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Nomad Series PD-2 to PD-4 Drying and Conveying

1. e Page 44 amp c Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Figure 15 Typical PD2 4 Electrical Schematic Drawing 1 BRANCH FUSING ELE 1M 10L L1 111 A 211 1 1 12 u 22 S 12 Y process c BLOWER 13 QM 13 23 173 GRD 9 2M an 106 lt M EARTH 212 C am 2MTR REGENERATION GROUND PANEL BLOWER GROUND 213 273 39 w an im Jr 2 am LOADER CONVEY 13 BLOWER C il aeu 5L1 m bay 471 12 12 2 uu HOPPER AMTR CONVEY BLOWER 5L3 OPTIONAL A ai 1 1H1 1HTR LEFT BED 612 192 REGENERATION U HEATER 1H3 C 2 2H1 2HTR RIGHT BED 2 2 REGENERATION HEATER 2H3 t 9 e 3HTR A2 BLACK POWER WIRE d SEE ENCL LAYOUT lt FOR GAUGE SIZE 713 3H3 4 1 PI Pr 83 284 ON OFF 7 18 GA WHITE 18 GA GRN YEL IRSAT 1 2 2 gt 2 G 1 GRD 4 DMA 2 7 DAY TIMER OPTIONAL 4 IPS
2. a A i T5 Time setting knob Scale range gt Time unit display window display window Time range 5 selector Time unit selector Range Selection Table Time units 10h ten hours 1 2 to 12 0 3 to 3 0 3 to 3 0 3 to 3 3 to 30 12 to 120 30 to 300 0 instantaneous output 4 12 Convey Dump Delay Setting After the convey timer times out the PLC will start a dump delay before allowing the convey cycle to start again The dump delay time is adjusted by jumper inputs into the PLC The yellow jumpers are wired into yellow terminal blocks located on the sub panel For example a ten 10 second dump delay would have a yellow jumper wired from a number four terminal to number 33 PLC I 18 terminal Terminals number 31 and 32 would have no jumpers Dump delay time is the same for both convey stations a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 39 Figure 13 Dump Delay Settings Conveying 31 31 Y 1 16 dump delay timing inputs Jumpers 18GA Terminals Yellow for jumpers i32 32 117 33 35 s 4 Yellow 4 for jumper terminals See Timing Configuration Chart gt 119 PLC below for timing configurations Timing Configuration Chart Dump delay preset 0 S seconds 1 10 seconds 0 5 0 __ seconds 0 GS5secnds Note Jumpers are provided for setting the dump delay time Use this chart t
3. 7 Closed loop convey take off compartment Machine Loader Diagram Levels A and C conveying Material Conveying Legend blower Convey material ____ Convey vacuum side i Drying conveying filter Drying Hopper Loader Diagram Levels B and C a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 17 3 3 Drying Hopper Removing the Rust Inhibitor Rust preventative has been applied to internal unfinished surfaces Remove rust inhibitor before using the drying hopper Using a non water based degreasing agent clean all inside surfaces of the drying hopper Allow components to dry thoroughly Inspect the inside of the drying hopper for loose connections foreign objects or a blocked diffuser Air Trap Considerations AEC Whitlock s exclusive air trap assembly in the top of the drying hopper prevents ambient air from contaminating the material being dried Keep the material level at the mid point of the air trap for maximum efficiency Use a hopper loader or vacuum conveying system to maintain the proper material level 3 4 Installing the Sight Glass Loader Levels A and C Sight glass loaders use flange mountings See Figure 5 on Page 18 for sight glass flange templates You can mount the material receiver hopper directly to the processing machine by cutting a hole in the machine bin lid and fastening the receiver to it The material receiver mou
4. Aftercoolers for high and low temperature applications Seven day timer to allow programmable dryer startup Audible visual critical alarm Fusing for blowers and heaters Dirty Filter indicator for each individual blower Proportioning valve for the drying hopper loader Levels and EK Stainless steel convey hose Levels A Figure 1 Nomad PD 2 through PD 4 Specifications Dryer Hopper Process Output Full Model model size air flow temperature Standard load number number ft liters 195 Kg cmh range voltage amps 160 100 20 8 90 188 140 Em 60 204 C 460 3 60 24 LIN CEPR piao aeo yaco CT WS 4ewaeo L 2r woro rra ferz ehea f2s feo 00 Etro ae 160 400 F za 204 C 460 3 60 48 Level C Machine Loader and NT ae Loader ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 9 1 6 The Closed Loop Drying System AEC Whitlock dryers force hot dry air through the resin in the drying hopper where the air picks up moisture from the material and is drawn back to the dryer In the dryer a desiccant bed strips moisture from the air The dryer then re heats dried process air and sends it back into the drying hopper to dry material again This system is a closed loop because ambient outside air is never introduced into the process air AEC Whitlock uses
5. WHITLOCK MATERIAL HANDLING Operation and Installation Manual Nomad Series PD 2 to PD 4 Drying and Conveying Systems Important Read Carefully Before Attempting to Install or Operate Equipment Part No A0548523 Revision D Bulletin No WH1 620B 4 Performance figures stated in this manual are based on a standard atmosphere of 59 F 15 C at 29 92 Hg 1 014 millibars at sea level using 60 hz power Altitude is an important consideration when specifying drying and conveying systems AEC Whitlock can advise you on proper selection and sizing of systems for your operating environment AEC Whitlock is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice Copyright AEC Whitlock and AEC Inc 2008 All rights reserved Effective 4 25 2008 Part No A0548523 Revision D Bulletin No WH1 620B 4 Page 2 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Safety Considerations AEC Whitlock Nomad Series drying and conveying systems are designed to provide safe and reliable ope
6. 1 to Scaling Upper heh owen Scaling Upper Limit to SP Lower Limi 200 Default CnEL PID ON OFF PID ON OFF Default PID SE b ST Stable Range 0 1 to 999 9 C F Default ALFA a 01 to 1 00 Default Calculated o 416 Default rESE Standby Expansion Sequence Reset 0 1 perau Setting Method _ rEE Automatic Return AE H AT Hysteresis 0 1 to 9 9 FS Default LBA Detection 19 o to 999 9 FS Default Option Boards Available Option Boards RE232C RS 485 Eventinput Transfer Output Board Number E53 CKO01 E53 CK03 E53 CKB E53 CKF Mode Parameter Setting range Default AEC setting Option Eu A Multi SP Function oi O Defaut Eu 1 Event Input Assign 1 SbCE Communication Stop Bit Len Comm Data Length 7 8 BITS Even P IB BITS PrEY Commication Parity Even 6 5 Comm Baud Rate 0 Defaut Er E Transfer Output U n6 Comm Unit No 0 to 99 Er H Xfer Output Upper Limit 5 Default Option Er L Xfer Output Lower Limit Default Note Use the Default setting for any setting not listed here a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 67 E5CK Factory Setting for Dew Point 1 Make sure jumper setting for input type is set for Current Input D right jumper 2 Return controller to housing 3 Press the Co Display Key for one 1 second to enter Menu Display AR 4 Press the Arrow U
7. 5 p 2 Low COMPRESSED AIR 5 PLC INPUT 1 7 LINE 172 AUDIBLE ALARM OPTIONAL LOW AIR PLC INPUT 4 6 6410 TO PLC INPUT 1 1 LINE 158 BLOWER ENABLE B PLC INPUT 6587 SOLID STATE X RELAY gt 18 GA RED gt 18GA BLUE 1CNTL 24VDC 716 12 2 NPN 4 4 5 2 PROCESS TEMPERATURE CONTROLLER 4 3 3 1 AT 2 HIGH TEMP PROCESS AIR gy TO PLC INPUT 1 8 HIGH TEMP PROCESS AIR i d LINE 174 PLC INPUT PAN HRED g 2CNTL 4 7 110 TO PLC INPUT 14 11 Q i DEW POINT BED SWITCH INPUT 4 11 2 HIGH DEW POINT 4 2 POINT DISPLAY CONTROLLER ix o 6 WHT B a BLK DEW POINT SHIELDED SENSOR CABLE 22GA 2COND 2 amp CABLE DEW POINT CONTROL 4 BOARD amp SENSOR 1CR 1601 4 M V 2 BEDSHIFTSOLENOID 1CR EAS 4 MIA 2 LEFT BED IN REGEN a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 45 DRYER ON SEQUENCE SHUTDOWN COMPRESSED AIR INPUT PROCESS BLOWER ENABLE REGEN BLOWER ENABLE DEW POINT BED SWITCHING HIGH RIGHT BED REGEN TEMP ALARM HIGH LEFT BED REGEN TEMP ALARM LOW COMPRESSED AIR ALARM HIGH PROCESS TEMP ALARM PUSH TO SILENCE OPTIONAL ALARM MACHINE LOADER POWER ON MACHINE LOADER DEMAND PROX SW MAHCINE LOADER LOADING COMPLETE DRYING HOPPER CONVEY POWER ON OPTIONAL DRYING HOPPER DEMAND REED SW OPTIONAL DRYING HOPPER
8. Setup CnCE Parameter Initialize Yes No Default 6Ut1 Control Output 1 Heat Cool Alarm 1 Alarm 2 Sep Assignment Alarm 3 LBA ped COOL 6Ut2 Control Output 2 Heat Cool Alarm 1 Alarm 2 AL 2 Default SetU Sub 1 Auxiliary Output 1 Alarm 1 Alm 2 Alm 3 LBA S p Assignment ERR E333 e Default Setup ALti Alarm 1 Type to 11 Setup 1 Alarm 1 open in alarm NO NC Setup ALt2 Alarm 2 Type 0 to 11 8 O Default Default 1300 15 F 9C 200 40 F 40C ON OFF Default Default Setup AL2n Alarm 2 open in alarm NO NC 6rEU Direct Reverse 4 9P Lower Limit 1 to Expansion SL H Set Point Upper Limit Scaling Upper Limit Scaling Upper Limit to Sp Expansion SL L Set Point Lower Limit CntL _____ Expansion CntL PID ON OFF PID ON OFF __ 51 Standby Sequence pasion Reset Setting Method ud 4 rEt Automatic Return of Expansion Display Mode 0 to 99 SEC 2 2 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 69 Notes Page 70 ec Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 7 Troubleshooting Desiccant beds are contaminated by material or Little or no air coming from plasticizer leaking into the system the process delivery tube ud overload contaminants clean baffles replace Stop the dryer Replace desiccant If the dryer was connected to the drying hopper check to see if the desiccant and pro
9. LOADING COMPLETE OPTIONAL CONVEYING DUMP DELAY TIMING INPUTS TERMINALS FOR J UMPERS SEE TIMING CHART FOR TIMING CONFIGURATIONS DRYING HOPPER LOW LEVEL SENSOR OPTIONAL LEVEL SENSOR ELECTRICAL UNIT Figure 15 Typical PD2 4 Electrical Schematic Drawing 2 4 2 2 AC COM D Wo 2 2 2 2RS 1TMR 7 DAY TMR 6 R m LINE 129 Cn GRD 7 GROUND 1M Bow VACNDC Z 2M 4 212 22 125 2 18 2 6 a 5 4 ACCOM LINE 139 PT on 21 2 2 20 2 4 13 22 4 276 NS VACNDC 7 DTA T50 i a VEL type K feos 3 23 os 137 1558 2 OTs TOT D We 2 P TES NEL gt TC 38 MATO 2 cy LINE 129 2 D n 03 2 a 2 2 39 QR 2 PM LINE 136 D VACINDC 2 3RS s 21219 22 190 1C 2 4RS LT d 2 40 p 5 gt ino os 2 Sus 41 au 2 4 A 26 42 AULT 2 lt gt Qum 0 6 1AH 4 2MTR aj an g 2 6 VN 2 2 6 cw 4 2 H VACIDC 2 30L MS BI gt 44 E 2 LN 4 3MTR 3 gt ns om o 2 6 8 lt lt 47 2 31 3 2 ine 58 JUMPERS 18GA YELL
10. You should have Nomad drying conveying system Sight glass loader Material tubing Bill of Lading Packing list Operation 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 Determine that the item was not inadvertently taken from the area before you checked in the shipment Notify AEC Inc immediately of the shortage 2 4 If the Shipment is Not Correct If the shipment is not what you ordered contact the parts and service department immediately at 847 273 7700 Have the item and order numbers ready to expedite the return Hold the items until you receive shipping instructions 2 5 Returns Important Do not return any damaged or incorrect items until you receive shipping instructions from AEC Inc a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 15 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 is not limited to OSHA NEC CSA and any other local national and international regulations e Read and follow these operating instructions when installing operating and maintaining this equipment If the instructions become damaged or unreadable add
11. controller has a four 4 hour timer override if it does not receive a signal from the dew point control a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 37 Set the shift on dew point set point to the highest process air moisture content you want to allow before the dryer shifts air flow to the regenerated desiccant bed The dew point controller is set at the factory for 20 F 29 A B To change the dew point setting press the cer Up Arrow and Down Arrow keys to the shift point you want 4 10 Setting the High Dew Point Alarm The high dew point alarm is factory set for 10 F 23 C The high dew point alarm will energize the High Dew Point light Entering the Level 1 operating parameter changes the high dew point alarm setting 1 Press Co once keep the pressure on the button for about 1 1 5 seconds in order to switch between modes Level 0 displays 2 Press display Level 1 Lu 1 displays 3 Press 3 c once more for about one to one and a half seconds Now use short presses Co until AL 1 displays ad 4 Press and to set the higher or lower value for the high dew point alarm 5 Press for about one to one and a half seconds Level 1 displays 6 Press until Level 0 displays IS OU 7 Press for about one to one and a half seconds to go to Operating mode Note T
12. dried sufficiently high scrap reject rate e Air temperature at the top of the regenerating desiccant bed rapidly climbs to 350 F 177 C or more shortly after the start of regeneration even though a saturated bed has just started heating e The process air dew point measured with a portable dew point monitor is higher than 10 F 23 C throughout the process drying cycle e Smoke or dust blows out of the process air outlet e 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 AEC Whitlock Parts Department If you want an AEC Whitlock technician can repack desiccant beds at your site WARNING Desiccant material causes eye irritation Breathing may be harmful and 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 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 57 6 5 Replacing Worn Desiccant Caution Make sure desiccant beds are sufficiently cool before replacing worn desiccant 1 Disconnect the electrical and compressed air supply 2 Remove the rear and side shrouds to expose the desic
13. evel 2 CnF Input Digital Filter evel 2 ALH1 Alarm 1 Hysteresis Default evel 2 ALH2 Alarm 2 Hysteresis 0 Default evel 2 ALH3 Alarm 3 Hysteresis Default evel 2 Cn5H Input Shift Upper Limit Default evel 2 Cn5L Input Shift Lower Limit Default age 2 0 20 Ss r r rr Qo lt o oco m nm D r r r co m m D r D r D ET NIN a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 65 Figure 18 Setting List for Process Temperature Controller Part No A0555756 Cont d 20 c O etu 100 etup Cn L Scaling Lower Limit 1999 to SP Setting Upper Limit 0 1 EU dP Decimal Point etu 6UE1 Control Output 1 Heat Cool Alarm 1 Alarm 2 Alarm 3 6UE2 Control Output 2 Heat Cool Alarm 1 Alarm 2 Alarm 3 p agmen Alarm 1 Alm 2 Alm 3 LBA S ERR E333 AL 1 Default etup ALE1 Alarm 1 Type 0 to 11 Default AL1n Alarm 1 open in Default ALE2 Alarm 2 Type 0 to 11 Default AL2n Alarm 2 open in etup ALE3 Alarm Type 0 to 11 Default tup Cn E Input Type 0 to 21 NJN 5 F 6rEu Direct Reverse P Operation ORD 0 c Page 66 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Figure 18 Setting List for Process Temperature Controller Part No A0555756 Cont d Mode Parameter Setting range pefault AEC setting _ SL H Set Point Upper SP Lower Limit
14. other than proper lead wires Process value is abnormal or not obtained 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 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 73 H XC Whitlock Preventive Maintenance Checklist AEC Whitlock Nomad Drying Conveying Systems System model Date Date Date Date Date Date Date Date Date Date Date Date Date Every week Inspect all filters for wear replace clean if dirty or worn Check air regulator to make sure pres sure is 60 80 psi 413 7 to 551 6 kPa 4 1 to 5 5 bars If applicable Lock out electrical power and inspect electrical wiring for integrity Lock out electrical power and check heater elements for continuity using an ohmmeter Check dew point and temperature tracking with an external dew
15. point monitor and pyrometer Visually inspect the shifting of the airflow valve during one cycle inspection Date By inspection Date By meae 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 eme TC Photocopy this page for your maintenance records Page 74 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Service Notes a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 75 Service Notes Page 76 ec Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Service Notes a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 77 Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 847 273 7700 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 800 423 3183 or call 847 273 7700 Emergencies a
16. right bed regenerates and is in the heat up portion of the regeneration cycle Process Blower On Light The Process Blower On indicator lights when the process blower energizes Process Heater On Light The Process Heater On indicator lights when the process air heater is energized Low Compressed Air Light The Low Compressed Air alarm indicator lights when the dryer compressed air supply drops below 60 psi 413kPa 4 13 bars Upon loss of compressed air the pressure switch opens and sends a signal to the PLC controller to shut down dryer operation Dryer operation automatically resumes when 80 psi 551 kPa 5 51 bars air is restored High Temp Process Air Light The High Temp Process Air alarm indicator lights when the temperature at the process air thermocouple is above the high alarm set value Upon high temperature alarm condition the process heaters turn off the process blower remain on The alarm mode and value are factory set to track 25 above the process set point The alarm value is an upper limit deviation above the process set point When the temperature at the process thermocouple returns to within the acceptable range the alarm output de energizes and all heaters turn on again automatically High Temp Regen Air Light The High Temperature Regen Air alarm indicator lights when the thermostat above the regeneration heater assembly senses an abnormally high temperature The regeneration heaters shut down until the te
17. switch must be in the SEQUENCE SHUTDOWN position e The OUT switch 12 should be set to AUTO e The P1 P2 RUN mode switch 11 should be set to RUN for normal 7 day timer operation set to P1 for changing times P2 is not used Open the front cover the MODE switch 13 must have Mode set to TIMER up 2 is not used BOOT 14 is set to AUTO down e Program 1 is operational Program 2 is not used Note To bypass the 7 day timer operation turn the 7 day timer OUT switch 12 to off Turn the Dryer On Sequence Shutdown rocker switch located on the dryer control panel to DRYER ON Programming the Optional Timer Setting the Current Day of the Week Hour and Minute 1 Apply main power to the dryer 2 The 7 Day timer MODE selector switch 11 should be in the RUN position 3 Hold the TIME ADJ key 7 for 1 second or longer 4 Press the SHIFT key 1 to move the cursor V to the desired day position Holding down this key advances the day Press the SET key 2 The bar mark will turn on under the chosen day Press the h key 3 to adjust the hours Holding the key will rapidly advance the hour Press the m key 4 to adjust the minutes Press the WRITE key 6 to store the correct time Mo 2995 cd cO The time and day can be adjusted or changed while the timer is operating Daily Timer Operation Daily time is typically set to operate from 8 00 AM and to stop at 5 00 PM from Monday through Fri
18. the closed loop system because the process air is typically much drier than ambient air even after carrying moisture out of the plastic resin Recycling process air maintains drying efficiency at a consistently high level Figure 2 Dryer Air Flow Diagram Page 10 ec Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems From Ambient drying hopper Y Regen Process filter S Regen Process air x filter bleed heater _ To drying Upper valve Desiccant Desiccant beds beds Regen heater Regen heater Lower valve d Regen blower Process blower a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 11 1 7 What is Desiccant Desiccant is a material which attracts and holds absorbs water from the air AEC Whitlock dryers use a synthetic crystalline metal aluminosilicate desiccant blended with a clay binder and formed beads 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 1 8 The Process Regeneration Cycle AEC Whitlock 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 moi
19. 3 mm dia nozzle at least 2 5 cm away from the filter Don t shoot the air in a crisscross motion against the grain of the pleats you may damage it Washing As a last resort wash the filter However do so only if the pressure drop is too high from fine dirt embedded in the filter or if oily mist is present near the intake air location Soak in a solution of FM 1400 or comparable detergent and warm water from five to ten minutes then gently agitate for several minutes Rinse thoroughly with clean water to remove all detergent a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 55 Important Let the filter dry completely before returning it to service A damp filter can contaminate the closed loop system of the dryer Do not use a light bulb to dry the filter You should get satisfactory filtration after second or third washings however dirt holding capacity of the filter decreases after each washing After each cleaning e Inspect the filter element Briefly hold a light bulb behind the element and look for any fatigued paper or residual dirt Inspect for holes and tears by looking though the filter toward a bright light Check for damaged gaskets or dented metal parts Do not re use a damaged filter e Inspect the end plates Any damage here can allow air to bypass the filter e Look for rust on the end plates and metal core Rust particles can flake off and contaminate the dryer and resi
20. DOWN SILENCE MACHINE DRYING HOPPER LOADER LOADER 5 1 5 4 v 1 ON 3 ON 25 5 25 o x0 7 OFF X OFF OFF OFF MATERIAL MATERIAL LOADING LOADING DIRTY DIRTY FILTER FILTER Page 34 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 4 2 Process Air Dew Point Display The Dew Point display indicates the current process air delivery moisture content The display uses a microprocessor based controller for reading dew point air temperature The controller is a modular self contained removable unit in the mounting housing All parameters are factory set and adjusted no field adjustment to the internal controls is necessary The high dew point alarm is also factory adjusted 4 3 Process Air Temperature Controller AEC Whitlock dryers use a microprocessor based PID temperature 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 is factory set and adjusted no field adjustment to the internal controls is necessary 4 4 Machine Loader Timer AEC Whitlock Nomad systems use a solid state analog set 1 16 DIN machine loading timer It has a large dial for setting convey times and has several timing modes available 4 5 Optional Drying Hopper Loader Timer If installed AEC Whitlock Nomad systems use a solid state analog set 1 16 DIN drying hopper loading timer It has a large dial f
21. OW ja 2 D 2 DATM 3 33 118 YELLOW 4 _ TERMINALS 4 FOR JUMPER A 15 P i C1 NO yam 4 m 2 PROCESS BLOWER CONTACTOR PROCESS BLOWER ON REGEN BLOWER CONTACTOR REGEN BLOWER ON PROCESS HEATER CONTACTOR PROCESS HEATER ON RIGHT REGEN HEATER CONTACTOR RIGHT BED HEATER ON LEFT REGEN HEATER CONTACTOR LEFT REGEN HEATER ON BED SHIFT RELAY RIGHT BED IN REGEN HIGH REGEN TEMP AUDIBLE ALARM OPTIONAL ALARM STROBE OPTIONAL MACHINE LOADER CONVEY BLOWER MATERIAL LOADING DRYING HOPPER CONVEY BLOWER MATERIAL LOADING MACHINE LOADER CONVEY TIMER DRYING HOPPER CONVEY TIMER CRITICAL LEVEL DRYING HOPPER These schematics are for reference only Refer to the electrical schematic in your Customer Information Packet ec Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 46 4 15 Optional Seven Day Timer The seven day timer can be programmed for daily or weekly over midnight on off operation An internal battery back up holds the settings in memory when the dryer is de energized Timer SUN MON TUE WED THU FRI SAT 16 Timing chart display pay 2 1 SHIFT key rp L SETIRESET D 4 00 2 SET RESET key 15 Output indicator 3 key QuT He PROG 4 k
22. Remove the bolts securing the heater plate assembly and slide out the assembly 5 Remove the heater from the mounting plate by removing the large brass nuts and washers a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 59 6 Re install the heater and heater plate assemblies in reverse order Install new heater gaskets and securely tighten all fasteners Page 60 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Caution Heater loops should not touch each other Hot spots lead to premature heater failure 7 Reinstall the wires based on the sketch you made earlier 8 Secure the heater access cover 6 7 Replacing the Regeneration Heater Nomad Series dehumidifying dryers use heater elements located below each desiccant bed WARNING Disconnect and lock out power before you replace heater elements Remove the cover plate secured by bolts Sketch the heater wiring configuration so you can properly re assemble the heaters Remove the wiring for the heater being removed or replaced Remove the bolts securing each heater mounting plate Slide out the heater DUS ups Re install the new heaters in reverse order Install new heater gaskets and securely tighten all fasteners Caution Heater loops should not touch each other Hot spots lead to premature heater failure 6 Re install the wiring based on the sketch you made earlier 7 Secure the he
23. al disconnect with all wiring to a common terminal point PLC microprocessor control of the drying and conveying stations Digital Dew Point monitor indicates dryer efficiency Sequence shutdown of the dryer Level A Machine Loader Only Sight glass loader with high efficiency centrifugal blower and adjustable convey timer M Cartridge type two stage air filters for the blower M Quick disconnect cable for sight glass loader material demand switch Two 2 ten 10 foot 3 m lengths of vinyl flex hose and clamps Closed loop dry air convey take off compartment on discharge of drying hopper Page 8 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Level Drying Hopper Loader Only Drying hopper loader with high efficiency centrifugal blower and adjustable convey timer M Cartridge type two stage air filters for the blower Quick disconnect cable for drying hopper loader material demand switch Pick up wand and ten 10 foot 3 m length of vinyl flex hose and clamps Standard take off compartment open loop on discharge of drying hopper Level C Both Machine Loader And Drying Hopper Loader Features of both level A and level B including closed loop dry air convey take off compartment 1 5 Options Options can tailor your AEC Whitlock Nomad system to meet the exact requirements of the drying task being performed 13X desiccant
24. ater access cover 6 8 Restoring the 5 Temperature Controller and Dew Point Meter to Factory Setup If preset parameters on the controller have been tampered with and it no longer properly controls temperature and displays dew point you can restore the controller to factory setup a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 61 E5CK Operating Parameters The ESCK has several mode selections Within each mode are numerous parameters that can be set The setting is different for the temperature control unit and the dew point display Before you can access the several modes of operating parameters you must change the security lock out of the controller AEC factory sets the security level to protect the parameters from being accidentally changed Below is an explanation of the operating modes how to change out the security level and the AEC default settings Available Modes Menu Display Level 0 Mode For normal operation Execute AT auto tuning change to manual mode Level 1 Mode For adjusting primary control parameters Execute Set alarm values set the control period set PID parameters Level 2 Mode For adjusting secondary control parameters Nomad Cart uses ESCK default settings Setup Mode For setting the basic specifications Set parameters for input type scaling output assignments and direct reverse operation Expansion Mode For setting expanded functions Set ST self
25. cant beds 3 Free the bed covers by removing the hex nuts on the retaining rods and remove the upper screens from both beds 4 Remove the desiccant in one of the following ways e Vacuum out the desiccant e Remove the entire bed from the frame and dump it out To do this remove the hose connections unclamp the beds and unbolt from the regen heater assembly Make sure the bed interiors are clean Important You should properly dispose of any discarded desiccant Consult local disposal regulations for more information Before re packing the beds determine the proper amount of desiccant for the dryer being serviced See Figure 14 on the following page for more information Pre measured desiccant kits are available from the Whitlock Parts Department at AEC Inc Attach the beds to the frame for Steps 6 through 9 6 Carefully place half of the large bead in the bottom of the beds in an even layer on the bottom screen Place the small bead on top of it in an even layer Carefully place an even layer of the remaining large beads over the small beads 7 Install the top screen making sure that the edge is in contact with the sides of the bed all the way around Install the washers and nuts and tighten down Gently tap the around the sides of the desiccant canister with a rubber mallet to settle the desiccant As settling occurs re tighten the nuts Repeat the tapping and tightening process until little additional settlin
26. cess air heater has been contaminated with resin Suction in delivery tube pressure from the return tube Phase is reversed on power drop coming into the dryer If so replace the desiccant and remove any resin carry over Otherwise change the phase of two legs of the three phase power drop Process heaters are fault Replace if required erum ai Loss or reduction of process air temperature Make sure that plant Process temperature was personnel are aware of the adjusted in error by plant proper temperature set point personnel A sign posted next to the controller is helpful Process heaters are faulty Replace Desiccant beds are Replace desiccant contaminated Drying systems are designed for the material which was originally specified Different materials may need a longer residence time or different drying temperature Break in flex hose to from Inspect for air leaks replace drying hopper if necessary a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 71 Loss or reduction in drying Material being dried differs Capacity from material specified at the time of purchase Problem Possible cause Corrective action a Check for proper operation of n valve actuators Repair or Loss or reduction in drying 9 replace if necessary capacity Cont d nos Remove blower side plate Replace filter elements Power LED is off p
27. day 1 Set the MODE switch 11 to P1 2 Press the SHIFT key 1 to move the cursor to the desired day of the week Or select several days at once by using the SHIFT 1 and SET keys 2 The bar mark will turn on under the chosen days Page 48 Zc Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 3 Press the SET key 2 T Set the desired start time by pressing the h key 3 to adjust the hour Holding this key will rapidly advance the hour 5 Press the m key 4 to adjust the minutes 6 7 8 Press the WRITE key 6 to store the start time in the timer memory Next set the stop time by using the h and m keys then press WRITE Turn the MODE switch 11 to run Multiple Day Operation Multiple day operation will start the dryer on one day and run continuously for several days before stopping the dryer Me IOS quo auo cae nn purs n Turn the MODE switch 11 to P1 Select the desired start day with the SHIFT 1 and SET keys 2 Set the start time with the h and m keys Press the WRITE key 6 to store the dryer startup hour in the timer memory Next cancel the day that was just set by using the RESET key 2 Now select the stop day by using the SHIFT 1 and SET key 2 Set the stop time with the h and m keys Press the WRITE key 6 Turn the MODE switch 11 to RUN Checking the Set Time The set times can be checked in the sequence the timer is to operate
28. e Security Levels 59 1 8 Setting List for Process Temperature Controller Part No A0548565 61 63 1 9 Setting List for Dew Point Controller Part No A0548565 64 65 Page 6 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 1 General Information 1 1 Models Covered This manual provides instructions for installing and operating AEC Whitlock Nomad Series PD 2 PD 3 and PD 4 portable drying and conveying systems with WD90 WD100 WD150 and WD225 cabinet style dehumidifying dryers The dryer number designation represents air flow capacity The carts also include insulated drying hoppers and various levels of conveying options 1 2 Equipment Function Nomad Series portable drying and conveying systems are used for automatic pneumatic handling and drying of most free flowing dry pelletized or granular materials AEC Whitlock dehumidifying dryers are designed to generate heated dehumidified air at carefully controlled temperatures for use in closed loop plastic drying systems Moisture removal from hygroscopic moisture attracting plastic pellets is an essential step in the manufacture of high quality plastic products AEC Whitlock dehumidifying dryers are used to generate very low dew point air heated to a controlled temperature for drying plastic pellets and regrind AEC Whitlock Mass Flow Series drying hoppers are engineered to be used with the dehumidifying dryers The dryer circulates hot air through the column o
29. een shipped loose Mount the drying hopper loader to top cover of drying hopper The drying cover has the appropriate bolt holes supplied to mount the vacuum hopper See Section 3 5 on Page 18 for mounting tips a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 23 Complete the vacuum tubing from the filter cartridge to the vacuum inlet tube located on top of the vacuum receiver See Section 3 6 on Page 18 for recommendations Install the pickup probe See Section 3 11 on Page 23 for pickup probe installation information Connect the quick disconnect cable for the demand switch to the Nomad cart Figure 7 Hopper Loader Flapper Detail Page 24 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Drying hopper loader Level demand ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 25 3 10 Installing the Pickup Probe for Hopper Loaders Pickup probes are used to empty gaylords or bulk material containers located beside the processing machine The VacTrac conveying system can use horizontal take offs or vertical pickup probes or a combination of the two to supply material to the vacuum hoppers For maximum conveying rates locate the supply container near the vacuum hopper Connect the pickup probe to a vacuum hopper material inlet tube with a minimum amount of tubing bends and flex hose Secure the flex hose at the probe and the material inlet wit
30. erial Vacuum Tubing Note System capacity is directly affected by the pressure drop in the overall system such as number of material line bends footage of pipe Y tubes T tubes etc Use the minimum effective amount of vinyl flex hose to maximize material line efficiency Keep material lines as straight as possible Important Vacuum leaks anywhere in your system reduce capacity a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 19 K KNIE NAN Vacuum leaks anywhere in the system reduce system capacity Keep the number of material tube bends to a minimum for maximum system capacity Use long radius tube bends on material lines Keep the total footage of material conveying flex hose to a minimum Long flex hose material runs reduce system capacity Support tubing about every ten feet with straps pipe hangers or brackets Tube joints must be rigid to prevent vacuum or material leaks Cut tube ends square and chamfer edges smooth Use a fixed band saw or power miter saw when making cuts You can use a tubing cutter on aluminum tubing for cutting stainless steel use a saw with a carbide or diamond impregnated saw blade Chamfer stainless steel edge cuts with a die grinder or a hardened rasp file Clean all tubing after cutting and before assembly Run a rag dampened in a non volatile cleaning solvent through all tubing and couplers to remove sediment from shipping or cutting Run a quantity of low grade mater
31. et the rate you want If Material is Not Conveying or the Line Plugs Up l Make sure the inner tube is not set beyond the outer limit the five eighths inch 16 mm setting e Adjust the inner tube to a reduced convey flow setting Make sure that the flex connection to the machine hopper inlet is straight without any bends e Trim the hose length just enough to reach the machine hopper Make sure the convey time is not set too high e Lower the convey time Page 22 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Figure 6 Machine Loader Dry Air Closed Loop Take Off Compartment Indicator knob Hold down screw Hose Material from _ IL s outlet blower 4 4 Adjustable inner tube FCO 1 5MD Outer tube 3 8 Adjusting Sight Glass Proximity Sensor Sensitivity You can adjust the sensitivity of the material level proximity sensor in the sight glass The factory setting is correct for most applications The sensor is factory installed to the frame however you should install the sensor at the material level height you want When adjusting fill the glass and verify that the sensor detects your material The LED on the switch goes out when it detects material For increased sensitivity turn the potentiometer clockwise E For decreased sensitivity turn the potentiometer counterclockwise 3 9 Drying Hopper Loader Levels B and C The drying hopper loader may have b
32. etting 4 13 PLC Controller 4 14 PLC LED Indicators 4 15 Optional Seven Day Timer 5 Startup Shutdown and 49 5 1 Pre Startup Checks 5 2 Startup 5 3 Shutdown D Maintenance etes 51 6 1 Work Rules 6 2 Servicing Process Air Filters 6 3 Servicing the Dew Point Monitor 6 4 Symptoms of Worn Desiccant 6 5 Replacing Worn Desiccant 6 6 Replacing the Process Heater 6 7 Replacing the Regeneration Heater 6 8 Restoring the 5 Temperature Controller and Dew Point Meter to Factory Setup Troubleshooting eere retten natns 67 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 5 Charts and Figures 1 Nomad PD 2 through PD 4 Specifications 9 2 Dryer Air Flow Diagram 10 3 Typical Nomad System with Cabinet Style Dryer 12 4 Typical Machine Loader and Drying Hopper Loader Diagrams 16 5 Sight Glass Hopper Flange Templates 18 6 Machine Loader Closed Loop Dry Air Take Off Compartment 21 4 Hopper Loader Flapper Detail 23 8 Typical Pickup Probe 24 9 Typical Quick Disconnect Cable Connections 26 1 0 Typical Nomad Interface Panel 31 1 1 Typical Nomad Temperature Controller 34 12 Typical Nomad System Timer and Range Selection Table 36 13 Dump Delay Settings and Timing Configuration Chart 37 14 Typical Subpanel Layout 41 15 Typical PD2 4 Electrical Schematic Drawings 1 and 2 42 43 1 6 Required Desiccant Amounts Per Bed 56 1 7 Display Readout for Mode Settings and Availabl
33. ey 5 CHECK key 1 OUT 2 CHECK WRITE 6 WRITE key ON P1 12 OUT switch Puro NE i 11 MODE switch x 7 TIME ADJ key TIMER 12 MAN CYCLE PULSE COPY CLR Mope Eri ee 10 CLR key 9 COPY key 8 CYCLE PULSE key 13 TIMER PULSE switch 14 MAN AUTO RESET switch Display SUN MON TUE WED THU FRI SAT a Cursor Day indicator Time adjustment E M Sr i mode indicator MOESIA e Main display NES j HA Pulse width indicator Power failure indicator O v C Indicator for number 1 gp 1 e Output circuit indicator 2 __ of remaining steps Set circuit Timing chart display number indicator No Function O 6 Sets parameters Write S y O 8 Specifies a cyclic operation or sets a pulse width Not used 9 Specifies substitution operation Copy P1 Circuit 1 programming mode P2 Circuit 2 programming mode Run Run mode O Doo o M 12 AUTO Executes according to the program OFF Turns off the output regardless of the program PULSE Executes a pulse output operation The Output indicator will light when the timer output is energized Dryer On Displays the time at which the next operation will be preformed a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 47 Important For timer operation the System Power rocker switch must be in the ON position and the Dryer on Sequence shutdown rocker
34. f plastic resin in the drying hopper The resin in the hopper is discharged through a slide gate in a first in first out manner Material conveying systems convey dry material from the drying hopper to a sight glass loader The optional drying hopper loader conveys material from a gaylord to the drying hopper Nomad Series Portable Drying and Conveying systems are sized to meet the specific requirements stated by the purchaser at the time of purchase a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 7 1 3 Necessary Documents The documents listed below are necessary for the operation installation and maintenance of AEC Whitlock Nomad carts You can obtain additional copies from AEC Inc Make sure that the appropriate personnel are familiar with these documents This manual The schematic and assembly drawings included in the customer information packet The Customer Parts List included in the information packet Operation and installation manuals for any optional controls or auxiliary equipment in the drying system 1 4 Standard Features Rugged compact cart with handle and sturdy 4 10 cm casters Dual blower dryer with dual desiccant beds and 4 way compressed air operated valves Up to 400 F 204 C drying temperature range Insulated drying hopper with sight glass Cartridge type two stage air filters for all blowers Integral Control Center for dryer and loading options Electric
35. feature in the power main leading to the dryer The power drop must include a ground wire Make sure quick disconnect cables are connected at the junction boxes on the sight glass loader Machine Loader and the optional vacuum hopper drying hopper loader Figure 9 Typical Quick Disconnect Cable Connections MACHINE LOADER DRYING HOPPER LOADER WARNING Proper grounding of the main power line is critical Page 28 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 3 14 Checking for Proper Blower Rotation Three Phase Models The blower rotates properly when air flows from the delivery outlet and a vacuum is felt on the blower inlet 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 If the three phase blower rotates improperly reverse any two wires at the fused disconnect outside the dryer or at the disconnect terminal in the control enclosure This assures that the blower rotates in the proper direction ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 29 Notes Page 30 ec Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 4 Controls 4 1 Control Panel Indicator Lights and Switches Rocker Switches System ON OFF Rocker Switch Press the ON OFF rocker switch energizes or de energi
36. fter 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 www acscustomerservice com Sales Department Call 847 273 7700 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 847 273 7700 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 Inc 1100 E Woodfield Road Suite 588 Schaumburg IL 60173 Page 78 amp c Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems
37. g occurs 8 Install the covers and gaskets on the beds making sure they are tight and sealed Replace desiccant bed gasket if necessary 9 Re connect any hoses that were disconnected Page 58 ec Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 10 Re install the rear and side shrouds Re connect the compressed air supply and electrical power Figure 16 Required Desiccant Amounts per Bed Type 4X Desiccant 2 beds per unit Dryer Large bead Type 4X Small bead Type 4X Total per bed model _model_ _Partno ibs Ibs mn 1 362 9 534 10 896 secondo 10 896 Era 90 4086 WD225 4086 Type 13X Desiccant Dryer Ibe ka WD WD150 3 0 4086 Wo 90 4 086 6 6 Replacing the Process Heater Nomad Series dehumidifying dryers use Calrod type heater elements mounted in a heater tube located in the top rear of the cabinet The wattage of the heater varies with model voltage temperature range etc but the replacement procedure is the same WARNING Disconnect and lock out power before you replace heater elements Procedures 1 Remove the bolts securing the process heater access cover 2 Sketch the heater wiring configuration so you can properly re wire the heater 3 Remove the wires to the heater plate assembly being removed or replaced 4
38. h hose clamps Be sure to avoid loops and kinks and install grounding wire around the outside of flex hose to prevent static built up Make sure you ground both ends of the grounding wire Put the pickup probe in the material supply The burrowing action of the probe provides steady flow of material To vary the convey rate cover or open the vent holes on the pickup probe as needed with the inlet tube If your material bridges frequently and triggers No Convey alarm conditions you should consider using a gaylord tilter or tilter jogger to supply a steady stream of material to your VacTrac system Figure 8 Typical Pickup Probe 0536903 Vent 49 holes E Page 26 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 3 11 Connecting Cooling Water to the Optional Aftercooler High temperature applications 300 F to 400 F 148 C to 204 C require aftercoolers to cool moist air returning to the dryer from the drying hopper An aftercooler cools the return air by 100 F 38 C this maintains dryer efficiency and condenses unwanted plasticizers from the airstream Aftercoolers are also required in extremely low temperature applications Installing Water Lines e Use the 1 2 about 13 mm brass pipe nipples for water line connections Inlet and outlet line positions do not matter e Make sure you grip the nipple tightly when attaching a fitting Doing so prevents damage to the soft copper coils You s
39. he ESCK controller has several levels of securities to lock out access to parameters and menu settings If the controller will not allow you to change settings see Section 6 8 on Page 60 to set the ESCK security to access the function you need 4 11 Setting the Convey Timer and Range Selection Set the convey timer by rotating the large dial to the convey time you want The time units is factory set for seconds The time range is factory set to 0 30 seconds The operating mode is set to A for on delay Remove the black cover to gain access to the time unit selector and the time range selector Page 38 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems The rotary selector switches are located under the dial Turn the lower right rotary selector switch to set the time unit selection By turning the screw the time units will cycle between seconds minutes hours and ten 10 hours Turn the lower left rotary selector switch to set the time range selection The dial digits appear in the windows around the time setting knob The dial digits change when different time ranges are selected Time ranges are 0 0 5 0 1 0 5 and 0 10 Figure 12 Typical Nomad System Timer Power indicator green LED Flashes when Operating mode timer operates display window POWER lit when timer QD OUT oe stops operating x OF Operation mode LN 2 selector factory ot 0 set A On Delay Output indicator red LED
40. he process heater The indicator lights when the process heater is energized This condition occurs when no blower failures or high temperature conditions exist Right Bed Regeneration Output O 5 The right Bed Regeneration Output activates the right bed regeneration indicator lights when the right bed regenerates When this indicator is off the left bed is energized Left Right Regen Heater Output O 3 O 4 The Regen Heater Output indicator lights when the indicated bed regeneration heater energizes High Regen Temp Alarm O 6 When ON indicates a high regen temp condition in either the left or right bed Page 42 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Alarm Horn Output O 7 Optional The Alarm Horn Strobe Output indicates a high process temperature condition and optional critical low level at the drying hopper Machine Loader Convey Blower 0 8 When ON the Machine Loader convey blower contactor is energized Drying Hopper Convey Blower 0 9 Optional When ON the Drying Hopper convey blower contactor is energized Machine Loader Convey Timer 0 10 When ON the convey timer starts timing a loading process Drying Hopper Convey Timer 0 11 Optional When ON the convey timer starts timing a loading process Status LED Indicators Power The Power indicator lights when the PLC receives 115V control power Run The Run indicator lights when the PLC executes the program in normal c
41. here High Process Temp Alarm 1 8 When ON sends the information to the PLC to be used later in forming alarm procedure Push To Silence 1 9 Optional When the existing rocker switch is pressed the audible horn will be silenced and flashing strobe will be turned off Also it serves as an alarm acknowledgment Machine Loader Power On 1 10 When ON enables the Machine Loader conveying process Machine Loader Demand Proximity Switch 1 11 When ON indicates a demand in the sight glass loader this activates the conveying cycle a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 41 Machine Loader Loading Complete 1 12 An input coming from a conveying timer that indicates when the conveying time is complete Drying Hopper Convey Power On 1 13 Optional When ON enables the Drying Hopper conveying process Drying Hopper Convey Demand Reed Switch 1 14 Optional When ON indicates a demand in the Hopper Loader this activates the conveying cycle Convey To Process Loading Complete 1 15 Optional An input coming from a conveying timer that indicates when the conveying time is complete Dump Relay Jumper Setup 1 16 1 17 1 18 These inputs determine the dump delay time period a period that follows conveying period Output LED Indicators Blower On 0 0 The Blower On indicator lights when the blower energizes Process Heater Enable O 2 The Process Heater Enable activates t
42. hould make connections with flexible hose to allow removing the coil assembly for cleaning e The aftercooler is designed to utilize either tower or city water as warm as 85 F 29 C Recommended flow rate is one to three 1 to 3 gallons per minute 4 to 11 liters per minute 3 12 Connecting Compressed Air Note Connect compressed air to the dryer before operation Caution Excessive air pressure damages the neoprene components of the air distribution valve e Connect to a clean dry lightly lubricated source of 80 psi 551 kPa 5 51 bars compressed air e A pressure gauge and regulator are recommended components of your plant air supply e Connect the air supply using 4 NPT fitting The compressed air indicator switch prevents the dryer from starting without an 80 psi 551 kPa 5 51 bars air supply If the air supply drops to below 60 psi 413 kPa 4 13bars during operation the dryer shuts down until at least 80 psi 551 kPa 5 51 bars is restored a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 27 3 13 Making Electrical Connections NANA NAN Fulfill all national state and local safety and electrical code requirements Connections should be made by a qualified electrician Make sure all electrical connections are tight 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
43. ial through new lines to remove any remaining sediment and discard the material immediately Tube ends must butt together inside couplers Tighten tube coupler nuts from the center outward to create a tight seal and allow proper contact of the internal grounding strip Each material tubing run must maintain a continuous ground through the tubing and couplers from pickup point to vacuum hopper Ungrounded flexible hoses should have ground wires wound around the outside If you must cut bends cut the straight section and allow enough straight length for complete insertion into a coupler You can attach a quick change or standard tube coupler to vinyl flex hose by inserting a stub of hard tube into the hose and securing it with a hose clamp Make sure that enough tube extends from the hose to properly install the quick change or coupler Apply clear silicone caulk around adjoining tube seams for exterior bolted couplers If you use stainless flexible material hose the material flow must be in the same direction as the arrows on the hose Material direction is not critical with vinyl flex hose Page 20 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 3 7 Adjusting the Machine Loader Closed Loop Dry Air Take Off Compartment Levels A and C The FCO 1 5MD model fast take off compartment has an adjustable inner tube fitted to the fixed outer tube A hold down screw on the outer tube locks down the adjustable inner tube Lo
44. ify that the drying hopper is clean of rust prohibitive oil or any foreign objects 2 Verify that process and return hose connections are tight 3 If your dryer has a water cooled aftercooler make sure that sufficient cooling water flows properly through the coil and that you have bled any trapped air from the system Make sure that the aftercooler has the proper supply water temperature 4 Check all companion equipment such as the sight glass loader and drying hopper loader verify that all convey tubing is in place and the loading system is ready for operation 5 Make sure quick disconnect cables are connected at the junction boxes on the sight glass loader Machine Convey and the optional vacuum hopper Drying Hopper Convey 6 Verify that all electrical connection are tight and the unit is properly grounded 7 With main power on turn the dryer on until the process blower starts verify blower rotation 8 Turn on the machine loader and verify blower rotation repeat for the drying hopper loader Important Clean the rust preventing oil from inside the drying hopper Failure to clean the hopper fouls the desiccant and voids your warranty 5 2 Startup Turn on energize the disconnect switch in your power drop Turn the system ON OFF switch to ON to energize the display panel 1 2 3 Close the slidegate at the bottom of the drying hopper 4 On three phase models make sure that the blowers turn in the right direc
45. ing 1 10 Specifying a Drying Conveying System 2 Shipping Information eene 13 2 1 Unpacking and Inspection 2 2 In the Event of Shipping Damages 2 3 Ifthe Shipment 15 Not Complete 2 4 Ifthe Shipment is Not Correct 2 5 Returns 3 Mechanical Installation eere nnne 15 3 1 Work Rules 3 2 Positioning Your Nomad System 3 3 Drying Hopper 3 4 Installing the Sight Glass Loader 3 5 Flange Mounting Tips 3 6 Installing Material Vacuum Tubing 3 7 Adjusting the Machine Loader Closed Loop Dry Air Take Off Compartment 3 8 Adjusting Sight Glass Proximity Sensor Sensitivity 3 9 Drying Hopper Loader 3 10 Installing the Pickup Probe for Hopper Loaders 3 11 Connecting Cooling Water to the Optional Aftercooler 3 12 Connecting Compressed Air 3 13 Making Electrical Connections 3 14 Checking for Proper Blower Rotation Page 4 ec Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Table of Contents 4 uoo 29 4 1 Control Panel Indicator Lights and Switches 4 2 Process Air Dew Point Display 4 83 Process Air Temperature Controller 4 4 Machine Loader Timer 4 5 Optional Drying Hopper Loader Timer 4 6 Identifying Temperature Controller LED Indicators 4 7 Identifying Temperature Controller Keys 4 8 Setting the Process Air Temperature 4 9 Setting the Shift on Dew Point 4 10 Setting the High Dew Point Alarm 4 11 Setting the Convey Timer and Range Selection 4 12 Convey Dump Delay S
46. itional copies are available from AEC Whitlock e Only qualified personnel familiar with this equipment should work on or with this dryer e Work with approved tools and devices e 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 Positioning Your Nomad System The Nomad system was designed to be wheeled into place The entire assembly is mounted on a rugged compact frame with an integral handle The cart is equipped with sturdy 6 15 cm heavy duty casters two locking and two swivel Caution Use caution and observe safety rules when placing your cart Page 16 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Figure 4 Typical Machine Loader and Drying Hopper Loader Diagrams MMM yy SS GSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS SS Drying hopper Whitlock Quick disconnect cable Machine loader conveying Machine throat A qo blower SA LA J Material Conveying Legend _ 4 Dry material a zt d Machine loader Closed loop convey conveying pressure side filter Material
47. itlock Only qualified personnel familiar with this equipment should work on or with this unit K Work only with approved tools and devices Disconnect power before servicing your dryer If the disconnect switch you installed has lockout lock it in the OFF position before you perform any maintenance or service 6 2 Servicing Process Air Filters Important Operating the dryer without the process air filter installed voids your warranty Filter cleaning is an important part of your dryer maintenance proc Nomad carts have a single cartridge canister type filter in the process and conveying air loop The process filter is mounted above the process blower on the rear of the dryer The conveying filters are located under the drying hopper next to the conveying blowers These filters protects the blowers from plastic fines drawn in from the drying hopper Regular filter cleaning is essential to keep your dryer operating at peak efficiency You can wash or blow out the filters but remember you reduce dirt holding capacity with each washing The risk of dirt reaching the clean side of the filter during cleaning plus possible filter damage from high pressure washing or blowing makes washing a gamble You can carefully clean or wash the filter when airflow becomes restricted Do not wash filters more than six 6 times or use them for more than a year whichever comes first Page 54 a Whitlock Nomad Series PD 2 to PD 4 Dr
48. l Press the CHECK key 5 Each time the key is pressed the operation schedule is displayed in the time sequence If the time switch is left untouched for 20 seconds during check the display automatically returns to RUN mode a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 49 Day Override If a holiday occurs during the weekly operation the off time for Sunday can be executed for the holidays The override will execute for one week only then the timer will automatically go back to the previous program 1 Hold the COPY key 9 for one 1 second or longer Make sure that the mode selector switch is in RUN mode 2 Select the day s you want with the SHIFT 1 and SET keys 2 If a previous override had been set this will show up when you first hold the COPY key To clear a previous override press the CLR key 10 3 Press the WRITE key 6 4 Select Sunday or another shutdown day with the SHIFT 1 and SET keys 2 5 Press the WRITE key 6 Canceling the Settings All the operations can be cancelled 1 Set MODE selector switch 11 to P1 2 Press the CLR key 10 Note The 7 day timer cycle and pulse output are not used for dryer applications Page 50 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Notes ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 51 5 Startup Shutdown and Operation 5 1 Pre Startup Checks 1 Ver
49. m the tube positioned all the way in minimum setting then slowly pull the inner tube out until the distance from the outer edge to the indicator knob is one eighth of an inch 3 mm This is the eighth inch 3 mm setting a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 21 If higher rates are required pull the tube out in increments of one eighth of an inch 3 mm Check the rate If you still require a higher flow rate repeat these procedures to go to the next setting Important Never set the inner tube all the way out to start with the maximum flow rate 2 Check the flexible hose used for conveying material from the FCO to the sight glass loader inlet Make sure that the hose is straight down from the bend to the inlet If there are any loops cut the hose to the right length to remove the bends The hose lengths are cut at factory to ten feet 10 3 m but if the hose is too long cut it to the right length Every time you change the material make sure you e Purge all the material in the line e Adjust the inner tube all the way in Factory recommended setting e Slowly adjust by one eighth of an inch 4 3 mm increments if you want a higher throughput The distance is measured from the inside edge of the indicator knob to the outer edge of the collar on the take off compartment Adjust the inner tube out in the increments of one eighth of an inch 1 3 mm until you g
50. mperature falls below the alarm point The regeneration blower continues to run for cooling the heaters and desiccant bed The alarm condition clears when the temperature drops below the thermostat setpoint The heaters re energize automatically High Dew Point Light The High Dew Point alarm indicator lights when the process air delivery dew point exceeds a dew point of 10 F 23 C Page 32 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Material Loading Light The Material Loading indicator lights when material is being conveyed Optional Dirty Filter Light If installed the Dirty Filter alarm indicator lights when the pressure differential across the process regeneration and conveying air return filter exceeds the pressure switch setting Service the filter when this indicator lights The indicator and the alarm condition clears after you service and reinstall the filter Figure 10 Typical Nomad Interface Panel ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 33 Whitlock DEW POINT PROCESS TEMPERATURE ALARMS py Low ETT COMPRESSED AIR HIGH TEMP PROCESS AIR x YIA AT HIGH TEMP REGEN AIR REGENERATION PROCESS HIGH DEW BLOWER ON BLOWER ON POINT PROCESS zum AQ mom sone DIRTY FILTER LEFT REGEN RESEN HEATER ON idu DRYER DIRTY FILTER ON ON RIGHT BED IN REGEN RIGHT REGEN HEATER ON OFF SEQUENCE PUSH TO SYSTEM SHUT
51. n e Check the gasket for damage A damaged gasket allows contaminants into the process Replace as needed e Allow the filter to dry before re using Circulate warm air at less than 160 F 71 C Do not use a light bulb to dry the filter 6 3 Servicing the Dew Point Monitor The accuracy of the dew point monitor on Nomad cart systems depends on proper operation of the dew point sensor and the control board The dew point sensor is in the process air stream and is therefore susceptible to contamination Dew point sensor life depends on e Air temperature and flow passing over the sensor e The amount of fines dust in the process air e The amount of plasticizer vapor in the process air 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 Page 56 ec Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 6 4 Symptoms of Worn Desiccant The moisture absorption capacity of the desiccant used in your AEC Whitlock dryer degrades after an indefinite period of time Useful life depends on variables such as material moisture content plasticizer vapors in the return air and number of regeneration cycles Your AEC Whitlock dryer may need new desiccant if it exhibits any of the following symptoms e Plastic material is not being
52. ng machine If a demand is still present the PLC starts the convey cycle over Page 12 ec Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 1 10 Specifying a Drying Conveying System Many variables were 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 If your operating environment changes AEC Whitlock can advise you on necessary equipment and process time and temperature modifications required for your system AEC Whitlock can advise you on your system capabilities based on system makeup distance material and the conveying rates you select Figure 3 Typical Nomad System with Cabinet Style Dryer Drying hopper loader x Whitlock H I 1 Drying Optional T HEU Material hopper aftercooler Machine H loader probe CTS Machine throat Dryer Take off compartment P a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 13 2 Shipping Information 2 1 Unpacking and Inspection You should inspect your Whitlock dehumidifying dryer for possible shipping damage Save the container and packing materials for re shipment if they are in re
53. nting flange mates with existing AEC Whitlock equipment and uses the same mounting holes as previous AEC Whitlock models Complete the vacuum and material tubing from the take off tubes located on the Nomad cart See Section 3 6 on the following page for information on installing material vacuum tubing Connect the quick disconnect cable for the demand sensor to the Nomad cart See Figure 9 on Page 26 for more information Page 18 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Figure 5 Sight Glass Hopper Flange Templates Models SGV011 SGV012 Optional Models SGV031 032 2 50 14cm 6cm 0 28 9 32 hole 1 25 dean 2 75 7 mm 3em d hole 7cm 4 places H 4 places gt 4 00 250 y 10cm j 125 Sem 7 00 5 50 2 00 3cm 18 cm i 14 cm 5cm i 275 Y v E 2 125 2 1 8 hole Pend 5 5 1 4 00 10 cm a i 3 00 7 75 cm hole 7 00 18 cm 3 5 Flange Mounting Tips Run a bead of silicone sealant around the mounting flange before seating the vacuum hopper This makes a better seal Use rivets to mount the hopper Nuts and bolts can loosen fall off and damage process equipment Check across the mounting flange with a bubble level A level installation is important for proper hopper dump Properly ground all sight glass loaders and vacuum hoppers 3 6 Installing Mat
54. o remove or add jumpers and set the dump delay time you want 4 13 PLC Controller The PLC controller uses an Allen Bradley programmable logic controller PLC This brick type controller has 32 I O points twenty 20 inputs and twelve 12 outputs all inputs and outputs are 115 VAC All programming and logic is factory installed on an EEPROM chip and cannot be modified A battery backup retains programming if power fails Battery life is five 5 years at room temperature If the alarm indicator blinks intermittently replace the battery within one week Page 40 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 4 14 PLC LED Indicators Input LED Indicators System Start Sequence Shutdown 1 0 When ON activates the operation of the dryer portion Compressed Air Input 1 1 This input point is jumpered because this unit does not contain the feature thereof Process Blower Enable 1 2 Confirms the operation of the process blower Bed Switch Set Point Input 1 4 Since this is strictly a time base unit this device is jumpered so that it constantly yields power to this input point High Regen Temp Alarm Right Bed 1 5 When OFF indicates a situation of a temperature exceeding the set level in the right regen bed High Regen Temp Alarm Left Bed 1 6 When OFF indicates a situation of a temperature exceeding the set level in the right regen bed Universal Alarm Input 1 7 Not used
55. onditions Fault The Fault indicator lights when the PLC program has a problem or failure condition Force The Force indicator is not used a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 43 Figure 14 Typical Subpanel Layout S E EN LA T Ut S n 5 1 o H o fala alio lel 2 12 22 o 8 om p p p 222 222 222 1 2529 505 599 V e e amp e e e e 0 e e 9 e e e e e e e e oo To E 909010090 900060 5 2 5 TERMINALS
56. or setting convey times and has several timing modes 4 6 Identifying Temperature Controller LED Indicators Process Value Numeric LED During normal operation the process value PV numeric LED indicator displays the process temperature at the To Process thermocouple It also lists parameters during setup and error messages if any errors occur Set Value Numeric LED During normal operation the set value SV numeric LED indicator displays the process set point you selected for the dryer The dryer then maintains this set point temperature This LED indicator also displays parameter and pre set function values during setup a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 35 OUT1 Lit when control output 1 turns on The OUT indicator lights when the controller signals the process heaters to be energized OUT2 Lit when control output 2 turns on Not used in this application MANU Lit when the manual operation mode is being used STOP Lit when control operation has been stopped Not used in this application RMT Lit during remote operation Not used in this application AT Flashes during auto tuning SUB1 Lit when the output function assigned to auxiliary output 1 turns on The SUB1 indicator lights when the process temperature exceeds the set point temperature by more than the alarm deviation value This alarm output de energizes the heaters Heaters re energize when the temperature fall
57. osen the screw to adjust the inner tube Vary the distance of the indicator knob from the outer collar See Figure 6 to control the flow of material to be conveyed Adjust the inner tube so that the inside edge of the vertical knob touches the outer collar This position is the minimum and factory recommended setting The minimum and factory setting should adequately meet the throughput requirements on Nomad cart systems For higher flow rates increase the distance by pulling the adjustable tube away until you get the flow rate you want The maximum amount of material should be conveyed when the adjustable inner tube is pulled all the way out Note This condition may cause the flow to be unsteady and eventually may plug up the line Along with the take off adjustment take special care when setting the convey time e Too short of a time shortens the service life of the blower e Too long of a convey time causes material to back up in the convey line which could lead to plugging Suggested convey time is a minimum of five 5 seconds and a maximum of twelve 12 seconds Basic Tips Every material has different conveying characteristics because of factors such as bulk density and particle size Some material is easier to flow than others That is why the inner tube is adjustable to give you the flexibility to control how much material you want to convey 1 When adjusting the inner tube always adjust from the inside out Start fro
58. ower wiring to PLC PLO Regeneration Bed LED Ej tty PLC PLC Power light is on Run light is off and or Replace PLC Error light is on Regenerating bed cooldown Verify that blower contactor is Blower Input indicator is off on Check input wiring to PLC Left Right output indicators temperature condition Power light is off power wiring to PLC Faulty PLC PLC Power light is on Run light is off and or Replace PLC Error light is on Check resin manufacturer s data sheet for proper drying Process temperature set too temperature Make sure plant high due to operator error personnel are aware of the correct process temperature Material in drying hopper set point cakes or meltdown occurs High temperature alarm not Reset high temperature set properly alarm Process set point is out of Restore temperature acceptable range controller to factory pre sets Function set for degrees Celsius C set point at degrees Fahrenheit F Burned out regeneration Repair or replace heater Contaminated or worn out Replace desiccant Poor dew point performance Leaking process air hoses Repair or replace Dryer operates beyond its Check dryer and drying Capacity hopper sizing Bad dew point sensor Fouled dew point sensor Clear obstruction Air should manifold flow freely through sensor Verify correct Celsius or Fahrenheit settings Page 72 ec Whitlock Nomad Series PD 2 to PD 4 Dr
59. p to switch between menus 2 5 switch parameters within menu press Arrow Up Figure 19 Setting List for Dew Point Controller Part No A0548567 Parameter Settingrange Default Ec dog s AEC setting Protect SECr Security 0 to 6 Protect YEYP Key Protect ON OFF Default Default Default 10 0 F 23 C 10 0 F 23 C Default Default Default Default Default Default Default Default Default Default Manual Manual MV 5 0 to 105 0 Level 0 Level 0 Level 1 Level 1 Level 1 Level 1 0 01 to 99 99 FS Level 1 Level 2 SPrU Sp Ramp Time Unit Level 2 SPrt Sp Ramp Set Value Level 2 Level 2 Level 2 Level 2 Level 2 Cn5L input shift lower limit 8 1 Mode Level 0 Level 0 Level 1 Level 1 Level 1 Level 1 Level 1 Level 2 Level 2 Level 2 Level 2 Level 2 Level 2 Level 2 olo olo J olo PO PO olo Page 68 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Figure 19 Setting List for Dew Point Controller Part No A0548567 Mode Parameter Setting range Default AEC setting Setup Cn t Input Type 0 to 21 2 x Scaling Lower Limit 1 to o Setup Scaling Upper Limit 9999 EU 100 15 F 9C ha 1999 to SP Setting Upper Setup Cn L Scaling Lower Limit Limit 0 1 EU 40 F 40C Setup Decimal Point 0 to 3 Default
60. put type is set for thermocouple TC PT middle jumper 3 Return controller to housing 4 Press the Co Display key for one 1 second to enter Menu Display S 5 Press the Arrow Up key to get to Setup mode 6 To switch parameters within Setup mode press the Co Display key Page 64 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Figure 18 Setting List for Process Temperature Controller Part No A0548565 Mode Parameter Setting range Default AEC setting Protect SECr Security 0 to 6 1 5 Manual Manual MV 5 0 to 105 0 0 0 Default Default AEC setting Default un Default Default Parameter ___ evel 0 SP Lower Limit to Upper Limit EU SP Lower to Upper EU evel 1 SP Lower to Upper EU 1999 to 9999 EU 2 Default Default Default 1999 to 9999 EU 1999 to 9999 EU 1 to 999 9 FS evel 1 1 Integral Time to 3999 SEC to 3999 SEC 01 to 99 99 evel 1 19 99 to 99 99 FS 0 to 100 0 J c 5 e o no 5 o C2 01 to 99 99 FS 01 to 99 99 FS to 99 SEC evel 1 to 99 SEC Parameter ____ Settingrange AEC setting Default M Minutes H Hours Default Default ev Default eve Default ev Default ev 105 0 Default evel L L MV Lower Limit 5 0 to MV Upper Limit 0 196 5 0 Default rL MV Change Rate Limit 0 0 to 100 0 SEC Default
61. ration when installed and operated within design specifications following national and local safety codes To avoid possible personnel injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices NAN Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Disconnect and or lock out power before servicing or maintaining the dryer 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 this equipment It is a good idea to remove the fuses and carry them with you Make sure the dryer and components are properly GROUNDED before switching on power Do not jump or bypass any electrical safety control Do not restore power until all tools test equipment etc have been removed and the dryer and conveying equipment are fully reassembled Only PROPERLY TRAINED personnel familiar with the information within this manual should work on this equipment ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 3 Table of Contents 1 General Information enr 7 1 1 Models Covered 1 2 Equipment Function 1 3 Necessary Documents 1 4 Standard Features 1 5 Options 1 6 The Closed Loop Drying System 1 7 Whatis Desiccant 1 8 Process Regeneration Cycle 1 9 Closed Loop Machine Convey
62. rocessing 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 the SEQUENCE SHUTDOWN position The sequence shutdown operation turns off process heaters and keeps the process blower on for twenty minutes to cool down the process The regeneration cycle of the off line bed completes the cycle before the dryer shuts down completely To override the sequence shutdown turn the system ON OFF switch to OFF 5 To completely shut off the unit after sequence shutdown has completed turn the system ON OFF switch to OFF 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 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 53 6 Maintenance 6 1 Work Rules The installation operation and maintenance of this equipment is to be conducted in accordance with all applicable work and safety codes for the installation location This may include but is not limited to OSHA NEC CSA and any other local national and international regulations In addition you must observe the following specific work rules Keep these operating instructions on hand and follow them when installing operating or maintaining your dryer If these instructions become damaged or unreadable you can obtain additional copies from AEC Wh
63. s within the acceptable range 4 7 Identifying Temperature Controller Keys Co Display Key This key shifts the display to the next set of parameters Then the menu screen displays 1w Down Key The Down arrow key lets you 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 Pw Up Key The Up arrow key lets you 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 ar Auto Tune Key Hold down for two seconds to initiate auto tune Repeat to cancel Page 36 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Figure 11 Typical Nomad Temperature Controller E5CK 4 8 Setting the Process Air Temperature To change the process air temperature set point with the dryer running f B Press to raise the set point to the temperature you want X WB Press to lower the set point to the temperature you want Press the Auto tune key to initiate auto tuning 4 9 Setting the Shift on Dew Point Nomad dryers shift air flow from the on line desiccant bed to the regenerated desiccant bed based on actual dew point demand not fixed time cycles After the off line bed regenerates the PLC controller waits for a high dew point signal from the process air dew point controller before switching beds The PLC
64. sture 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 heats air to over 500 F 260 C and forces it through the desiccant bed Moisture driven off the bed bleeds to the atmosphere If you measure the temperature of the air bled to the atmosphere bleed temperature you should observe a rise after a period of time This condition bed breakthrough indicates that the bed is dry At bed breakthrough the bleed air temperature peaks between 350 F 176 C and 400 F 204 C The Dew Point meter measures the dew point of the process air A properly regenerated bed produces process air dew point of 40 F 40 C This ultra low humidity level is more than adequate to dry plastics to as little as 003 moisture depending on the process and material 1 9 Closed Loop Machine Conveying A high efficiency centrifugal blower and special designed take off compartment provides closed loop dry air conveying of material from the drying hopper to a sight glass loader located at the press The single station control includes a low level sensor that sends a signal to the PLC and starts the blower and conveys material for a set amount of time An adjustable convey timer is located on the control panel Once the convey time is over the blower shuts down and starts a dump delay time to allow material to flow into the processi
65. tion 5 Fill the drying hopper with material Use optional Drying Hopper Loader by turning on the Drying Hopper Loader ON OFF switch and setting the convey timer Turn the DRYER ON SEQUENCE SHUTDOWN switch to ON to start the dryer D 7 The process blower will start 8 Set the process set point on the temperature controller to the recommend drying temperature provided by the resin manufacturer Press and hold the Auto Tune key on the process temperature controller for two 2 seconds to initiate the auto tune function Page 52 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 10 11 12 Note After the proper pre drying time for the initial hopper fill has elapsed fully open the drying hopper slide gate Turn the machine loader ON OFF switch to ON and set the convey timer for the proper conveying time A ten 10 second convey time is recommend to start Adjust the inner tube on the take off compartment if material does not flow easily to the sight glass loader on the molding press If you are running out of material at the sight glass before the machine loader starts the convey cycle again lower the dump delay time by adjusting the yellow jumpers inside the control panel To allow proper residence time during continuous processing maintain the material level in the hopper at the midpoint of the air trap assembly Shutdown Turn off the conveying system supplying the drying hopper When p
66. tuning SP setting limiter Select advance PID or ON OFF control Option Mode This mode is only accessible when and option board is installed Calibration Mode For calibrating communication unit E53 CKF Not used Manual Mode Sets the controller to manual operation mode Not used on Nomads Page 62 ac Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Figure 17 Display Readout for Mode Settings PV Menu display sv Level 0 mode SV A Level 1 mode SV y Level 2 mode SV a re Setup mode SV Expansion mode SV Option mode SV Calibration mode Setting E5CK Security in Protect Mode 1 To access protect mode press and hold the AT key and the Co display key for more than one and a half to two 1 5 to 2 seconds 2 The display should read SECT for security mode If you press the Co display key for short presses you will toggle between SECT and KEYP for AT protect 3 With the display reading SECr set the security levels by the arrow up and down keys Change the security level to 1 to make changes to the operating parameters The temperature controller is factory set to Security Level 5 the dew point indicator is factory set to Security Level 3 Available Security Levels mode Wee eo 1 21314 516 Calibration X Any mode marked with an X is displayed in the Security Le
67. usable condition 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 case of breakage damage shortage or incorrect shipment refer to the following sections 2 2 In the Event of Shipping Damages Important According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment The Carrier then assumes full responsibility of the 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 to AEC Inc before the transportation company inspection and authorization File a claim against 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 AEC Inc regarding your wish for replacement and to obtain an RMA return material authorization number Page 14 a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems 2 3 If the Shipment is Not Complete Check the packing list The apparent shortage may be intentional Back ordered items are noted on the packing list
68. vel indicated To return to the main display run mode press and hold the AT and display key for 1 5 to 2 seconds a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 63 Entering Operating Parameters to Select Modes To enter the menu display 1 Press Co for one second keep the pressure on the button for about 1 5 to 2 seconds The screen displays 2 Press Up Arrow key to toggle through the different modes The SV readout displays the mode you selected 3 To switch parameters within a mode press the Co Display key once more for about one and a half to two 1 5 to 2 seconds The PV readout displays the different parameters within each mode 4 Use short presses on the Co Display key to display each parameter within a mode The SV readout displays the different values for the parameter within a mode uo 5 Press and to set the higher or lower the values of a parameter 9 6 Press for about one and a half to two 1 5 to 2 seconds to move up a level back into the different modes 7 Press until Level 0 displays oO LM 8 Press for about one to one and a half 1 to 1 5 seconds to go to Operating mode Factory Settings E5CK for Process Temperature 1 Remove controller from housing and check for output board number E53 QR4R Pulse NPN Relay 2 Make sure jumper setting for in
69. ying and Conveying Systems Problem Possible cause Corrective action The internal mechanism is not inserted properly into the housing The power supply is not Properly connect the power connected to its terminals supply to the power supply properly terminals No power is supplied or the Supply a voltage of 85 to 125 supplied power is not within VAC to the power supply the specified range terminals of the controller Check control power fuse for continuity Turn disconnect switch and control power switch ON Properly insert the internal mechanism into the housing Nothing displays when the controller is turned on Disconnect switch or Control Power switch not set to ON Control Power fuse blown Input polarity on thermo couple is wrong or Properly wire the terminals connection is wrong No compensating lead wires used for extension of the thermocouple Use proper compensating lead wires and terminals Use a dedicated thermo couple connector If a connector is a metal different from the thermocouple and controller a temperature error may result Sensor is broken or short circuited Replace with a good sensor E Separate input wires as far The controller is influenced a9 by noise or other induction MOm INe Celcius temperatures used Setup mode level 2 display instead of Fahrenheit or vice d U S V display shows versa setting Thermocouple and controller are connected by wires
70. ying and Conveying Systems Use a detergent that won t damage filter media Such a detergent permits easy removal of dirt particles through flushing and rinsing An effective detergent removes the fine particles from the pores of the filter media The filter manufacturer recommends FM 1400 washing compound It is formulated specifically for air filter element cleaning It is non sudsing and works in hot or cold water FM 1400 contains biodegradable synthetic detergents and is non phosphate non NTA For more information contact Filter Service Corporation 2603 A West Main Farmington NM 1 505 326 1127 Recommendations for Cleaning and Replacing Filters e Turn off and or lock out electrical power to the dryer e Remove the threaded fastener securing the filter access cover then remove the cover e Remove the nut on the center retaining rod to remove the filter cartridge 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 clean side Remove loose dirt from the filter with compressed air or a water hose Compressed air should be less than 100 psi 689 5 kPa 6 89 bars Use a
71. zes control power to the indicator panel allowing separate control of the dryer and conveying systems Dryer ON Sequence Shutdown Rocker Switch Press the ON Sequence Shutdown rocker switch to start the dryer Move this switch to the Sequence Shutdown position to turn off the process heaters finish the regeneration cycle and then turn off the dryer Machine Loading ON OFF Rocker Switch Press the ON OFF rocker switch to start or stop the machine loader conveying system Optional Drying Hopper Loader ON OFF Rocker Switch Press the ON OFF rocker switch to start or stop the Drying Hopper loader conveying system Optional Alarm Silence Rocker Switch Press the Alarm Silence switch to silence the horn when a high temperature alarm activates The alarm repeats every five minutes until the problem causing the alarm condition is cleared Indicating Lights Regen Blower On Light The Regen Blower On indicator lights when the regeneration blower energizes Left Bed In Regen Light The Left Bed In Regen LED lights when the left bed is in regeneration Left Bed Heater Light The Left Bed Heater indicator lights when the left bed regenerates and is in the heat up portion of the regeneration cycle a Whitlock Nomad Series PD 2 to PD 4 Drying and Conveying Systems Page 31 Right Bed In Regen Light The Right Bed In Regen LED lights when the right bed is in regeneration Right Bed Heater Light The Right Bed Heater indicator lights when the

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