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Sterling Plumbing 100 User's Manual

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1. 40 6 6 Replacing the Process 41 6 7 Replacing the Regeneration 242 244 42 Changing the Controller Security LeVej 42 Restoring Factory Defaults on the Process Temperature Controller 42 Restoring Factory Defaults on the Dew Point Controller 46 6 8 Restoring the Temperature Controller and Dew Point Meter to Factory Setup 47 CHAPTER 7 TROUBLESHOOTING 48 CHAPTER 8 APPENDIX uy iu ul Z Eee e M EE eu 52 8 1 Contact Information pp 52 8 2 Technical SpecificatigonsS a 52 Cabinet Series Dehumidifying Dryer 4 Charts and Figures 1 Dryer Air Flow Diagram 12 2 Typical Dryer Interface Panel 18 3 Typical Dryer Temperature Controller 20 4 Display Readout for Mode Settings and Available Security Levels 22 5 Typical Subpanel Layout 25 6 Typical Cabinet Dryer Electrical Schematic Drawings 1 and 2 26 27 7 Required Desiccant Amounts Per Bed 41 8 d List for Process Temperature Controller art No A0548565 43 9 Setting List for Dew Point Controller Part No A0548565 46 Cabinet Series Dehumidifying Dryer 5 Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining the l
2. 24 St t s LED Inaibators s e E de da ie iud 24 4 8 Setting the Shift on Dew Point mte pan nk RR PR REA d RE x NER EC SK EPMEX UI EE 28 4 9 Entering Operating Parameters to Select Modes 28 4 10 Setting the High Dew Point Alarm pp 28 4 11 Optional Seven Day Timer set eoe riae sioe et pesto tentes 29 Programming the Optional Tu td 30 Checking the Set Time eer ere E Re 31 Day Override ETC 32 Canceling the Settings top lacerto ted dana ns dise p eade pne enc 32 CHAPTER 5 OPERATION u eoe 34 5 1 Pre Stanup Checks uuu PER M 34 5 2 Startups eee tet tiis qu Let ONU RO cies an Sut Me ias atau ec 34 3537 etl UT rc 34 CHAPTER 6 36 6 17 Work huleS iss ets rhe ore EE sus EF te Miran VE Pr rv a ER PETER ER 36 6 2 Servicing Process Air Filters edem ote e Eun 36 Recommendations for Cleaning and Replacing Filters 37 6 3 Servicing the Dew Point a 39 6 4 Symptoms or Worn Desiccant rr pet aad tetas 39 6 5 Replacing Worn
3. 15 Installing Water LINES a due coud tee or o E ec ence qul sarees eee 15 9 7 Brying HOP DEM acd eoe teehee ma upas Si aasawa aqata tap datis nies 15 Removing the Rust Inhibitor Rei vocas o bind 15 Air Trap Considerations ees d eee abe da E 15 CHAPTER 4 CONTROLS 16 4 1 Control Panel Indicator Lights and 16 Rocker SWIIGIIBS uu u s ani A e eius 16 indicating Lights EE S 16 4 2 Process Air Dew Point Display pp 19 4 3 Process Air Temperature 0000 19 4 4 Identifying Temperature Controller LED Indicators pp 19 45 Identifying Temperature Controller Buttons 20 E5CK Operating Parameters aaa teet 21 Available E5CK Modes 21 Cabinet Series Dehumidifying Dryer 3 4 6 Setting the Process Air Temperalture 22 E 22 PLG LED IRGICAIOMS pese ai R Cae 23 Qu tp t LED IDdlIG8l0r8
4. 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 manufacturer s parts department Attach the beds to the frame for Steps 5 through 9 5 Carefully place half of the large bead in the bottom of the beds in an even layer on the bottom screen Place the small bead on top of it in an even layer Carefully place an even layer of the remaining large beads over the small beads 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 settling occurs Install the covers and gaskets on the beds making sure they are tight and sealed Replace desiccant bed gasket if necessary Re connect any hoses that were disconnected Re install the rear and side shrouds R
5. 8 Maintenance Responsibility need 9 Reporting a Safety Defect dd 10 CHAPTER 2 GENERAL INFORMATION 11 251 Models GOVOLBU us eee dedita USE aT 11 Equipment FUNGUO 11 2 3 Necessary DOCUITIOntS coeno rc 11 2 4 Standard Features ede e ee e ae ERR LE ESTER EE XR 11 2 5 Er 11 2 6 The Closed Loop Drying System pp 12 2er a What is Desi6earite ua ebd ele oed eee equ 13 2 8 The Process Reqeneralion Cycle SER ee es 13 2 9 Specifying a Drying Conveying System pp 13 CHAPTER 3 14 3 1 Positioning Your Dryer soa tecto prre parto re olet ase doct lone oie Pie 14 3 2 Making Electrical Connections Nt 14 3 3 Connecting Compressed paite 14 3 4 Checking for Proper Blower Rotation pp 14 Three Phase 1MoaejS am 2d cs last os 14 3 5 Process Air Connections Between the Dryer and the Drying Hopper 15 3 6 Connecting Cooling Water to the Optional Aftercooler
6. O 6 Alarm Horn The Alarm Horn Strobe Output indicates a high Output O 7 process temperature condition and optional critical Optional low level at the drying hopper Status LED Indicators Name Description 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 conditions Fault The Fault indicator lights when the PLC program has a problem or failure condition Force The Force indicator is not used Cabinet Series Dehumidifying Dryer 24 Figure 5 Typical Subpanel Layout Cabinet Series Dehumidifying Dryer 25 Figure 6 Typical Cabinet Dryer Electrical Schematic Drawing 1 Cabinet Series Dehumidifying Dryer 26 Figure 6 Typical Cabinet Dryer Electrical Schematic Drawing 2 158 DRYER ON SEQUENCE SHUTDOWN 160 COMPRESSED AIR INPUT 161 PROCESS BLOWER ENABLE 162 REGEN BLOWER PROCESS ENABLE CONTACTOR PROCESS BLOWER ON 164 DEW POINT BED SWITCHING 166 HIGH RIGHT BED REGEN BLOWER REGEN TEMP ALARM CONTACTOR 167 REGEN BLOWER ON 168 HIGH LEFT BED REGEN TEMP ALARM 169 PROCESS HEATER CONTACTOR PROCESS HEATER ON 170 LOW COMPRESSED AIR ALARM 172 HIGH PROCESS RIGHT REGEN HEATER TEMP ALARM CONTACTOR RIGHT BED HEATER ON 174 PUSH TO SILENCE OPTIONAL ALARM LEFT REGEN HEATER CONTACTOR LEFT REGEN HEATER ON BED SHIFT RELAY RIGHT
7. Operation and Installation Manual 90 100 150 225 CFM Cabinet Series Dehumidifying Dryers Important Read Carefully Before Attempting to Install or Operate Part No 882 00282 00 Effective 4 28 08 Bulletin No DH1 630 1 Cabinet Series Dehumidifying Dryer Chapter 1 Safety 1 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 The manufacturer can advise you on proper selection and sizing of systems for your operating environment We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice Copyright 2008 All rights reserved Effective 4 28 2008 Part No 882 00282 00 Bulletin No DH1 630 1 Cabinet Series Dehumidifying Dryer Table of Contents CHAPTER T SAFETY Su 6 1 1 How to Use This Manual rrt nn a 6 Safety Symbols Used in this MamUaj sss 6 1 2 Warnings and Precautions pp 7 137 EUN 8 General Responsibility Dietas andina iu 8 Operator Hespotnsibilily adn
8. 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 should make connections with flexible hose to allow removing the coil assembly for cleaning e The aftercooler is designed to utilize either tower or city water as warm as 85 F 29 C Recommended flow rate is one to three 1 to 3 gallons per minute 4 to 11 liters per minute 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 The air trap assembly in the top of the drying hopper prevents ambient air from contaminating the material being dried Keep the material level at the mid point of the air trap for maximum efficiency Use a hopper loader or vacuum conveying system to maintain the proper material level Cabinet Series Dehumidifying Dryer 15 Chapter 4 Controls 4 1 Control Panel Indicator Lights and Switches Rocker Switches System ON OFF Rocker Switch Used to de energize control power to the indicator panel
9. allowing separate control of the dryer and conveying systems Dryer ON Sequence Shutdown Rocker Switch Used 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 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 Indicator Name Description Regen Blower The Regen Blower On indicator lights when the 6 On Light regeneration blower energizes Left Bed In The Left Bed In Regen LED lights when the left bed Z Regen Light is in regeneration Z ss Left Bed Heater The Left Bed Heater indicator lights when the left G Light bed regenerates and is in the heat up portion of the regeneration cycle S Right Bed In The Right Bed In Regen LED lights when the right G J Regen Light bed is in regeneration JE Right Bed Heater The Right Bed Heater indicator lights when the right f G 3 Light bed regenerates and is in the heat up portion of the regeneration cycle Process Blower The Process Blower On indicator lights when the 6 On Light process blower energizes Process Heater The Process Heater On indicator lights when the G y On Light process air heater is energiz
10. BED IN REGEN HIGH REGEN TEMP AUDIBLE ALARM OPTIONAL ALARM STROBE OPTIONAL 222199 Cabinet Series Dehumidifying Dryer 27 4 8 Setting the Shift on Dew Point 4 10 Our dehumidifying 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 controller has a four 4 hour timer override if it does not receive a signal from the dew point control 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 299 To change the dew point setting press the Up Arrow and Down Arrow buttons to the shift point you want Entering Operating Parameters to Select Modes To enter the menu display Press the Display button for one second keep the pressure on the button for about 1 5 to 2 seconds The screen displays Press the Up Arrow button to toggle through the different modes The SV readout displays the mode you selected To switch parameters within a mode press the Display button once more for about one and a half to two 1 5 to 2 seconds The PV readout displays the different parameters within each mod
11. C SC Cooling 0 01 to 99 99 1 00 Default Coefficient Level 1 Dead Band 19 99 to 99 99 FS Default Level 1 6F r Manual Reset 0 0 to 100 0 50 0 Default Level 1 HYS Hysteresis Heat 0 01 to 99 99 FS 0 10 Default Level 1 5 Hysteresis Cool 0 01 to 99 99 FS Default 10 Heat Level 1 Control Period 20 Default Cool Parameter Setting range Factory setting lt Default co DID wi kak Level 0 Default Level 0 Default Level 1 Default Level 1 Default Level 1 AL 1 Alarm Value 1 1999 to 9999 EU 0 25 0 Cabinet Series Dehumidifying Dryer 43 Default Default Default 0 Default Level 1 C SC Cooling 0 01 to 99 99 Coefficient AL 2 Alarm Value 2 1999 to 9999 EU Blo N AR C db Dead Band 19 99 to 99 99 FS 6F r Manual Reset 0 0 to 100 0 50 Value HYS Hysteresis Heat 0 01 to 99 99 FS Default CHYS Hysteresis Cool 0 01 to 99 99 FS Default Heat setting L M Minutes H Hours ojo N ojo 105 0 Level 2 6L L MV Lower Limit 5 0 6 0 0 Default rL MV Change Rate Limit 0 0 to 100 0 SEC CnF Input Digital Filter to 9999 SEC ALH1 Alarm 1 Hysteresis 0 01 to 99 99 ALH2 Alarm 2 Hysteresis 0 01 to 99 99 ALH3 Alarm 3 Hysteresis 0 01 to 99 99 Cn5H Input Shift Upper 199 9 to 999 9 C Limit Cn5L Input Shift Lower 999 9 to 999 9 C Limit Default Fact
12. Install new heater gaskets and securely tighten all fasteners 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 Cabinet Series Dehumidifying Dryer 41 6 7 Replacing the Regeneration Heater The 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 1 2 3 Remove the wiring for the heater being removed or replaced 4 Remove the bolts securing each heater mounting plate Slide out the heater 5 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 heater access cover Changing the Controller Security Level 1 3 To access protect mode press and hold the AT button and the Display button for more than one and a half to two 1 5 to 2 seconds The display should read SECr for security mode If you press the Display button for short presses you will toggle between SECT and KEYP for AT protect With the display reading SECT
13. 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 Press the WRITE key 6 Select Sunday or another shutdown day with the SHIFT 1 and SET keys 2 Press the WRITE key 6 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 Cabinet Series Dehumidifying Dryer 32 Cabinet Series Dehumidifying Dryer Notes 33 Chapter 5 Operation 5 1 e N 90 NON Pre Startup Checks Verify that the drying hopper is clean of rust proh
14. a negative way following an accident The following are some of the ways that accidents can affect your production e Loss of a skilled operator temporarily or permanently e Breakdown of shop morale e Costly damage to equipment e Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operati
15. for two 2 seconds to initiate the auto tune function After the proper pre drying time for the initial hopper fill has elapsed fully open the drying hopper slide gate Note To allow proper residence time during continuous processing maintain the material level in the hopper at the midpoint of the air trap assembly Shutdown Turn off the conveying system supplying the drying hopper When processing is complete close the hopper slide gate and shut down any in line companion equipment 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 Cabinet Series Dehumidifying Dryer 34 twenty minutes to cool down the process The regeneration cycle of the off line bed completes the cycle before the dryer shuts down completely 4 To override the sequence shutdown turn the system ON OFF switch to OFF To completely shut off the unit after sequence shutdown has completed turn the system ON OFF switch to OFF 6 Ifneeded empty the drying hopper 7 For maintenance or a long term shutdown open de energize the electrical disconnects at the dryer and at the power drop Cabinet Series Dehumidifying Dryer 35 Chapter 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 i
16. 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 1 Turn the MODE switch 11 to P1 2 Select the desired start day with the SHIFT 1 and SET keys 2 3 Set the start time with the h and m keys 4 Press the WRITE key 6 to store the dryer startup hour in the timer memory 5 Next cancel the day that was just set by using the RESET key 2 6 Now select the stop day by using the SHIFT 1 and SET key 2 7 Set the stop time with the h and m keys 8 Press the WRITE key 6 9 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 1 Press the CHECK key 5 Each time the key is pressed the operation schedule is displayed in the time sequence 2 If the time switch is left untouched for 20 seconds during check the display automatically returns to RUN mode 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 Cabinet Series Dehumidifying Dryer 31 Hold the COPY key 9 for one 1 second or longer Make sure that the mode selector switch is in RUN mode Select the day s you want with the SHIFT 1 and
17. the controller The 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 factory default settings Available E5CK 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 The dehumidifying dryer uses 5 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 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 dehumidifying dryers Cabinet Series Dehumidifying Dryer 21 4 6 Figure 4 Display Readout for Mode Settings PV i Menu display ul Level 0 mode i sv i Level 1 mode SV A i Level 2 mode SV a e Setup mode sv Expansion mode SV Option mode SV m Calibration mode Setting the Process Air T
18. the right regen bed Right Bed 1 5 When OFF indicates a situation of a temperature High Regen exceeding the set level in the right regen bed Temp Alarm Left Bed 1 6 Compressed Air When ON it indicates loss of compressed air Alarm Input 1 7 High Process When ON sends the information to the PLC to be Temp Alarm 1 8 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 Cabinet Series Dehumidifying Dryer 23 Output LED Indicators Name Description Blower On 0 The Blower On indicator lights when the blower energizes Process Heater The Process Heater Enable activates the process Enable O 2 heater The indicator lights when the process heater is energized This condition occurs when no blower failures or high temperature conditions exist Left Right Regen The Regen Heater Output indicator lights when the Heater Output indicated bed regeneration heater energizes 0 3 4 Right Bed The right Bed Regeneration Output activates the Regeneration right bed regeneration indicator lights when the Output O 5 right bed regenerates When this indicator is off the left bed is energized High Regen When ON indicates a high regen temp condition in Temp Alarm either the left or right bed
19. acement date Date Work done by replacement date Date Work done by eee Photocopy this page for your maintenance records Cabinet Series Dehumidifying Dryer 38 6 3 Servicing the Dew Point Monitor The accuracy of the dew point monitor on dehumidifying dryer systems depends on proper operation of the dew point sensor and the control board The dew point sensor is in the process air stream and is therefore susceptible to contamination Dew point sensor life depends on Air temperature and flow passing over the sensor The amount of fines dust in the process air The amount of plasticizer vapor in the process air 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 6 4 Symptoms of Worn Desiccant The moisture absorption capacity of the desiccant used in your dehumidifying dryer degrades after an indefinite period of time Useful life depends on variables such as material moisture content plasticizer vapors in the return air and number of regeneration cycles Your dehumidifying dryer may need new desiccant if it exhibits any of the following symptoms e Plastic material is not being 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 sho
20. al disconnect with all wiring to a common terminal point PLC microprocessor control of the drying and conveying stations F Digital Dew Point monitor indicates dryer efficiency Sequence shutdown of the dryer 2 5 Options Options can tailor your dehumidifying dryer system to meet the exact requirements of the drying task being performed 13X desiccant Aftercoolers for high and low temperature applications Seven day timer to allow programmable dryer startup Cabinet Series Dehumidifying Dryer 11 Audible visual critical alarm Fusing for blowers and heaters Dirty Filter indicator for each individual blower 2 6 The Closed Loop Drying System Dehumidifying dryers force hot dry air through the resin in the drying hopper where the air picks up moisture from the material and is drawn back to the dryer In the dryer a desiccant bed strips moisture from the air The dryer then re heats dried process air and sends it back into the drying hopper to dry material again This system is a closed loop because ambient outside air is never introduced into the process air See Figure 2 Our dehumidifying dryers use the closed loop system because the process air is typically much drier than ambient air even after carrying moisture out of the plastic resin Recycling process air maintains drying efficiency at a consistently high level Figure 1 Dryer Air Flow Diagram Fro
21. arge dehumidifying dryer The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The General Information section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the large dehumidifying dryer We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the dryer These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Controls and Operations chapters include a description of electrical and mechanical controls in addition to information for operating the dryer safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that the dehumidifying dryer provides excelle
22. ay Pulse width indicator Indicator for number of remaining steps Set circuit number indicator 29 No Function Sets or cancels reset a specified day 6 Setsparameters Write x C 8 Specifies a cyclic operation or sets a pulse width Notused 9 Specifies day substitution operation Copy LT S Circuit 1 programming mode P2 Circuit 2 programming mode Run Run mode LE ON Turns on the output regardless of the program 12 AUTO Executes according to the program 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 Note For timer operation the System Power rocker switch must be in the ON position and the Dryer on Sequence Shutdown rocker 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 pa
23. e Use short presses on the Display button to display each parameter within a mode The SV readout displays the different values for the parameter within a mode Press Up Arrow and Down Arrow buttons to set the higher or lower the values of a parameter Press Display button for about one and a half to two 1 5 to 2 seconds to move up a level back into the different modes Press Down Arrow button until Level 0 displays Press the Display button for about one to one and a half 1 to 1 5 seconds to go to Operating mode 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 Use the following procedure to set the high dew point alarm 1 Press and hold the Display button to access Level 0 The controller displays Level 0 2 Press Up Arrow button to display Level 1 Lu 1 displays 3 Press the Display button to select Level 1 4 Press the Display button until the controller displays AL 1 Cabinet Series Dehumidifying Dryer 28 5 Use the Up and Down Arrow buttons to set the higher or lower value for the high dew point alarm Hold the Display button to save the value and return to Level One 6 Press the Down Arrow button until the controller displays Level 0 7 Press and hold the Display button to return to Operating mode Note The ESCK cont
24. e connect the compressed air supply and electrical power Cabinet Series Dehumidifying Dryer 40 Figure 7 Required Desiccant Amounts per Bed Type 4X Desiccant 2 beds per unit Large bead Type 4X Small bead Type 4X Total per bed CFM 100 9 0 4 086 90 4 086 10 896 wo0000892 00000893 10 896 Type 13X Desiccant Large bead Type 13X Small bead Type 13X Total per bed CFM 90 4086 9 0 4086 6 6 Replacing the Process Heater Our dehumidifying dryers use Calrod type heater elements mounted in a heater tube located in the top rear of the cabinet The wattage of the heater varies with model voltage temperature range etc but the replacement procedure is the same If the process heater is mounted to the hopper contact the manufacturer for the appropriate replacement procedure WARNING Disconnect and lock out power before you replace heater elements Use the following procedure to replace the process heater 1 Remove the bolts securing the process heater access cover 2 Sketch the heater wiring configuration so you can properly re wire the heater 3 Remove the wires to the heater plate assembly being removed or replaced 4 Remove the bolts securing the heater plate assembly and slide out the assembly 5 Remove the heater from the mounting plate by removing the large brass nuts and washers 6 Re install the heater and heater plate assemblies in reverse order
25. ed Low Compressed The Low Compressed Air alarm indicator lights Air Light when the dryer compressed air supply drops below 60 psi 413kPa 4 13 bars Upon loss of Cabinet Series Dehumidifying Dryer 16 Indicator Name Description 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 temperature 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 drop
26. ed 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 turns on Cabinet Series Dehumidifying Dryer 19 4 5 Identifying Temperature Controller Buttons Co Display Button This button shifts the display to the next set of parameters Then the menu screen displays ML Down Arrow Button The Down Arrow button 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 Up Arrow Button The Up Arrow button 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 Button Hold down for two seconds to initiate auto tune Repeat to cancel Figure 3 Typical Dryer Temperature Controller Cabinet Series Dehumidifying Dryer 20 E5CK Operating Parameters The E5CK 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
27. efault 2 nee LBA Detection 6 o to 999 9 FS Default Option Boards Available Option Boards Cabinet Series Dehumidifying Dryer 45 RE232C RS 485 Eventinput Transfer Output Board Number E53 CK01 E53 CK03 E53 CKB E53 CKF Factory Option O Option Eu A Multi SP Function Default STOPIMAN Eu 1 Event Input Assign 1 SbCE Communication Stop Bit 7 BITS 2 Defaut i STOP MAN STOP Default Len Comm Data Length 7 1 2 PrEY Commication Parity 6PS Comm Baud Rate U n6 Comm Unit No 409 10 pefaut Er E Transfer Output Type SP SP M PV O C O Er H Xfer Output Upper Limit Er L Xfer Output Lower Limit Restoring Factory Defaults on the Dew Point Controller Make sure jumper setting for input type is set for Current Input D right jumper Return controller to housing Press the Display button for one 1 second to enter Menu Display Press the Arrow Up button to switch between menus RNS Re 259 a To switch parameters within a menu press Up Arrow button Figure 9 Setting List for Dew Point Controller Part No A0548567 un 0 01 10 99 99 FS M MinutesY ti Hours Factory setting Default Default Default 10 0 F 23 C 10 0 F 23 C Default Default Default Default Default Default Default Default Default Cn5H input shift upper limit olo olo gt olo mi IS olo T O zo Cabinet Series Dehumidifying Dryer 46 Cn5L input shift lo
28. emperature To change the process air temperature set point with the dryer running Press the Up Arrow button to increase the set point to the temperature you want Press the Down Arrow button to lower the set point to the temperature you want Press the Auto tune button to initiate auto tuning 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 Cabinet Series Dehumidifying Dryer 22 PLC LED Indicators The following indicators are located inside the dryer cabinet See Figures 5 6 and 7 Name Description System When ON activates the operation of the dryer Start Sequence portion Shutdown 1 0 Compressed Air When ON confirms that compressed air is present Input 1 1 Process Blower When ON Confirms the operation of the process Enable I 2 blower Bed Switch Set When ON indicates that dewpoint is above bed Point Input 1 4 switching set point High Regen When OFF indicates a situation of a temperature Temp Alarm exceeding the set level in
29. ial in the drying hopper 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 Cabinet Series Dehumidifying Dryer 14 3 5 3 6 3 7 Process Air Connections Between the Dryer and Drying Hopper Remove the cap plugs from the inlet discharge and bleed tubes before operation Use high temperature flexible dryer hose to connect the dryer to the drying hopper Keep the delivery hose as short as possible to minimize heat loss Insulated dryer hose is available for maximum energy savings M Do not shorten the return hose M Make sure the hoses are not kinked Drying hopper air inlet and outlet locations vary from one drying hopper model to another but always connect the hoses so the dry process air from the dryer enters the bottom of the drying hopper and flows out the top to return to the dryer inlet 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
30. ibitive oil or any foreign objects Verify that process and return hose connections are tight 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 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 Verify that all electrical connection are tight and the unit is properly grounded With main power on turn the dryer on until the process blower starts verify blower rotation Important Clean the oil from inside the drying hopper Failure to clean the hopper fouls the desiccant and voids your warranty Startup Turn on energize the disconnect switch in your power drop Turn the system ON OFF switch to ON to energize the display panel Close the slidegate at the bottom of the drying hopper On three phase models make sure that the blowers turn in the right direction Fill the drying hopper with material Turn the DRYER ON SEQUENCE SHUTDOWN switch to ON to start the dryer The process blower will start 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
31. m Ambient drying hopper Regen 7 Process filter v Regen Process air wp filter eater bleed To drying l e hopper Upper valve Desiccant Desiccant 1 beds beds Regen heater Regen heater l 1 Lower valve l d Regen blower Process blower Cabinet Series Dehumidifying Dryer 12 2 7 What is Desiccant Desiccant is a material which attracts and holds absorbs water from the air Our dehumidifying 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 2 8 The Process Regeneration Cycle Our dehumidifying dryers have two desiccant beds While one bed is on line in the process air loop the other is off line being regenerated When a desiccant bed is on line it absorbs moisture from the process air In time the bed becomes saturated with moisture and needs to be regenerated The dryer automatically redirects the process airflow to the second bed and starts the regeneration cycle on the first bed During regeneration the dryer 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 ri
32. mmercial 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 lg 3 mm dia nozzle at least 2 5 cm away from the filter Don t shoot the air in a crisscross motion against the grain of the pleats you may damage it Washing 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 Caution 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 fil
33. n your information packet for replacement part numbers Service Department Call toll free 8am Spm CST 800 423 3183 or call 262 641 8610 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most our products Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contracting Department Call 262 641 8610 Monday Friday 8am 5pm CST Let us install your system The Contracting 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 Technical Specifications Output Amps Process Approx Process temperature 460 3 60 blower Regen Dimensions shipping air flow range name power blower weight cfm cmh in lbs 25 1402 4009 60 204 1 00 0 75 0 25 2 1855 4009 85 204 2 160 400 71 204 160 400 71 204 5 00 3 75 0 33 Aftercooler required above 250 F 121 C operation Q 100 CFM operation below 185 F 85 C requires a precooler Cabinet Series Dehumidifying Dryer 52
34. nel 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 6 Press the h key 3 to adjust the hours Holding the key will rapidly advance the hour 7 Press the m key 4 to adjust the minutes Cabinet Series Dehumidifying Dryer 30 8 9 Press the WRITE key 6 to store the correct time 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 Friday 1 2 oy 8 Set the MODE switch 11 to P1 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 Press the SET key 2 Set the desired start time by pressing the h key 3 to adjust the hour Holding this key will rapidly advance the hour Press the m key 4 to adjust the minutes Press the WRITE key 6 to store the start time in the timer memory Next set the
35. ng your equipment Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor Cabinet Series Dehumidifying Dryer 8 NEVER place your hands or any part of your body in any dangerous location NEVER operate service or adjust the dryer without appropriate training and first reading and understanding this manual NEVER try to pull material out of the dryer with your hands while it is running Before you start the dehumidifying dryer check the following e Remove all tools from the dryer Be sure no objects tools nuts bolts clamps bars are laying in the area If your dryer has been inoperative or unattended check all settings before starting At the beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment B When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting Report the following occurrences IMMEDIATELY e unsafe operation or condition e unusual dryer action e leakage e improper mai
36. nstallation location This may include but is not limited to OSHA NEC CSA and any other local national and international regulations In addition you must observe the following specific work rules Keep these operating instructions on hand and follow them when installing operating or maintaining your dryer If these instructions become damaged or unreadable you can obtain additional copies from the manufacturer Only qualified personnel familiar with this equipment should work on or with this unit Work only with approved tools and devices Disconnect power before servicing your dryer If the disconnect switch you installed has a 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 program Our dehumidifying dryers 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 protect the blowers from plastic fines drawn in from the drying hopper Regular filter cleaning is essential to keep your dryer operating at peak efficiency You can wash or blow out the filters but remember you reduce di
37. nt long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Cabinet Series Dehumidifying Dryer 6 Dryer Safety Tags Tag Description Tag Description 2 High Voltage Inside Enclosure Manual Hot Lifting Point Protected Earth Earth Ground Ground 1 2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation
38. ntenance e NEVER stand or sit where you could slip or stumble into the dehumidifying dryer while working on it B DO NOT wear loose clothing or jewelry which can be caught while working on the dryer In addition cover or tie back long hair Clean the dehumidifying dryer and surrounding area DAILY and inspect the machine for loose missing or broken parts Shut off power to the dryer when it is not in use Turn the switch to the OFF position or unplug it from the power source Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical and pneumatic power Attach warning tags to the disconnect switch and air shutoff valve When you need to perform maintenance or repair work on a dehumidifying dryer above floor level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk on your dryer use it The work platform should have secure footing and a place for tools and parts DO NOT climb on the dehumidifying dryer machines or work from ladders Cabinet Series Dehumidifying Dryer 9 If you need to repair a large component use appropriate handling equipment Before you use handling equipment por
39. ory setting Cn E Input Type O to 21 Scaling Upper scaling Lower Limit 1 to 9999 EU Default on E Gallo ower 1999 to SP Setting Upper Limit 0 1 EU Default Limit P Decimal Point Default Setup d U C F Selection Default CnCE Parameter ojo olojo NIN ge OBRIR Cabinet Series Dehumidifying Dryer 44 Initialize 6 i Setup 2 1 Z 1 Alarm 2 Alarm 3 Heat Default Output 2 T EL 1 Alarm 2 Alarm 3 Default men e Alarm 1 Alm 2 Alm 3 LBA S ERR E333 AL 1 Default ALE1 Alarm 1 01011 Default REI Mam 1 open Default ALE2 Alarm 2 Type 01011 Default ec ec 2 open No NC N Default 2 Setup ALES Alarm Type 001 12 Defaut 6rEu Direct Reverse oR R OR D Default Operation Factory Parameter Setting range setting SL H Set Point Upper SP Lower Limit 1 to Scaling Upper 1300 400 0 Limit Limit nes Scaling Upper Limit to SP Lower Limi 200 0 CnEL PID ON OFF PID ON OFF Default Expansion SERT Adapivestuning OFF ON OFF Default Fuzzy 2 i a open in NO NC Default SE b ST Stable Range 0 1 to 999 9 C F Default ALFA a 01 to 1 00 Default 0 5 i ee Calculated o 4 i5 10 0 Default ain rESE Standby Sequence Reset 0 1 Setting Method rEE Automatic Return P De Hee 59 SEC E Default AE H AT Hysteresis _ 0 1 to 9 9 FS D
40. ou remove all tools test equipment etc and the equipment and related components are fully reassembled M Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment Cabinet Series Dehumidifying Dryer 7 We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machines should become familiar with their operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No matter who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in
41. roller 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 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 LLL ANE L sET RESET PM h 15 Output indicator j lt B 1 m QuT Hr PROG 5 CHECK key 1 OUT 2 CHECK WRITE 1 12 OUT switch TIME AD P2 TIMER 12 MAN CYCLE PULSE COPY CLR MODE BOOT PULSE 12 AUTO 13 TIMER PULSE switch 1 SHIFT key 2 SET RESET key 3 h key 4 m key 6 WRITE key 11 MODE switch 7 TIME ADJ key 10 CLR key 9 COPY key 8 CYCLE PULSE key 14 MAN AUTO RESET switch Display SUN MON TUE WED THU FRI SAT Time adjustment 127 T m mode indicator E 0 0 Power failure indicator v 1 4403 0000 a d DT 147 Output circuit indicator N Timing chart display Cabinet Series Dehumidifying Dryer Cursor Day indicator Main displ
42. rt holding capacity with each washing The risk of dirt reaching the clean side of the filter during cleaning plus possible filter damage from high pressure washing or blowing makes washing a gamble You can carefully clean or wash the filter when airflow becomes restricted Do not wash filters more than six 6 times or use them for more than a year whichever comes first Use a detergent that won t damage filter media Such a detergent permits easy removal of dirt particles through flushing and rinsing An effective detergent removes the fine particles from the pores of the filter media The filter manufacturer recommends FM 1400 washing compound It is formulated 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 Cabinet Series Dehumidifying Dryer 36 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 and 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 co
43. rtly 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 manufacturer s parts department If you want a service 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 Cabinet Series Dehumidifying Dryer 39 First Aid In case of eye contact immediately flush eyes with plenty of water for at least 15 minutes If irritation persists see a physician 6 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 desiccant 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 Vacuum out the desiccant
44. ryer Notes 48 Chapter 7 Troubleshooting Desiccant beds are contaminated by material or plasticizer leaking into the Replace desiccant Little or no air coming from system overload contaminants clean baffles replace Stop the dryer If the dryer was connected to the drying hopper check to see if the desiccant and process air heater has been contaminated with resin Suction in delivery tube pressure from the return tube Phase is reversed on power drop coming 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 Check for open heaters Replace if required opes 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 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 Inspect for air leaks replace Break in flex hose to from if necessary drying hopper Cabinet Series Dehumidifying Dryer 49 Material being dried differs from material specified at the time of purchase Loss or reduc
45. s 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 Repair or replace Cabinet Series Dehumidifying Dryer 50 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 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 switch and control power Control Power fuse blown switch ON Input polarity on thermo couple is wrong or Properly wire the terminals connection is wrong No compensating lead wires Use proper compensating di E MU lead wires and terminals thermocouple 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 Replace with a good sensor circuited Separate input wires as far as possible from the origin of
46. s below the thermostat setpoint The heaters re energize automatically High Dew Point Light Material Loading Light The High Dew Point alarm indicator lights when the process air delivery dew point exceeds a dew point of 10 F 23 C 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 Cabinet Series Dehumidifying Dryer 17 Figure 2 Typical Dyer Interface Panel DEW POINT 20 g EMA REGENERATION BLOWER ON 9 LEFT BED IN REGEN NO LEFT REGEN HEATER ON RIGHT BED IN REGEN NOW RIGHT REGEN OFF HEATER ON SYSTEM Cabinet Series Dehumidifying Dryer PROCESS TEMPERATURE PROCESS BLOWER ON PROCESS HEATER ON SEQUENCE SHUTDOWN COMPRESSED AIR HIGH TEMP PROCESS AIR HIGH TEMP REGEN AIR HIGH DEW POINT PROCESS BLOWER DIRTY FILTER DRYING HOPPER LOW LEVEL LH PUSH TO SILENCE 18 4 2 4 3 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 poin
47. se 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 2 9 Specifying 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 the manufacturer can advise you on necessary equipment and process time and temperature modifications required for your system Cabinet Series Dehumidifying Dryer 13 Chapter 3 Installation 3 1 3 2 3 3 3 4 Positioning Your Dryer The dehumidifying dryer system was designed to be wheeled into place The entire assembly is mounted on a rugged compact frame and is equipped with sturdy 4 10 cm heavy duty casters two locking and two swivel Caution Use caution and observe safety rules when placing your dryer Making Electrical Connections Fulfill all national state and local safety and electrical code requirements Connections
48. 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 eae 6 0 12 3 4 5 6 Calibration X Option Expansion Any mode marked with an X is displayed in the Security Level indicated To return to the main display run mode press and hold the AT and display key for 1 5 to 2 seconds Restoring Factory Defaults on the Process Temperature Controller 1 Remove controller from housing and check for output board number E53 QR4R Pulse NPN Relay Cabinet Series Dehumidifying Dryer 42 Make sure jumper setting for input type is set for thermocouple TC PT middle jumper Return controller to housing Press the Display button for one 1 second to enter Menu Display Press the Up Arrow button to get to Setup mode Qv cin ode 095 To switch parameters within Setup mode press the Display button Figure 8 Setting List for Process Temperature Controller Part No A0548565 setting Protect YEYP A M Key Protect ON OFF Manual Manual MV 5 0 to 105 096 Default Level 0 Default Level 0 Default Level 1 Default Level 1 Default Level 1 Level 1 Level 1 Default Level 1 10 0 Level 1 Integral Time Level 1 Level 1
49. should be made by a qualified electrician Make sure all electrical connections are tight E NIE Connect main power to the dryer at the disconnect or terminals in the upper right corner of the control enclosure Install a fused disconnect with a lockout feature in the power main leading to the dryer The power drop must include a ground wire WARNING Proper grounding of the main power line is critical Connecting Compressed Air Connect compressed air to the dryer before operation Caution Excessive air pressure damages the neoprene components of the air distribution valve Connect the air supply using a 4 NPT fitting to a clean dry lightly lubricated source of 80 psi 551 5 51 bars compressed air A pressure gauge and regulator are recommended components of your plant air supply 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 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 mater
50. t 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 Process Air Temperature Controller Our dehumidifying 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 Identifying Temperature Controller LED Indicators LED Description Indicator Process Value During normal operation the process value PV Numerical numeric LED indicator displays the process LED temperature at the To Process thermocouple It also lists parameters during setup and error messages if any errors occur Set Value During normal operation the set value SV Numeric LED 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 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 us
51. table A frames electric boom trucks fork trucks overhead cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable Carefully test the condition of lifting cables chains ropes slings and hooks before using them to lift a load Be sure that all non current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you have completed the repair or maintenance procedure check your work and remove your tools rigging and handling equipment Do not restore power to the dehumidifying dryer until all persons are clear of the area DO NOT start and run the dryer until you are sure all parts are functioning correctly BEFORE you turn the dehumidifying dryer over to the operator for production verify all enclosure panels guards and safety devices are in place and functioning properly Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment Cabinet Series Dehumidifying Dryer 10 Chapter 2 General Information 2 1 2 3 Models Covered This manual provides instr
52. ter toward a bright light Check for damaged gaskets or dented metal parts Do not re use a damaged filter e Inspect the end plates Any damage here can allow air to bypass the filter e Look for rust on the end plates and metal core Rust particles can flake off and contaminate the dryer and resin e Check the gasket for damage A damaged gasket allows contaminants into the process Replace as needed 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 Cabinet Series Dehumidifying Dryer 37 Preventative Maintenance Checklist Dehumidifying Dryer 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 point monitor and pyrometer Visually inspect the shifting of the airflow valve during one cycle inspection Date By inspection Date By if brown or broken Scheduled Actual replacement Scheduled Actual replacement Every two years repl
53. the noise Celsius 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 other Process value is abnormal or than proper lead wires not obtained The controller is influenced by noise or other induction 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 Cabinet Series Dehumidifying Dryer 51 CHAPTER 8 APPENDIX 8 1 Contact Information Parts Department Call toll free 7am Spm CST 800 423 3183 or call 262 641 8610 Fax 262 641 8653 The Parts Department is ready to provide the parts to keep your systems up and running DEM replacement parts ensure operation at design specifications Please have the model and serial number of your equipment when you call Consult the Customer Parts List included i
54. tion in drying capacity Problem Possible cause Corrective action ER Check for proper operation of valve actuators Repair or Loss or reduction in drying replace if necessary capacity Cont d m Remove blower side plate clean baffles replace Replace filter elements PLC Regeneration Bed LED Power LED is off power wiring to PLC indicators both off Faulty PLC PLC Power light is on Run light is off and or Replace PLC Error light is on 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 heater Contaminated or worn out Replace desiccant Poor dew point performance Leaking process air hoses Repair or replace Dryer operates beyond it
55. uctions for installing and operating 90 100 150 and 225 CFM cabinet style dehumidifying dryers Equipment Function Our 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 Our dehumidifying dryers are used to generate very low dew point air heated to a controlled temperature for drying plastic pellets and regrind Necessary Documents The documents listed below are necessary for the operation installation and maintenance of Cabinet Series dehumidifying dryers You can obtain additional copies from the manufacturer 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 NARA Operation and installation manuals for any optional controls or auxiliary equipment in the drying system Standard Features Rugged compact frame with handle and sturdy 4 10 cm casters Dual blower dryer with dual desiccant beds 4 way compressed air operated valves Up to 400 F 204 C drying temperature range Cartridge type two stage air filters for all blowers Integral Control Center for dryer options Electric
56. wer limit 999 9 to 999 9 C 0 0 Default Cn t Input Type 0 to 21 Scaling Lower Limit 1 to Setup Scaling Upper Limit 9999 EU 1999 to SP Setting Upper Setup Cn L Scaling Lower Limit Limit 0 1 EU Factory setting 17 100 15 9 N 40 F 40C Default Default Heat COOL 6Ut2 Control Output 2 Heat Cool Alarm 1 Alarm 2 Sub 1 Auxiliary Output 1 Alarm 1 Alm 2 Alm 3 LBA S dP Decimal Point 0 to 3 ALt1 Alarm 1 Type 0 to 11 CnCE Parameter Initialize Yes No Setu 6Ut1 Control Output 1 Heat Cool Alarm 1 Alarm 2 p Assignment Alarm 3 LBA AL1n Alarm 1 open in alarm NO NC ALt2 Alarm 2 Type 01011 AL2n Alarm 2 open alarm NO NC 6rEU Direct Reverse SL H Set Point Upper Limit Scaling Upper Limit _ Scaling Upper Limit to Sp SL L Set Point Lower Limit ower Limit PIDION OFF CntL PID ON OFF PID ON OFF Expansion rESt Standby Sequence 0 1 Reset Setting Method rEt Automatic Return of Display Mode 6 8 Restoring the 5 Temperature Controller and Dew Point Meter to Factory Setup Default Default Default SP Lower Limit 1 to 1300 15 F 9C 200 40 F 40C ON OFF Default Default z z 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 Cabinet Series Dehumidifying Dryer 47 Cabinet Series Dehumidifying D
57. when installed and operated within design specifications following national and local safety codes This may include but is not limited to OSHA NEC CSA SPI and any other local national and international regulations To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment S RRAK ISl Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power M When welding or brazing in or around this equipment make sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be nearby and ready for use if needed Do not restore power until y

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