rapidly climbs to 350 F or more shortly after the start of regeneration even though a saturated bed has just started heating e The process air dewpoint measured with a portable dewpoint monitor is higher than 10 F throughout the process drying cycle e Smoke or dust is being blown out of the process air outlet 350 2100 cfm Dryers Chapter 6 Maintenance 38 of 58 e Noticeable amounts of desiccant in t
21. 00 850 1000 1250 1500 1800 and 2100 cfm large dehumidifying dryers in both standard 300 F and 400 F high temperature RT models 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 2 2 General Description Dehumidifying Dryers are designed to generate heated dehumidified air at carefully controlled temperatures for use in closed loop plastic drying systems Drying systems are sized to meet the specific requirements stated by the purchaser at the time of purchase Moisture removal from hygroscopic moisture attracting plastic pellets is an essential step in the manufacture of high quality plastic products ACS dryers are used by the plastics industry to generate very low dewpoint air that is heated to a controlled temperature for drying plastic pellets and regrind 2 3 Typical Features and Components 1 Branch Fusing provides additional protection to the operator and the components on the dryer s sub panel 2 Dewpoint Monitor indicates dryer efficiency 2 4 Optional Features Options can tailor an ACS dryer to meet the exact requirements of the drying task being performed e Dirty filter indicator to advise the operator when it s time to clean the filters e Water cooled aftercooler for closed loop regeneration air cooling e SMART PLC to combine PLC features and a Plain English interface This option is full
22. C Operation amp Installation Manual part number A0536527 MODE KEY This key scrolls through the parameters that can be set in indication levels 0 and 1 Note During normal operation use this key to change the alarm setting only The factory alarm settings are 25 F above and below the setpoint and are satisfactory for most applications DOWN KEY This key lowers the process air set point temperature During setup it decreases the value of the parameter displayed by the Set Value SV LED UP KEY This key raises the process air set point Temperature During setup it increases the value of the parameter displayed by the Set Value SV LED AUTOTUNE KEY When pressed and held for one second or more this key starts the Auto Tune function 4 7 Optional Communications Protocols For SPI RS 232C RS 422 and RS 485 communications a connection port on the electrical cabinet permits easy hook up to the host computer The connection port is a direct pin to pin extension from the plug on the back of the temperature controller For pin outs consult the control module s communication manual part number A0535959 350 2100 cfm Dryers Chapter 4 Control Panel 26 of 58 Chapter 5 Startup Shutdown amp Operation 5 1 ia Startup Checks Check the process and return hoses for tight connections Check that all companion equipment such as the drying hopper loading system and aftercooler are ready for operat
23. T o Auto Tune LED This orange LED flashes during the Auto Tune sequence The controller will automatically determine the proper P I D values for the operating conditions See Section 6 11 ALM1 Alarm LED High Temp Alarm This lights when the process air temperature has risen more than 25 F factory default from the setpoint The alarm relay in the PLC is energized when this LED is lit The audible visual alarm will sound if the dryer is so equipped All heaters turn off and the blowers stay on to cool the heaters It is adjustable see Section 5 5 ALM2 a Alarm Two LED Low Temp Alarm This lights when the process air temperature drops more than 25 F factory default from the setpoint The alarm relay in the PLC is energized when this LED is out The audible visual alarm will sound if the dryer is so equipped It is adjustable see Section 5 5 350 2100 cfm Dryers Chapter 4 Control Panel 25 of 58 4 6 Temperature Controller Keys See Figure 5 in Section 3 6 LEVEL KEY w When pressed for two seconds or more this kev selects the next of the three indication levels 0 1 and 2 where specific control parameters may be set The control defaults to level 0 on power up REMOTE KEY This key is on controls with optional communications For information on RS 232C RS 422 or RS 485 communications refer to the Communications Manual part number A0535959 For RS 232C units with the SPI CPC protocol converter refer to the CP
24. arameter is then displayed on DI ana A the LED display Use to change y to save the new setting to memory the setting When you are satisfied with the new setting press Sensor Input Type l V k The regeneration monitor is factory equipped with and configured to use a type K thermocouple Type R S J L T U E and 100 W RTD s can also be used The factory setting is HE Press after Lm k appears on the LED displav Use A to scroll through the available sensor types Then press e to save the new setting to memory H H H H Scale Indication The regeneration monitor can display the regeneration bleed air temperature in either Fahrenheit F the factory default or Celsius C The control is factory set to the scale indicated on the dryer at the time of purchase Press after F appears on the LED display Use to toggle between the two choices Then press to save the new setting to memory _ jo Display Refresh Cycle tL l The regeneration monitor s display refresh speed can be set separately from the sampling speed WA Press after cl c appears on the LED display Use to toggle between the two choices FASE 500 ms or GLAT 2 seconds Then press to save the new setting to memory The factory setting is FASE Note Even if the
25. are factorv set with the protection turned Off Enabling the Lockout Feature 1 Disconnect main electrical power to the dryer 2 Press up the latch at the bottom of the control module s front panel and slide out the control chassis 3 Locate the slide type switch SW101 PROTECT on the left circuit board Slide it to ON 4 Slide the chassis back into the control module s housing Tamper protection will now be enabled 350 2100 cfm Dryers Chapter 5 Startup Shutdown amp Operation 29 of 58 5 9 Changing the Display from Fahrenheit to Centigrade To change the display from the factory F setting to C Disconnect main electrical power to the dryer Press up the latch at the bottom of the control module s front panel and slide out the control chassis Locate DIP switch SW201 FUNCTION on the right circuit board Slide the 5 pin to OFF Slide the chassis back into the control module s housing NW FY m Cover the F label with the C sticker included in the information packet 5 10 setting the Dewpoint Extend Shift Point 350 2100 cfm dryers shift air flow from the on line desiccant bed to the regenerated desiccant bed based on actual dewpoint demand not by fixed time cycles 2 Set the Dewpoint Shift Point to the highest process air moisture content you would like to allow before the dryer shifts air flow to the regenerated desiccant bed 3 The Dewpoint Shift Point is set with the dewpoint meter the P
26. ate injury or in property damage 350 2100 cfm Dryers Chapter 1 Safety 6 of 58 1 2 Safety Tag Information Dryer Safety Tags Hot Read Operation and Installation Manual High Voltage Earth Ground Inside Enclosure Protected Earth Lifting Point Ground 350 2100 cfm Dryers Chapter 1 Safety 7 of 58 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 A RA RA ARK RI 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 re
27. ckage of a clean filter 350 2100 cfm Dryers Chapter 6 Maintenance 37 of 58 9 Remove the restriction from the filter element and re install the clean filter The alarm light should remain off 6 6 Dewpoint Control System Service The Dewpoint Shift feature on dryer models 350 through 2100 depends on the proper operation of the dewpoint sensor and its control board The dewpoint sensor is in the process airstream and is therefore susceptible to contamination Dewpoint sensor life is dependent 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 The dryer operator should monitor the initial dewpoint sensor readings and establish a periodic replacement schedule as needed Note Note Do not attempt to check the continuity or resistance of a dewpoint sensor The sensor will be destroyed If you suspect that the dewpoint readings on the dewpoint meter are incorrect a dewpoint simulation calibrator is available from the manufacturer part number A0549143 This device simulates various dewpoint outputs It can confirm proper operation of the dewpoint sensor and dewpoint system control board To check the dewpoint sensor and dewpoint control board 1 Remove the sensor cable from the sensor hex nut adapter 2 Connect the cable to the plug on the rear of the simulator 3 Turn the rotary knob on the simulator to each position and note
28. close loop and cool the regeneration air The very dry regeneration bleed air is directed back into the aftercooler where it is cooled to about 150 and then back into regeneration blower inlet This ensures that no moisture will be added to the desiccant bed until it goes back on line HH Setpoint Heater Cut Off Temp 300 F This setpoint is the temperature at which the PLC is signaled to shut off the regeneration heaters because the desiccant is dry and begin the cool down process Raising this setpoint will not significantly improve dryer performance but merely increase energy consumption Basic information is listed below For more detailed information refer to the processor manual shipped with the dryer To change the Regeneration Monitor System Setpoints e Press until the LED above the parameter to be changed LL L H or HH is lit The number value displayed is the selected parameter s current set point e Within 5 seconds press until the digit to be changed blinks A e Press until the desired number value is displayed in that digit position 350 2100 cfm Dryers Chapter 5 Startup Shutdown amp Operation 3 of 58 AN e Press again to move one digit to the right Then press to display the desired value e Follow this procedure to set all four digits e When satisfied with the value displayed press to save the new value to the regeneration monitor s memory and move on to the next parameter if desired
29. critical operation stopping alarm occurs The alarm will repeat every five minutes unless the problem causing the alarm has been resolved 350 2100 cfm Dryers Chapter 4 Control Panel 2 of 58 VALVE POSITION ERROR A pair of position switches confirm proper shifting of the valves If full travel is not confirmed by the switches the cycle will not begin on the new bed 4 2 Switches and Meters ON OFF SELECTOR SWITCH This energizes or de energizes the dryer s control power START STOP PUSH BUTTON Press this momentary contact switch to start the dryer Press this switch to shut down an operating dryer The dryer shutdown sequence is 1 Process heaters shut off immediately 2 Process blower continues to run for 20 minutes to cool the process heater then shuts off 3 The regeneration cycle of the off line bed will continue until finished the regeneration heaters will shut off followed by the regeneration blower DEWPOINT METER This meter indicates the current process air delivery moisture content M When the Push To Set button is pressed the meter indicates the Dewpoint Shift point See Section 5 10 PUSH TO SET This push button is used when setting or confirming the Dewpoint Shift point See Section 5 6 DEWPOINT SHIFT ADJUST This potentiometer pot is used when setting the Dewpoint Shift point See Section 5 6 SHIFT SET SELECTOR SWITCH In the ON position the drying temperature is raised or lowered to th
30. d stop blinking Setting the start up time MODE 1 Press and hold until is lit and the hour indicator is blinking 2 Press or I until the desired drver start up hour is displaved The start up time is set in a 24 hour format 3 Press RI to store the dryer start up hour in the timer s memory The hour indicator will stop blinking 4 Press or I until the desired drver start up minute is displaved The minute indicator should be blinking 5 Press m to store the start up minute in the timer s memory The minute indicator will stop blinking 6 Now the 1 output status indicator should be blinking Press H to turn the output to the ON status 350 2100 cfm Drvers Chapter 5 Startup Shutdown amp Operation 33 of 58 7 Press m once The hour and minute display returns to zeroes and the hour indicator should be blinking Setting the stop time 1 Press H or __ until the desired dryer shut down hour is displayed The shut down time is set in a 24 hour format Press to store the shut down hour in the timer s memory The hour indicator should stop blinking Press or I until the desired drver shut down minute is displaved The minute indicator should be blinking Press to store the shut down minute in the timer s memory The minute indicator will stop blinking Now the 1 output Status indicator should be blinking Press __ once to set the output to the OFF status
31. de iz doeet Queste beds 32 CHAPTER 6 MAINTENANCE OO 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 10 6 11 6 12 Servicing the Process Air Filters Models 350 700 35 Filler Cleaning Replacement oats sesta a 35 Servicing the Process Air Filters Models 850 through 2100 36 Servicing the Regeneration Filter ss 37 Dirty Filter Alarm Calibration nnn 37 Dewpoint Control System Service nr 38 Symptoms of Worn Out DeSIGOAlL iii sis tw ERG t DU iH bc ue ee 38 Desiccant Replacement Procedure near 39 Process Heater Replacement Procedure ss 40 Regeneration Heater Replacement Procedure 41 Restoring a Temperature Controller to the Factory Setup 42 Regeneration Monitor Advanced Programming 48 CHAPTER 7 TROUBLESHOOTING 52 CHAPTER 8 APPENDIX itai erre a 99 8 1 8 2 DH1 655 1 Customer Satisfaction Warranty Program Error Bookmark not defined Technical ASSISTANCE s c ote ee o P vecta a Loca AEEA ue i cess um nese 58 Parts Department da oe it ere tetto Error Bookmark not defined Service
32. display refresh speed is set to two seconds the sampling times for the setpoints still remains at 500 milliseconds 350 2100 cfm Dryers Chapter 6 Maintenance 51 of 58 Chapter 7 Troubleshooting Little or no air coming from A Dirty Filters Clean or replace process delivery tube es Desiccant beds B Replace desiccant Ghee by material or plasticizer leaking into the system See Sec 6 6 C Blower fuse s blown C Fix problem and Replace fuse s D Overload tripped D Fix problem and reset the overload E Blower fins filled with E Remove blower dust or contaminants sideplate clean baffles replace Suction in delivery tube A Phase is reversed on JA Stop the Dryer pressure from the return power drop coming If the dryer was connected tube into the dryer to the drying hopper check to see if the desiccant and process air heater has been contaminated with resin If so replace the desiccant and remove any resin carry over Otherwise change the phase of two legs of the three phase power drop Never change the phase at the motor starters unless only one of the two blowers is rotating improperly 350 2100 cfm Dryers Chapter 7 Troubleshooting 52 of 58 PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Loss or reduction of A Process heaters are A Check for open or process air temperature faulty shorted heaters Replace if required Check the fuses B Solid state n PS B Replace faulty C Pr
33. e 14 DIN controller s alternate temperature see Section 4 5 OVER TEMPERATURE RESET Optional This push button resets the control system to allow restart of heaters and blowers after process air temperature has dropped below the high value programmed into the 1 8 DIN panel meter 4CNTL This is on dryers equipped with the auxiliary hi temperature safety option HEATER BURN OUT INDICATOR METERS Optional The six current indicating meters monitor the current draw on each phase of the process and regeneration heaters M During normal operation all three meters phases should read within one or two amps of each other 350 2100 cfm Dryers Chapter 4 Control Panel 22 of 58 If one or two of a heater s three meters indicates a low reading a burned out heater is likely and should be serviced 4 3 PLC Control These dryers are equipped with an Omron C28K programmable logic controller PLC The brick type PLC has 28 I O points 16 inputs and 12 outputs All inputs are 115 VAC except for the 24 VDC input 1 from the dewpoint circuit board All programming and logic is factory installed on an EPROM and cannot be modified A battery backup retains the programming during power failures Battery life is 5 years at room temperature If the alarm indicator blinks intermittently replace the battery P N A0544701 within one week 4 4 Process Air Temperature Controller Standard ACS dryers use a microprocessor based PID con
34. e Press repeatedly to review the new settings 5 12 Auxiliary Process Safety System Optional This option provides an extra level of protection from hopper meltdown due to a runaway heat condition such as a fused heater contactor When triggered this system will drop out high voltage to all heater contactors and blowers This drastic action to protect the resin and the drying hopper will only occur if a high temperature condition is not first handled by the 14 DIN control Section 4 1 on the dryer subpanel and or the heater contactor s is are fused This system must be manually reset by pressing the OVERTEMP RESET button after fixing the problem This option uses a signal processor identical to the one used in the regeneration monitoring system It monitors the process temperature through a thermocouple mounted at the drying hopper inlet Only one of the setpoints H is used See Section 5 11 for instructions on setting the H setpoint The H setpoint should be the highest temperature tolerable at the drying hopper before resin or drying hopper degradation occurs This temperature varies depending on the resin and the drying temperature but a suggested starting temperature is 75 F above the drying temperature 5 13 Seven Day Timer Optional The seven day timer can be programmed for weekly ON OFF operation of up to sixteen setpoints An internal battery back up holds the settings in memory when the dryer is de energized The dryer s Po
35. e or long term shut down open de energize the electrical disconnects at the drver and in the power drop 5 4 Setting the Process Air Temperature To Change Process Air Temperature Set Point e Press to raise the Setpoint e Press to lower the Setpoint 5 5 Setting the High and Low Temperature Alarms To Change the Process Air High Temperature Alarm Setting Press for at least two seconds to access the level 1 parameters 2 When the PV LED display shows ALI use and to set the desired high temperature alarm value The high temperature alarm value is a deviation of the process air temperature set point The alarm value will track the set temperature If the high temperature alarm is set to 25 a high temperature alarm occurs if the process air temperature rises more than 25 F above the process air temperature setpoint i 3 Press until the PV LED shows fil e Use and to set the desired low temperature alarm value 350 2100 cfm Dryers Chapter 5 Startup Shutdown amp Operation 28 of 58 The low temperature alarm value is a deviation of the process air temperature set point The alarm value will track the set temperature If the low temperature alarm is set to 25 a low temperature alarm occurs if the process air temperature falls more than 25 F below the process air temperature setpoint 4 Press until the Level 0 values process air temperature setpoint and process air temperature are displayed The High Tempe
36. ecifications Model Amp Dimensions Hose Shipping Process Regen Desiccant Number Draw Connection Weight Blower Blower Lbs Bed Inches 350 56 56 73 44 100 5 30 76 3S90RT 56 56 73 4 100 5 830 76 495 s2 fe 5 100 72 3 90 49RT tt f 5 se 5 1100 72 J 90 50 66 5 120 7v 40 500RT 66 94 5 120 7 40 100 o0 s 156 88 6 140 10 40 120 58 56 ss 6 140 10 40 120 z0 59 66 93 6 160 10 40 135 1059 86 08 6e 160 10 40 135 80 1 1 103 88 90 S3 120 120 850RT es 88 o 8 X 3 120 12 1000 f 88 f 88 o 120 130 1000 RT_ 146 as s4 o 7 120 130 1250 188 88 o 76 9 120 180 1250 _ 194 88 o X 9 7 120 180 1500 16 94 100 90 HH 120 240 150 RT 213 94 9A 7 120 240 1800 179 94 10 90 w 10 J 120 180 RT 285 94 J 10 120 310 2100 203 9 10 98 10 15 120 360 210 RT 278 94 100 98 15 4 120
37. er Setting Description LED SV LED Levels Display Setting Alarm Range 10 F Proportional Bandwidth 90 0 Seconds am MAI Lower Limit Value of 250 F Control Range p missionali Nu ALLE m Alarm l Unit Number EE with w Optional Network Communications Baud Rate Setting Varies With w Optional Network Communications 350 2100 cfm Dryers Chapter 6 Maintenance 45 of 58 FLASHES D When a type J thermocouple is used this error message is not displayed until the temperature has risen above the normal operating Figure 8 Process Temperature Control Error Messages Message Cause Input temperature has risen beyond the upper limit of the temperature range by more than 20 C 68 F Input temperature has fallen below the lower limit of the temperature range by more than 20 C 68 F The thermocouple has burned out or the short circuit bar has been removed The platinum RTD has burned out or A and B have been short circuited Memory failure E111 or analog to digital converter failure E333 has occurred Temperature controller must be repaired if recovery is not made by turning power off once and on again Control Output With current output unit With output unit other than current output unit OFF during reverse heating action ON during normal cooling action ON during reverse heating action OFF during normal cooling
38. erator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No matter who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production Loss of a skilled operator temporarily or permanently Breakdown of shop morale Costly damage to equipment 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 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
39. es OVERON and display value outside ON within the range Check the output type If correct press the mode key This erases OFF the set the parameters so re enter them If the problem persists call Service Turn the power OFF Output Output type and then ON again Type Error other than OFF OFF OFF once If the error specified persists call Service agg Check sensors for breakage short circuiting or incorrect wiring When Output output type Type has Change changed Input Input type Turn the power OFF Specifi other than and then ON again cation specified OFF once If the error Error persists call Service 350 2100 cfm Dryers Chapter 6 Maintenance 47 of 58 6 12 Regeneration Monitor Advanced Programming The regeneration monitor has three menu levels numbered 0 through 2 Each menu level allows specific parameters to be viewed and or set Moving Between Levels Level 0 the RUN mode is the default and automatically appears when the dryer is powered up To move to Level 1 press and hold for 2 seconds When Level 1 is reached press and hold both and for 1 second to move up a level or move back to RUN mode by pressing for 1 second See the flow chart below Press 2 sec Press L Al1 sec Press A 1 sec TI Level 0 Level 1 k 7 Level 2 Press LI 1 sec Press 1 sec
40. fsets the displayed temperature by the value you set here This may be useful to force the regeneration monitor to display the same temperature as a known or supposed temperature reading 350 2100 cfm Dryers Chapter 6 Maintenance 49 of 58 Press e 0 A after LT appears on the LED display Use and to set the value Then press to save the new setting to memory D um Security Protection F b When Securitv Protection is enabled the setpoints can t be changed when the Regeneration Monitor is in RUN mode The setpoints can only be changed in Level 1 using the LEE function Press factory setting is OFF When the selection has been made press memory 350 2100 cfm Dryers 0 after Prat appears on the LED display Use to toggle between ON and OFF The m to save the new setting to Chapter 6 Maintenance 50 of 58 LEVEL 2 In this level parameters such as the type of Sensor Input Type temperature sensor connected to the EL regeneration monitor Fahrenheit centigrade Lr display and display refresh cycle can be set gt _ Scale Indication C or F moves from one parameter to the next When the desired parameter appears on the LED display press CO to select that Y _ Display Refresh Cycle parameter for programming The current dJ value of the p
41. he beds is a medium brown color or darker If any of these signs are noticed the desiccant in the desiccant beds should be replaced Desiccant replacement kits are available from the Parts Department If you wish the desiccant beds can be repacked at your site by a technician WARNING DESICCANT MATERIAL CAUSES EYE IRRITATION BREATHING MAY BE HARMFUL MAY CAUSE SKIN IRRITATION Do not get in eyes Avoid prolonged contact with skin Use with adequate ventilation Wash thoroughly after handling FIRST AID In case of eye contact immediately flush eyes with plenty of water for at least 15 minutes If irritation persists see a physician 6 8 Desiccant Replacement Procedure Follow the procedure below to change the desiccant 1 Disconnect electrical power to the dryer 2 Remove the bolts and nuts securing the cover of each desiccant tower Remove the covers with a lifting fixture 3 With a shop vacuum carefully remove all desiccant from each tower 4 Inspect each lower desiccant screen for tears or burn through spots Replace if necessary After cleaning each tower add a level layer of half the large bead desiccant on top of the screen Next carefully add the full amount specified per bed of small bead desiccant Smooth the top level and finally add another layer of the remaining large bead desiccant to the top Make sure this layer is level and smooth 6 Repeatthe above step for the other bed
42. he proper direction e Reverse the wires at the motor starters only if one blower is rotating incorrectly 3 4 Drver Drving Hopper Process Air Hose Connection Use high temperature flexible dryer hose or rigid tubing to connect the dryer to the drying hopper 350 2100 cfm Dryers Chapter 3 Installation 17 of 58 RI Keep the deliverv to the drving hopper hose as short as possible to minimize heat loss Insulated hose is recommended and available for maximum energy savings Do not use insulated hose on the return from the drying hopper Do not shorten the return hose The return air to the blower must be 150 F or below Make sure the hoses are not kinked NANA A Drying hopper air inlet and outlet locations vary but always connect the hoses so the dry process air from the dryer enters the bottom of the drying hopper and flows out the top to return to the dryer inlet 3 5 Aftercooler Cooling Water Connection The Aftercooler cools the moist air returning to the dryer from the drying hopper The aftercooler can cool the return air from 250 F to about 150 F This maintains the dryer s efficiency and condenses unwanted plasticizers from the airstream 1 Support both sides of the fitting when making the cooling water connections to prevent damage to the aftercooler coil 2 Connect 85 F water to the 1 2 NPT inlet closest to the exiting air side of the aftercooler coil This will cool the process air about 100 F and raise the
43. ion Check the dryer electrical connections Note Clean the rust preventive oil from inside the drying hopper Failure to clean the hopper will cause fouling of the desiccant in the dryer and will void the warranty 5 2 Startup Close the slidegate at the bottom of the drying hopper 1 Fill the drying hopper with material 2 Turnon energize the disconnect switch in your power drop then turn on the one on the dryer 3 Hlip the on off switch to ON 4 Press the stop start button The blowers should start and the proper control panel indicators should light 5 Make sure both blowers are turning the right direction Verify rotation direction is correct If one or both blowers do not start Check to see if an overload on the blower motor starter has tripped If so set it properly and reset Check the blower fuses too e If one of the optional Valve Position Error lights is lit the blowers will not start Make sure the valve arm has tripped the proper limit switch If the electric actuator is not fully extended or retracted check the line fuse 8FU near the actuator s 24 VDC power supply The valve actuator has built in limit switches to shut off its motor It must fully extend and retract to prevent the motor from burning out e Ifa blower failure light is lit after the blower has run for a few seconds and shut down the blower pressure switch will need to be adjusted until the failure light goes out The press
44. larm is cleared REGEN BLOWER FAILURE ALARM This indicator lights if pressure switch IPS detects loss of regeneration blower air pressure All heaters are shut off until the alarm is cleared HIGH REGEN AIR TEMPERATURE ALARM This indicator lights when the thermocouple below the regeneration heater assembly senses an abnormally high temperature Note Do not adjust the factory setpoint of 3CNTL the V DIN panel mounted temperature controller inside the enclosure The regeneration heaters are shut off until the temperature falls below the alarm point The regeneration blower will continue to run and cool the heaters and desiccant bed The alarm light will clear automatically when the temperature drops below the alarm point and the heaters will re energize automatically LOW REGEN AIR TEMPERATURE This indicator lights if the regeneration bleed temperature has not reached the factory setpoint of 150 F within 30 minutes of the start of bed regeneration The panel meter 2CNTL and the PLC monitor the regeneration bleed temperature This alarm is informational and does not affect the regeneration process This alarm may indicate a very wet desiccant bed or if the light does not go off within an hour malfunctioning or burnt out regeneration heaters For more details on the regeneration monitoring system see Section 5 7 CRITICAL ALARM SILENCE Press this button to turn off the audible alarm and flashing beacon when a
45. lier 8 Re secure the process heater access cover 350 2100 cfm Dryers Chapter 6 Maintenance 40 of 58 6 10 Regeneration Heater Replacement Procedure Dryer models 350 through 2100 Dryers have four or eight three phase regeneration heaters wired in the wye formation mounted in the insulated box directly above the lower valve WARNING WARNING Disconnect and lock out power before heater replacement 1 Access the regeneration heaters from the rear of the dryer Remove the cover plate secured by two bolts 3 Sketch the heater wiring configuration so the heaters may be re assembled properly Also note that the loops of the heaters are vertical to prevent drooping when hot 4 Remove the jumper wires for the heater s being removed and or replaced Remove the four bolts securing each heater s 3 1 2 mounting plate Slide out the heater taking care to not damage the gasketing 6 Re install the new heaters in reverse order Be sure their loops are vertical like the original heaters were Securely tighten all fasteners Caution Caution The heater loops should not touch each other This will create hot spots and lead to premature heater failure 7 Re install the jumper wires according to the sketch made earlier 8 Re secure the regeneration heater access cover 350 2100 cfm Dryers Chapter 6 Maintenance 41 of 58 6 11 Restoring a Temperature Controller to the Factory Setup If the control s pre set parameters have been tampe
46. ll maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8610 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Service contracts are available for most of our products Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 262 641 8610 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations Sterling Inc 2900 5 160 Street New Berlin WI 53151 www sterlco com 350 2100 cfm Dryers Chapter 8 Appendix 58 of 58
47. move the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power Use EXTREME CAUTION when working with dryer HIGH HEAT can be dangerous Keep body parts tools clothing and debris away from dryer 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 Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 350 2100 cfm Dryers Chapter 1 Safety 8 of 58 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 op
48. ning will keep your dryer operating at peak efficiency To Clean the Regeneration Filter e Turn off and or lock out electrical power to the dryer e Slide the panel filter out of its housing e Vacuum or carefully blow out the filter with compressed air If the filter is worn or can t be cleaned replace it e Slide the filter back into its housing 6 5 Dirty Filter Alarm Calibration Dryer models 350 2100 may be equipped with an optional Dirty Filter Indicator When this indicator lights it is time to clean or change the filter The Dirty Filter indicator is tested and calibrated at the factory but it can be adjusted in the field 1 Be sure that your filter is clean and use the following procedure Remove the process air return filter element from its housing Block off approximately 50 of the filter s surface area to simulate a dirty filter Reinstall the cartridge and secure the cover While the process blower is operating adjust the trim screw on the differential pressure switch until the alarm light just comes on 6 Remove the restricted filter cartridge from the housing again The alarm light should stay off when the process blower operates if the switch is adjusted correctly 7 Re install the obstructed cartridge filter The alarm light should go on again if the switch is adjusted correctly 8 Fine tune the switch setting so it consistently warns of a blocked filter and does not falsely indicate a blo
49. ocess temperature C Make sure that plant was adjusted in error by personnel are aware of the plant personnel proper temperature setpoint A sign posted next to the control would be helpful capacity faulty contaminated C Material being dried C Drying systems are differs from material designed for the material specified at the time of which was originally purchase specified Different materials may need a longer residence time or different drying temperature to from drying hopper replace if necessary E Airflow valves sticking E Check for proper or failing to shift operation of linear valve actuator Check fusing Repair or replace if necessary F Blower fins filled with F Remove blower dust or contaminants sideplate clean baffles replace Replace filter elements 350 2100 cfm Dryers Chapter 7 Troubleshooting 53 of 58 PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Material in drying hopper A Process temperature set A Check resin cakes or meltdown occurs too high due to operator manufacturer s data sheet error for proper drying temperature Make sure plant personnel are aware of the correct process temperature Set Point B High temperature alarm B See Section 5 5 not set properly C Process set point is out C Restore temperature of acceptable range controller to factory pre sets Auto Tune if necessary See Sec 6 11 Performance heater out desiccant hoses beyond i
50. ol Panel Indicator Lights ligi fgat i e 20 4 2 Switches and Meters eh Eo Pe ob e eto Sauce dc ate co Redes 22 4 3 PLG COO cp 23 4 4 Process Air Temperature Controller nen 23 4 5 Temperature Controller LED Indicators sse 25 4 6 Temperature Controller Keys See Figure 5 in Section 3 6 26 4 7 Optional Communications Protocols nanna mnn 26 CHAPTER 5 STARTUP SHUTDOWN amp OPERATION 27 5 1 Pre Startup Checks so cet ise usata esie 27 ST MEER Cg mer UE 27 NM eo E 28 5 4 Setting the Process Air Temperature ss nn rent 28 DH1 655 1 iv 5 5 5 6 5 7 5 8 5 9 5 10 5 11 5 12 5 13 Setting the High and Low Temperature Alarms sse 28 Temperature Controller Autotune Procedure eene 29 Temperature Controller Internal Switches ss 29 Temperature Controller Anti Tamper Lockout Switch 29 Changing the Display from Fahrenheit to Centigrade 30 Setting the Dewpoint Extend Shift 30 Regeneration Monitoring System Signal 31 Auxiliary Process Safety System 32 Seven Day Timer ODtlOrial 3 ere
51. opper Regular filter cleaning will keep your dryer operating at peak efficiency The filter can be washed or blown out but remember the filter s dirt holding capacity is reduced with each washing The risk of dirt reaching the clean side of the filter during cleaning plus possible filter damage from high pressure washing or blowing makes washing a gamble Careful cleaning or washing can be done when the airflow restriction trips the dirty filter alarm Filters should not be washed more than six times or used for more than a year whichever comes first Use a detergent that won t damage the filter media Such a detergent permits easy removal of dirt particles through flushing and rinsing An effective detergent will remove the fine particles from the pores of the filter media The filter s manufacturer recommends FM 1400 washing compound It is formulated specifically for air filter element cleaning It is non sudsing and works in hot or cold water FM 1400 contains biodegradable synthetic detergents and is non phosphate non N T A It is marketed by Filter Service Corp 2603 A West Main Farmington New Mexico 505 326 1127 6 2 Filter Cleaning Replacement e Turn off and or lock out electrical power and compressed air if so equipped to the dryer e Remove the hand knobs or threaded fasteners securing the filter access cover and remove the cover e Remove the nut on the center retaining rod to remove a filter cartridge e Inspect the
52. power Attach warning tags to the disconnect switch When you need to perform maintenance or repair work on a dryer above floor level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk on your dryer use it The work platform should have secure footing and a place for tools and parts DO NOT climb on 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 Safe
53. r appears H on the LED display press to gt select that parameter for program Y Shift ming The parameter s current value appears on the LED display When the desired parameter is displayed use and LANI to view a _ Security Protection and or change the parameter Then H r mi Ca press to save the new setting to memory and to move on to the next parameter nre n Setpoints L L When L SEE appears on the LED display the HH H L and LL setpoints can be changed even while security lockout is enabled CA A on the LED displav Use and to view and or change the setpoint Then press to save the new setting to memory and to move on to the next setpoint After all setpoints are set the LED display returns to L SEE Hysteresis l The hysteresis value for the setpoints can range from 0 to 99 C or F To set the values press after CSEE appears The present value for the HH setpoint will appear Press after 5 appears on the LED display Use and LANI to set the value Then press to save the new setting to memory x Input Shift vt l The input shift value can range from 99 to 99 C or F The factory set value is O00 The input shift value of
54. rature Alarm is now set 5 6 Temperature Controller Autotune Procedure Auto tune fine tunes the control s PID to process requirements Auto tune whenever the process under control changes or when the controller cycles more than 2 or 3 above or below the setpoint Don t be alarmed by the control s response It may take the process temperature above and below the set points as many as three times It will then level off and control to the process set point Auto tuning can take up to 30 minutes and is best done before any process is being run To Auto Tune the Control 1 Press and hold down for several seconds until the AT indicator flashes The AT LED flashes to indicate that the control is tuning itself 2 When the AT LED light stops flashing the controller is tuned and ready for operation 5 7 Temperature Controller Internal Switches The control is set up and tested at the factory for optimum operation and the internal switches don t need to be adjusted If the control does not work properly or you suspect someone has accidentally changed some settings there are two solutions First try the AUTO TUNE PROCEDURE as described in Section 6 11 If that doesn t work see Section 6 15 5 8 Temperature Controller Anti Tamper Lockout Switch This slide switch prevents unauthorized changes to set points If this switch SW101 is On the IDI BI and kevs are disabled Onlv the process set point and alarm settings mav be viewed Drvers
55. rawn in from the drying hopper Regular filter cleaning will keep your dryer operating at peak efficiency Filter Cleaning Replacement Turn off and or lock out electrical power and compressed air if so equipped to the dryer Remove the hand knobs or threaded fasteners securing the filter access cover and remove the cover e Remove the nut on the center retaining rod to remove a filter cartridge Blow vacuum each filter until the filter is clean If the filter is worn through or can t be cleaned replace it Remove the small fines cleanout cover from the lower back portion of the filter unit below the air outlet transition e Vacuum out the fines and reinstall the cover and gasket e Reinstall all the filter cartridges tightening them securely e Replace the door or access cover being careful to keep the gasket intact if supplied Recommendations for Cleaning Heavily Soiled 850 through 2100 cfm Process Filters Vacuuming Try vacuum cleaning a soiled filter first Vacuuming removes most large particles and surface contaminants and may be all that s needed the first time a filter is cleaned Use a commercial duty recommended or household vacuum cleaner Vacuum the filter from the air intake dirty side only Compressed Air Cleaning Blow clean dry compressed air up and down the pleats blowing out the filter from the clean side Don t shoot the air in a criss cross motion against the grain of the pleats
56. red with and it will no longer control try restoring the factory set up 1 Turn off the power switch on the graphic display and remove all electrical power to the dryer 2 Press up the latch at the bottom of the module s front panel and slide out the control chassis 3 Locate the slide type lockout switch SW101 PROTECT on the left circuit board It should be Off OFF ON Protect SW101 4 Check to make sure the control output relays are installed on the right hand circuit board Dryers use one E53 S Solid State Relay SSR mounted in the socket marked S201 HEAT This relay switches the heaters on and off 5 Setthe output selector switch SW202 to PULSE This slide type switch is near the control output socket If the dryer is equipped with an S C R controller an E53 C output module is installed set the switch to Current 6 Set the rotary type alarm mode selector switch SW203 to position 2 for upper limit alarm 9 0 Ts NC or 5 Pulse Current SW203 9 0 1 TO 8 2 7 la NN 5 50 203 7 Set the rotary type 2 switch SW203 to position 3 for lower limit alarm 8 Set the rotary temperature sensor selector switch to position 2 It is marked SW206 INPUT TYPE and is on the right circuit board ACS Dryers are factory equipped with type K thermocouples 6 other temperature sensor types can be used if the switch is
57. s 350 2100 cfm Dryers Chapter 8 Appendix 55 of 58 Notes 350 2100 cfm Dryers Chapter 8 Appendix 56 of 58 Preventive Maintenance Checklist Dehumidifying Dryers Dryer Model Serial Date Date Date Date Date Date Date Date Date Date Date Date Date EVERE WEEK Inspect all filters for wear replace clean if dirty or worn Check air regulator to make sure pressure is 60 80 psi If applicable EVERY MONTH ara cise a and inspect electrical wiring for integrity Lock out electrical power and check heater elements for continuity using an ohmmeter Check Dew point and temperature tracking with an external dew point monitor and pyrometer Visually inspect the shifting of the airflow valve during one cycle EVERY YEAR Next Scheduled Actual Inspection Next Scheduled Actual Inspection Inspection Date By Inspection Date By Inspect desiccant Replace if brown or broken EVERY 2 YEAR Scheduled Actual Replacement Scheduled Actual Replacement ae ee Date Date Work Done pet eae EIL Date Date Work Done Tx Replace desiccant desiccant 350 2100 cfm Dryers Chapter 8 Appendix 57 of 58 8 2 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 262 641 8610 Fax 262 641 8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which wi
58. s that the bed is dry At bed breakthrough the bleed air temperature peaks between 350 F and 400 F Dryer models 350 through 2100 dryers are equipped with the Dewpoint Extend feature The regeneration heaters turn off automatically on bed breakthrough for additional energy savings A 550 F regeneration temperature will dry the desiccant beds sufficiently to produce process air dewpoint of 40 F In a properly sized system this ultra low humidity level will be more than adequate to dry plastics to as little as 003 moisture 2 8 Specifying a Drying System There were many variables considered in the selection of your drying system including type of materials residence time throughput of the extruder or injection molding machine ambient air moisture and temperature and the altitude at the processing site Should your operating environment change the manufacturer can advise you on necessary equipment and process time and temperature modifications 350 2100 cfm Dryers Chapter 2 Functional Description 14 of 58 Figure 3 Dryer Dimensions 34 RADIUS DOOR CLEARANCE TOP VIEW PROCESS BLOWER ELECTRICAL ENCLOSURE DESICCANT TOWER LEFT SIDE OPTIONAL AFTERCOOLER PROCESS AIR OUTLET PROCESS HEATER 1 PROCESS BLOWER PRES SWITCH 2 REGEN DIRTY FILTER PRES SWITCH 3 REGEN BLOWER PRES SWITCH 774 DIRTV PROCESS FILTER PRES SWITCH 350 2100 cfm Drvers
59. trol for maintaining process air temperature The controller is a modular self contained unit that can slide from its mounting housing All parameters except for the process air setpoint are factory set and adjusted no field adjustment to the internal controls is normally necessary 350 2100 cfm Dryers Chapter 4 Control Panel 23 of 58 Figure 6 Process Air Temperature Controller RMT SHIFT AT ALM1 ALM2 o U 0 0 O BLO 19 18 350 2100 cfm Dryers Chapter 4 Control Panel 24 of 58 4 5 Temperature Controller LED Indicators PV Process Value Numeric LED During normal operation this red LED on the control displays the process temperature at the To Process thermocouple It also lists parameters during setup and error messages if an error occurs SV Set Value Numeric LED During normal operation this green LED on the control displays the process set point you want the dryer to maintain It also displays parameter and pre set function values during setup OUT O Output LED This orange LED lights when the control output energizes the process air heater RMT Remote LED This lights when remote operation occurs on dryers equipped with optional communications SHIFT D Shift LED This orange LED lights if the optional Shift Set switch is closed The process temperature will be changed by the amount set in the P value in the Level 1 parameters To shift to a lower value be sure to enter a negative value A
60. ts capacity hopper sizing E Bad dew point sensor E Replace F Fouled dew point F Clear obstruction Air sensor manifold should flow freely through sensor 350 2100 cfm Dryers Chapter 7 Troubleshooting 54 of 58 Chapter 8 Appendix 8 1 Returned Material Policy Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMS 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 is subject to a 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 RMS 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 Purchased components are covered under their specific warranty term
61. ty Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment 1 5 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 Becoming familiar with materials inspection speed limitations screens and guard maintenance and total user responsibility will assist you in learning potential areas in need of observation for danger Each individual must take responsibility for observing the prescribed safety rules as outlined All caution warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor 350 2100 cfm Dryers Chapter 1 Safety 11 of 58 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for WD SDA CDA 350 425 500 600 7
62. uipment are functioning properly Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting Report the following occurrences IMMEDIATELY e unsafe operation or condition e unusual dryer action e leakage e improper maintenance e 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 Clean the dryer and surrounding area DAILY and inspect the machine for loose missing or broken parts Shut off power to the dryer when itis 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 350 2100 cfm Dryers Chapter 1 Safety 10 of 58 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
63. ure switches at the rear of the dryer were adjusted during factory testing Pressure changes in the drying system as installed may make some adjustment to these necessary during initial startup 350 2100 cfm Dryers Chapter 5 Startup Shutdown amp Operation 27 of 58 6 If the dryer has an aftercooler make sure there is proper flow of cooling water flow through the coil and any trapped air has been bled from the system 7 Make sure the damper on the hopper air inlet tube is about 50 open 8 Remove the lower end of the 2 2 flex hose from the tube stub on the lower drying hopper Carefully adjust the damper valve on the return line back to the filter to achieve approximately 200 cfm air flow out of the flex hose 9 Setthe process setpoint on the temperature controller 10 After the proper pre drying time for the initial hopper fill has elapsed fully open the drying hopper slidegate To allow proper residence time during continuous processing the material level in the hopper should be maintained at the midpoint of the air trap assembly 5 3 Shutdown Turn off the conveying system supplying the drying hopper When processing is complete close the hopper slide gate and shut down any in line companion equipment i e an aftercooler Push the Start Stop button After both blowers have shut down and regeneration is complete turn the On Off selector switch OFF e Empty the drying hopper if desired e For maintenanc
64. ush To Set push button and the Dewpoint Shift Adjust potentiometer pot To Change the Dewpoint Shift Point 1 Carefully loosen the locking hex nut on the Dewpoint Shift adjust pot The pot is just below the dewpoint meter 2 Press and hold the Push To Set push button next to the Dewpoint Shift Adjust pot 3 With a small screwdriver adjust the Dewpoint Shift Adjust pot until the dewpoint meter reads the highest acceptable process air dewpoint This is the point that airflow will be shifted from the on line bed to the regenerated bed providing the regeneration cycle has been completed 4 Release the Push To Set push button and re tighten the locking nut on the Dewpoint Shift Adjust pot Note Don t let the adjusting screw move and change the setting 5 Reconfirm the Dewpoint Shift Point by pressing the Push To Test push button Note Securely lock the Dewpoint Shift Adjust pot in place with the locknut An inadvertent change in the pot s setting will cause a change in the Dewpoint Shift Point 350 2100 cfm Dryers Chapter 5 Startup Shutdown amp Operation 30 of 58 5 11 Regeneration Monitoring System Signal Processor Dryer models 350 through 2100 have a 1 8 DIN signal processor that monitors the bleed air discharged from the desiccant tower being regenerated The signal processor has four programmable temperature setpoints that when reached signal the PLC to cycle through the regeneration process The PLC interprets the outputs
65. water out temperature about 10 F Recommended Cooling Model Water Flow Rate GPM 3 6 Drying Hopper Air Trap ACS s exclusive air trap assembly in the top of the drying hopper prevents ambient air from contaminating the material being dried 5 Keep the material level above the bottom edge of the air trap for maximum efficiency 6 Usea hopper loader or vacuum conveying system to maintain the proper material level 350 2100 cfm Dryers Chapter 3 Installation 18 of 58 s Air Temperature Controller Regeneration Dirty Filter Regeneration Heater On Regeneration Blower On egeneration Air Temperature egeneration Air Temperature Regeneration Blower Failure Process Air Dewpoint Meter 350 2100 cfm Dryers Figure 5 Typical Control Panel Process Blower On Process Delivery Temperature Regii Regen Blower On Heater On Right Bed In Regen int Critical Alarm Silence Process Heater On Process Dirty Filter Low Process Air Temp Process Blower Failure High Process Air Temp High Dew Point Left Bed In Regeneration Regeneration Monitor Critical Alarm Silence Dual Set Point Selector Valve Position Fault aL Im E aL m 15 Redundant High Temp Safety Redundant High Temp Redundant High Temp CET GE Reset Alarm EA RA cop aL m an XCHWehts as Be 25 aL m s
66. wer on The PV LED will display four zeros 0000 and then display the current process air temperature 14 Press to page through the Level 0 control parameters The PV LED displays codes indicating the currently selected mode the SV LED shows the selected parameter s current setting Use and to select a setting 15 Set Level 0 parameters according to Figure 10 16 n P for at least two seconds to access the Level 1 parameters Set them using the procedure in the previous step Note You can proceed to Level 2 but these parameters are read only Controls with optional communications have user set variables unit address and ID on Level 2 17 Turn off the power switch on the graphic display and remove all electrical power to the dryer 18 Press up the latch at the bottom of the control s front panel and slide out the control chassis ON ee 1 2 3 4 5 6 19 Set the 6 position of the DIP type function selector switch to OFF It is marked SW201 FUNCTION and is on the right circuit board Slide the control back into the chassis 20 Turn the control power on The PV LED will display four zeros 0000 and seconds later display the current process temperature 21 Auto tune the dryer using the procedure in Section 5 6 If the control still fails to control call the Service Department 350 2100 cfm Dryers Chapter 6 Maintenance 44 of 58 Figure 7 Factory Pre Set Control Parameters Parameter Parameter PV Dry
67. wer toggle switch must be in the ON position for normal or programmed dryer operation e To bypass programmed operation switch the manual override switch on the seven day timer to the ON position e To execute programmed operations set the manual override switch on the seven day timer to the RUN position e To de energize the seven day timer set the manual override switch to the OFF position The dryer will not run if the timer switch is OFF Program 1 is operational Program 2 is not used 350 2100 cfm Dryers Chapter 5 Startup Shutdown amp Operation 32 of 58 Setting the Current Day of the Week Hour and Minute 1 Apply main power to the dryer 2 Turn on the timer by sliding the left manual override switch to the ON position The timer s memory is cleared on power up MODE 3 Press and hold until becomes visible and blinks 4 Press or I until the current dav of the week is displaved 5 Press E to store the current day of the week in the timer s memory The day of the week indicator will stop blinking 6 The current hour indicator should now be blinking Press to set the current hour The time is set in a 24 hour format 7 Press B to store the current hour in the timer s memory The hour indicator will stop blinking 8 Press to set the current blinking current minute indicator 9 Press to store the current minute in the timer s memory The minute indicator shoul
68. y described in its own manual e Heater Burnout Indicator to monitor the heater s amp draw e Compressed air filter cleaning to lower maintenance on regrind dusty material drying processes e Auxiliary high temperature safety system to cut high voltage to the blowers and heaters in the event of run away process heaters e Seven day timer to allow programmable dryer start up e Communications to meet customer needs e Drying Hoppers come in many sizes and mounting configurations e Conveying Equipment to transport material to and from the drying system e Insulated Process Air Hose to minimize heat loss between the dryer and the drying hopper 350 2100 cfm Dryers Chapter 2 Functional Description 12 of 58 2 5 The Closed Loop Drying System ACS dryers force hot dry air through the resin in the drying hopper where the air picks up moisture from the material and is drawn back to the dryer In the dryer moisture is stripped from the air by a desiccant bed The dried process air is then re heated and delivered back into the drying hopper to dry material again This system is a closed loop because ambient outside air is never introduced into the process air The closed loop system is used by ACS because the process air is typically much drier than ambient air even after carrying moisture out of the plastic resin Recycling process air maintains drying efficiency at a consistently high level Figure 1 WD SDA CDA 350 2100 Dryer Sp

Sterling 350-2100 CFM Dehumidifier User Manual

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