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Sterling SDAA 25-100 Dehumidifier User Manual

1. Dimension E RN B 325 D Po 2375 60 2375 6o 233 71 Dehumidifying Dryers Chapter 3 Installation 17 of 59 Figure 1 Suggested Lift Rigging for Cart Mounted Dryers AU DO NOT Le USE o o Caution Do not use a hoist to move or rig your Dryer when it is mounted on a cart Moving the Dryer with a hoist will cause it to become unstable and may cause damage to the Dryer and or injury to personnel Recommended Dryer Lifting Hardware Vendor Vendor part no McMaster Carr S cMaster Carr cMaster Carr Figure 2 Suggested Lift Rigging for Floor Mounted Dryers USE Overhead V Crane ye VA ied nj ST HT a Note Floor Mounted Dryers can be lifted by hoist or fork lift Dehumidifying Dryers Chapter 3 Installation 18 of 59 Figure 3 Suggested Lift Rigging for Machine Mounted Dryers Caution When using a hoist to move a machine mounted dryer ALWAYS attach chains to the three 3 locations lifting points on the unit Moving the Dryer without the chains attached to all of the lifting points will cause the unit to become unstable and may cause damage to the Dryer and or injury to personnel 3 3 Electrical Connections When making electrical connections to your dryer
2. 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 Dehumidifying Dryers Chapter 1 Safety v of 59 1 2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes This may include but is not limited to OSHA NEC CSA SPI and any other local national and international regulations To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good
3. 2 1 Models Covered in This Manual 11 2 2 General Descnpion eee 11 Whats desiCcaht adeo a d d ertet aea quide Ene du 12 The Process Regeneration Cycle essei cese enatis aane exa anne 12 2 3 Standard Features detecte i Rd ke ire e ed bo Rt vta ra Tees 12 Mechanical Features E nnns 12 Electrical Features sese 12 Controller Feat lres ciis es epe i a den ute e ee pau gea 13 224 ODpIIOFIS sienta eer e e Fa equa ders gana Rao ax ER lant ee dendo un es cda dh 13 2 5 Safety Devices and Interlocks tie ace eee terere eese tes id ea bore taunts 13 CHAPTER 3 INSTALLATION cina iaa vpn eti eenn 15 3 1 Uncrating the Equipment cccccccccceeccceecceeeeeeeeaeeeeeeeaeeeaeseaaeeaaeeaaeeaaneaaeeaaeeaaeneas 15 3 2 Rigging and Placing the Dryer etr teorico eene te to Ae 15 Recommended Dryer Lifting Hardware eee ne 18 3 3 Electrical COMMECTIONS 2 ccccccccccceccceeecee eens eens ceeeceeaeeeaesaaecaaeeeaaeeaaeaaaneaaeeaaaeaaanaes 19 3 4 Setup Procedures sss 20 Checking for Proper Blower Rotation ient ka denda 20 Making Dryer Drying Hopper Process Air Connections ssssssusus 20 Drying Hopper Air Trap Considerations esses enne 21 Optional AN eO OO OT a r e r ea enne nnne nnne nnn nnn nnn nnn e Aea Aaa 21 3 5 Initial Start ups E E E rete ree eee etetktawwe gave 22 Pre Startup Check
4. Chapter 4 Operation 29 of 59 Entering Operating Parameters to Select Modes To enter the display 1 Press the Mode Display key to view the Run Stop amp Alarm Modes PAS ML 2 Press abus and FOE that function On or Off to set the higher or lower the values of the parameter or turn The SV readout displays the different values for the parameter within a mode 3 To switch modes within a level press and hold the Level Display key for one 1 second The PV readout will display the different parameters within each mode 4 Use short presses on the Co Mode Display key to display each parameter within a mode The SV readout displays the different values for the parameter within a mode Mos COND 5 Press Vp and rad that function On or Off 6 Press Level Key once to return to the Process Temperature Setting to set the higher or lower the values of a parameter or turn Figure 6 Settings for Process Temperature Controller ESCN Part No A0555757 Mode Parameter Settingrange Default Manuf setting Run Stop Run Stop Run Mode Parameter Settingrange Default Manuf setting AT execute cancel ON OFF Adjustment Proportional Band 0 1 to 999 9 8 0 7 Integral Time 233 Derivative Time 0 to 3999 40 7 Dehumidifying Dryers Chapter 4 Operation 30 of 59 Pro
5. High temperature alarm not set Reset high temperature alarm Material in drying hopper cakes properly or meltdown occurs Process set point is out of Restore temperature controller acceptable range to factory pre sets Function set for degrees Celsius C set point at degrees Fahrenheit F Verify correct Celsius or Fahrenheit settings Verify that the thermocouple is properly installed in the inlet tube Contaminated or worn out desiccant Leaking process air hoses Repair or replace Poor dew point performance Dryer operates beyond its Check dryer and drying hopper capacity sizing Bad dew point sensor Replace Fouled dew point sensor Clear obstruction Air should manifold flow freely through sensor 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 the VAC to the power supply specified range terminals of the controller Check control power fuse for continuity Turn disconnect switch and control power switch ON Process thermocouple not in airflow Replace 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 b
6. Optional Components teu uiis tut Ete tage HER etudes e tg ERN 53 7 3 Technical Specifications sre ee ana a e E d a E 54 LIST e IelrelerTa S 54 Aftercooler Design Specifications eessssssssssssesseees ene 55 Tob Drawings and DIGSralris ias roit rut deis ei t etr isles scare Debet E Rise Db einigen 55 T Spare Parts B tete teen fest bot tet Mete PS En ete Letto Dri fd 55 7 6 Returned Material P OMGy css scat exosen cates Lacer ordre be Debo at e eet 57 Gredm RetUmMS o dabit ise estesa Rr colis uai Ie Due ve Pest e Ld IM ROS 57 Warranty ROlUITis oou cuo o tM dct oe avete ith cuius dale de diee 57 7 Safety Tag BT elan i NET m 57 Dryer Safety Tags ui eee ee ote age cene ead te oA o gue 57 7 8 Dryer Identification Serial Number Tag eee 58 7 9 Technical Assistance ode ed epe oe pere od deos e be dede ey dto iue eode 59 Parts Department s 2 a 9732 aaa Aa aaa aAa eade Eni aa HLR 59 Dehumidifying Dryers iii Service Department eee eee Sales Department Contract Department e e de ee ns a e Y ade eda EEA Dehumidifying Dryers iv Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your dehumidifying dryer The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance
7. SDAA 25 100 15 60 cfm Dehumidifying Dryers Part Number 882 00290 00 Bulletin Number DH1 640 Effective 12 06 05 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2005 All rights reserved Shipping Information Unpacking and Inspection You should inspect your dryer for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for
8. Mode AL 1 the process temperature will be allowed to exceed the set point temperature An alarm output will de energize the heaters Dehumidifying Dryers Chapter 4 Operation 28 of 59 Adjustment Level Indicator Name Description nt Auto Tune Mode At See Page 19 of Chapter 3 for instructions on how to Auto Tune your dryer Note Although the controller is calibrated at the factory the manufacturer recommends that the unit be Auto Tuned prior to dryer startup Temperature Input This setting is used to offset an error between the L n 5 Shift Mode TnS set point and the actual temperature The entire input range is shifted by a set figure preprogrammed by the operator Proportional Band This setting controls the amount in which the Mode P manipulated variable MV is proportionate to the deviated value or controller error Integral Time Setting this feature gives the control an action that Mode 1 is proportionate to the time integral of the control error By using this setting proportional action is used in combination with integral action to offset the control error and the set point will begin to match the control temperature PV or process value E LEE Derivative Time Mode d Setting the derivative control provides the controller with the ability to correct for a future error in the previously set process output Dehumidifying Dryers
9. Re install the heater and heater plate assemblies in reverse order Install new heater gaskets and securely tighten all fasteners Caution Heater loops should not touch each other Hot spots lead to premature heater failure 7 Reinstall the wires based on the sketch you made earlier Dehumidifying Dryers Chapter 5 Maintenance 47 of 59 Chapter 6 Troubleshooting 6 1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshooting is indicated Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to provide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destroy the new
10. SYSTEM NORMAL Dehumidifying Dryers Chapter 4 Operation 35 of 59 11 When a dew point fault is generated by the optional dew point controller the alarm light will activate The alarm light will flash indicating a non critical fault Press Alarm Reset to deactivate the alarm until the next dew point fault occurs 12 The top 2 lines of the display show the HEAT and COOL times in minutes for the regeneration sequence Changes to these times can be made by the operator as follows a Press the up or down arrow until the cursor is positioned at the number to be changed b Press the key to increment the number or the key to decrement the number c Press the OK key to accept the value and write to the relay memory OR d Press the ESC key to cancel the changes Note A change will NOT take effect until step 12 c is done 13 The dryer is shut off by turning the control power switch to the OFF position 14 Refer to Schematic drawing A0566087 enclosed in the control enclosure Dehumidifying Dryers Chapter 4 Operation 36 of 59 Controller Operation With Optional Alarm Horn amp Reset Button 1 Turn the disconnect on the control panel to the ON position Power is applied to the voltage line fuses line side of the control power switch and the temperature controller 2 Turn the control power switch to the ON position Power is applied to the programmable relay and dew point controller The valve
11. and outlet locations vary but always connect hoses so the dry process air from the dryer enters the bottom of the drying hopper and flows out the top to return to the dryer inlet Dehumidifying Dryers Chapter 3 Installation 20 of 59 Drying Hopper Air Trap Considerations Our exclusive air trap assembly on the top of the drying hopper prevents ambient air from contaminating the material being dried To ensure that your unit will operate at peak efficiency do the following e Keep the material level at the mid point of the air trap e This can be achieved by utilizing a hopper loader or vacuum conveying system to supply material to the drying system Figure 1 Drying Hopper Air Trap Flapper Valve of the loader e Return air from the drying hopper Air Trap Suggested material level for the optimum efficiency Insulation Delivery low dew point heated air to the drying hopper TAF Recommended process temperature control thermocouple location Optional Aftercooler Water cooled 15 30 60 cfm models use a water to air heat exchanger as an aftercooler Cooling water is required for this design 3 gpm at 85 F or lower Return air from the hopper passes through the air filter to trap fines and dust before entering the heat exchanger Installing Water Lines Hose and Hose Clamp When installing the water lines ensure that the aftercooler utilizes either tower chi
12. component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necessary refer to the parts catalog section Dirty filter Clean or replace filter Desiccant beds are contaminated by material or plasticizer leaking Little or no air coming from into the 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 If so replace the desiccant and remove any resin carry over Otherwise change the phase of two legs of the three phase power drop Replace desiccant See Page 42 for more information Suction in delivery tube Phase is reversed on power drop pressure from the return tube coming into the dryer Dehumidifying Dryers Chapter 6 Troubleshooting 48 of 59 Process heaters are faulty rds ud Open Bieatersaleplaeg if required Solid state temperature controller faulty Replace Loss or reduction of process air Make sure that plant personnel Process temperature was are aware of the proper adjusted in error by plant temperature set point Post an personnel appropriate sign next to the controller Process heaters are faulty Desiccant beds are Replace desiccant contaminated Drying systems are designed for the material which was originally specified Different materials may n
13. have the following operational features e The bed in process at power down will remain in process e The bed in regeneration at power down will remain in regeneration e The regeneration timing cycle will restart from the beginning Dehumidifying Dryers Chapter 4 Operation 34 of 59 3 Once the control power is on and no fault conditions exist turning the OFF ON START switch to the START position will start the dryer as follows The process heater is turned on and controlled by the E5CN controller b The process regen blower is started c The regen heater is turned on and the regeneration timing sequence is initiated The regen heater is controlled by the E5C2 controller For default timing settings for regeneration see the table below Model Heating Cooling 15 cfm 30 cfm 99 2 60 cfm 35 30 Note In a humid environment you may change the setting to 40 25 for better results 4 Ifeither the left or right bed safety temperature switch opens a regen heater fault is generated HIGH TEMP is displayed on the relay screen The alarm light is activated The process heater regen heater and process regen blower are turned off Turn the Off On Start switch to the START position to deactivate the alarm light and restart the dryer If the switch is still open the dryer will not restart 5 Ifthe OMRON controller faults the optional redundant high temperature safety device opens or the process he
14. inspection Inspect desiccant Replace if brown or broken Scheduled Actual replacement Scheduled Actual replacement Every two years replacement date Date Work done by replacement date Date Work done by Photocopy this page for your maintenance records Dehumidifying Dryers Chapter 5 Maintenance 4 of 59 5 2 Preventative Maintenance This section describes maintenance procedures which will increase the longevity and efficiency of your dehumidifying dryer Perform them at the regular intervals listed on the dryer checklist on the previous page Servicing Process Air Filters Caution Operating the dryer without the process air filter installed voids your warranty Filter cleaning is an important part of your dryer maintenance program Dehumidifying dryers have a single cartridge canister type filter in the process air loop The filter protects blowers from plastic fines drawn in from the drying hopper and prevents the desiccant from being contaminated Regular filter cleaning is essential to keep your dryer operating at peak efficiency You can blow or vacuum the dirt out of the filter with compressed air but remember it could become damaged from high pressure blowing Recommendations for Cleaning and Replacing Filters e Turn off and or lock out electrical power to the dryer e Remove the threaded fastener securing the filter access cover then remove the cover e Remove the nut on the center retaining rod to remove the filte
15. judgment and follow these safe practices i A R S R S K m Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power Use EXTEREME CAUTION when working with dryer HIGH HEAT can be dangerous Keep body parts tools clothing and debris away from dryer When welding or brazing in or around this equipment make sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We ha
16. regen blower are turned off Pressing the ALARM RESET pushbutton will deactivate the alarm horn and light Reset the motor overload and turn the Off On Start switch to the START position to restart the dryer 7 The valve position limit switch enables the right bed heater and provides an input signal to the programmable relay when actuated by the cam lobe Each heater is ON OFF controlled by the OMRON ES5C2 controller 8 Upon completion of the HEAT portion of the regeneration sequence the regen heaters are disabled by the programmable relay and the COOL time begins 9 Once the COOL time has expired the valve motor is turned on until the cam switch makes a transition Upon making a transition the timing sequence is restarted for the new bed 10 When no fault conditions exist the display reads SYSTEM NORMAL 11 When a dew point fault is generated by the optional dew point controller the alarm horn and light will activate The alarm light will flash indicating a non critical fault Press Alarm Reset to deactivate the alarm until the next dew point fault occurs 12 The top 2 lines of the display show the HEAT and COOL times in minutes for the regeneration sequence Changes to these times can be made by the operator as follows a Press the up or down arrow until the cursor is positioned at the number to be changed KK Ke b Press the key to increment the number or the number key to decrement the c Pr
17. such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue For example if a safety switch is guarding a motor and the safety switch fails the motor should not be able to run Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used on these dryers are primarily concerned with electrical power disconnection and the disabling of moving parts that may need to be accessed during the normal operation of the machine Some of the safety devices utilize a manual activator This is the method of initiating the safety lock out This may be in the form of a plug lever or a handle Within this lockable handle there may be a location for a padlock Personnel servicing the equipment should place a padlock in the lockout handle In addition to the safety devices listed above these dryers are equipped with a line cord plug This allows the operator or maintenance personnel to unplug the dryer from its power source and tag it out The plug can then be tagged with any number of approved electrical lockout tags available at most electrical supply stores WARNING Always disconnect and lockout all electrical po
18. the bed that is on regeneration forcing moisture from the desiccant before exhausting To compensate for the humidity content in the air this dryer is supplied with the proper amount of desiccant What is desiccant Desiccant 1s a material that attracts and holds absorbs water from the air The desiccant our dryers use is a synthetic crystalline metal aluminosilicate blended with a clay binder and formed into beads The Process Regeneration Cycle Our dryers have two desiccant beds While one bed is on line in the process air loop the other is off line being regenerated When a desiccant bed is on line it absorbs moisture from the process air In time the bed becomes saturated with moisture and needs to be regenerated The dryer automatically redirects the process airflow to the second bed and starts the regeneration cycle on the first bed During regeneration the dryer system heats air and forces it through the desiccant bed The moisture driven off the bed bleeds to the atmosphere 2 3 Standard Features Mechanical Features e Dual desiccant beds e Electrically actuated air valve e 13X Molecular Sieve e Single regenerative process blower e Drying temperature range of 180 F to 250 F 71 C to 121 C e 2 5 hose connections Electrical Features e Process thermocouple to be connected to drying hopper air inlet e Nema 12 control enclosure Dehumidifying Dryers Chapter 2 Functional Description 12 of 59 e N
19. the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty Warranty Restrictions This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the Company s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the Company s express authorization Ifthe serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned immediately without any further use or handling Dehumidifying Dryers Chapter 7 Appendix 52 of 59 Warranty Liabilities THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT RESULT FROM THE USE OF THIS PRODUCT Some states do not allow the exclusion or limitation of special consequential or incidental damages so the above limitation may not apply to you The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not
20. will move to the start position as follows The valve motor rotates until the cam switch makes 2 transitions b Ifthe cam switch does not make a transition within 10 seconds a valve motor fault is generated VALVE MTR is displayed on the relay screen the alarm horn and light are activated The valve motor heaters and blower shut off Pressing the ALARM RESET pushbutton will deactivate the alarm horn and light Cycle control power to restart the dryer Note The relay screen which contains the Alarm Display Messages is located inside the controller enclosure For a list of Alarm Display Messages see Page 35 WARNING Do not attempt to check the Alarms on the Controller located within the unit enclosure unless you are a qualified electrician c The valve will normally complete one full cycle revolution If the drying process shuts down due to an alarm the dryer has been setup to have the following operational features e The bed in process at power down will remain in process e The bed in regeneration at power down will remain in regeneration e The regeneration timing cycle will restart from the beginning 3 Once the control power is on and no fault conditions exist turning the Off On Start switch to the START position will start the dryer as follows The process heater is turned on and controlled by the ESCN controller b The process regen blower is started c The regen heater is turned on and the regeneratio
21. FPA79 machinery electrical standards e Non fused electrical disconnect e Branch fusing e Mercury process heater contactor e Regeneration temperature control e Process high temperature alarm light e Process regeneration heater box e High temperature safety system Process Regeneration e Dew point monitor with digital read out Controller Features e Mitsubishi programmable relay controller e Display of process temperature set point and actual settings 2 4 Options Options marked with indicate options that can be factory installed or retrofitted in the field Process temperature 180 F to 400 F including aftercooler inside dryer and silicone insulated delivery hose Process temperature 120 F to 250 F includes precooler on back of dryer Jf the dryer is a central dry air generator it will not have a process heater box Plasticizer trap with cooling coil in lieu of optional aftercooler mounts outside on back of dryer Machine mount adapter to accommodate a dryer and corresponding hopper Drawer magnet stainless steel construction Casters two 2 fixed and two 2 swivel Cart with caster with hopper mounting place Redundant high temp safety control Audible alarm Insulated air hose for air delivery 2 5 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the Dryer This manual is not intended to supersede or alt
22. No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the dehumidifying dryer We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the dehumidifying dryer These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the dryer safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your dehumidifying dryer provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions
23. Page parameters accesible 3 Full Lockout Limit 1 High Set Dehumidifying Dryers Chapter 4 Operation 33 of 59 4 3 Dryer Operation Procedures Controller Operation Without Optional Alarm Horn amp Reset Button 1 Turn the disconnect on the control panel to the ON position Power is applied to the voltage line fuses line side of the control power switch and the temperature controller 2 Turn the control power switch to the ON position Power is applied to the programmable relay and dew point controller The valve will move to the start position as follows The valve motor rotates until the cam switch makes 2 transitions b Ifthe cam switch does not make a transition within 10 seconds a valve motor fault is generated VALVE MTR is displayed on the relay screen the alarm light is activated The valve motor heaters and blower shut off To restart the dryer cycle control power to deactivate the alarm light and restart the valve motor sequence Note The relay screen which contains the Alarm Display Messages is located inside the controller enclosure For a list of Alarm Display Messages see Page 35 WARNING Do not attempt to check the Alarms on the Controller located within the unit enclosure unless you are a qualified electrician c The valve will normally complete one full cycle revolution If the drying process shuts down due to an alarm the dryer has been setup to
24. Sj Sj el el ei elel eleal eal HHM l oj o aj a oO v oj G G GO xr I I I I I I T Q Q Q Q Q Q Q Q e e e e e e e e N N N N IIN N N N I I I rla c I I I o o o ojl l o o o 10 1 Ww 10 Ww 10 gt gt gt gt gt gt gt gt gt e e LO Sl O io e e N e GI oo N e N st lO N N LO N st 208V 3PH 230V 3PH 460V 3PH 208V 3PH 460V 3PH 208V 3PH 230V 3PH 460V 3PH 575V 60 HZ 3PH 60CFM i ah bl eal 1 apapa T Po 0 0 0 LI Lili 2 Jp ol Lo a ee po LI LlLld tb o TT i le EE Jen 56 of 59 7 6 Returned Material Policy Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from the manufacturer returned is subject to 15 75 00 minimum restocking charge ALL returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shi
25. alues during configuration setup OUT1 Out 1 LED Lit when Control Output 1 is on The Our indicator lights when the controller signals the process heaters to be energized OUT2 Out 2 LED Lit when Control Output 2 is on Not used in this application AT AT LED Flashes during auto tuning in process value PV screen Dehumidifying Dryers Chapter 4 Operation 26 of 59 Indicator Name Description ALARMI ALARM 1 LED Lights in the Operation Indicator Section when the output function assigned to auxiliary output turns on The ALARMI indicator lights when the process temperature exceeds the set point temperature by more than the alarm deviation value Alarm output de energizes the heaters Heaters re energize when the temperature falls within the acceptable range Identifying Temperature Controller Keys Indicator Name Description CO Mode Key Press the Mode key to shift the display to the next set of parameters The menu screen displays EA Down Key Press the Down arrow key to lower the process air set point temperature During setup it lets you decrease the value of the parameter displayed on the set point LED readout Up Key Press the Up arrow key to raise the process air set point temperature During setup it lets you increase the value of the parameter displayed on the set point LED readout Setting the Process Air Te
26. and down during that period After the flashing stops it means auto tuning has finished 4 5 ur Down the Dryer Turn off the conveying system supplying the drying hopper 2 When processing is complete close the hopper slide gate and shut down any in line companion equipment such as the aftercooler Turn the Dryer ON OFF selector switch to OFF Turn the system ON OFF switch to OFF If needed empty the drying hopper ONS ON ae m For maintenance or a long term shutdown open de energize the electrical disconnects at the dryer and at the power drop Dehumidifying Dryers Chapter 4 Operation 40 of 59 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule The checklist below contains a list of items which should be inspected and or replaced to keep your Dehumidifying Dryer operating at peak efficiency Perform each inspection at the regular intervals listed below System model Inspect all filters for puits EE E ERE E ME SEES A worn Sa CNET DN RERO e e e ee ERE Check to make sure that all hose conections are air tight Lock out electrical power and inspect electrical wiring for integrity Lock out electrical power and check heater elements for continuity using an ohmmeter Check dew point and temperature tracking with an external dew point monitor and pyrometer Visually inspect the shifting of the airflow valve during one cycle Next scheduled Actual inspection Next scheduled Actual
27. assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on it You should have M Dehumidifying Dryer M Bill of lading M Packing list M Operating and Installation packet V Electrical schematic and panel layout drawings Mi Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For shipments in the United States and Canada call 1 800 233 4819 for all other countries call our international desk at 630 475 7491 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Table of Contents CHAPTER 1 SAFETY aae V 1 1 How to Use This Manual sese V Safety Symbols Used in this Manual seen nnne V 1 2 Warnings and Precautions eui eee eee eee vi T3 Responsibly Gs aes eiecit TT vii General Responsibility acid dto i idest tu gna Quo des ee ou Tayr vii Operator Responsible eee Viii Maintenance ResporsiDIlly ir ree rola Debs eee Ix Reporting a Safety Defect ix CHAPTER 2 FUNCTIONAL DESCRIPTION 11
28. ater safety switch opens a heater fault is generated HIGH TEMP is displayed on the relay screen The alarm light is activated The process heater regen heater and process regen blower are turned off Turn the OFF ON START switch to the START position to deactivate the alarm light and restart the dryer If the fault condition still exists the dryer will not restart 6 Ifthe process blower overload trips a process blower fault is generated PROC BLWR is displayed on the relay screen The alarm light is activated The process heater regen heater and process regen blower are turned off Reset the motor overload and turn the Off On Start switch to the START position to deactivate the alarm light and restart the dryer 7 The valve position limit switch enables the right bed heater and provides an input signal to the programmable relay when actuated by the cam lobe When the cam lobe position is high the right bed is activated When the cam lobe position is low the left bed 1s activated Each heater is ON OFF controlled by the OMRON E5C2 controller 8 Upon completion of the HEAT portion of the regeneration sequence the regen heaters are disabled by the programmable relay and the COOL time begins 9 Once the Cool time has expired the valve motor is turned on until the cam switch makes a transition Upon making a transition the timing sequence is restarted for the new bed 10 When no fault conditions exist the display reads
29. before using them to lift a load Be sure that all non current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you have completed the repair or maintenance procedure check your work and remove your tools rigging and handling equipment Do not restore power to the dryer until all persons are clear of the area DO NOT start and run the dryer until you are sure all parts are functioning correctly BEFORE you turn the dryer over to the operator for production verify all dryer enclosure panels guards and safety devices are in place and functioning properly Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use 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 Dehumidifying Dryers Chapter 1 Safety ix Dehumidifying Dryers Chapter 1 Safety Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for 15 30 and 60 cfm dehumidifying dryers Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufact
30. cess Air Dew Point Display Optional The Process Air Dew Point meter indicates the current process air delivery moisture content Standard dryers use a microprocessor based controller for displaying dew point air temperature The controller is a modular self contained unit removable from the mounting housing All parameters are factory set and adjusted normally no field adjustment to the internal controls are necessary Figure 7 Typical Dew Point Display Monitor OUT1 By E m OUT2 MANU STOP RMT SUB1 O LJ 0O AT E AT l x7 A OMRON E5CK Note The only functional buttons on this contoller are the up and down keys Setting the High Dew Point Alarm The high dew point alarm setting is changed by pressing the up and down keys to input the alarm value The factory setting for Alarm Value 1 1 FL is 10 F 23 C Restoring the Process Air Dew Point Meter E5CK to Factory Setup If the preset parameters on the controller have been tampered with and it no longer functions properly call the Service Department This controller is not meant to be modified Note The dew point alarm monitors and indicates a deviation from the set point Dehumidifying Dryers Chapter 4 Operation 31 of 59 Redundant Safety Controller Display Optional The Redundant Safety Controller limits the process air temperature from exceeding the upper temperature range set by the ESCN Temperature Controller Standard dryers use a microproces
31. ds on variables such as material moisture content plasticizer vapors in the return air and number of regeneration cycles Your dryer may need new desiccant if it exhibits any of the following symptoms e The process air dew point measured with a portable dew point monitor is higher than 10 F 23 C throughout the process drying cycle 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 Parts Department If you want a technician can repack desiccant beds at your site Dehumidifying Dryers Chapter 5 Maintenance 44 of 59 WARNING Handling desiccant material is HAZARDOUS Wear an N 100 type safety filter mask or equivalent to avoid prolonged breathing of desiccant dust Wear safety goggles and gloves to avoid contact with eyes and skin Handle with adequate ventilation e Wash hands thoroughly after handling FIRST AID In case of eye contact immediately flush eyes with plenty of water for at least 15 minutes SEE A PHYSICIAN IMMEDIATELY IF IRRITATION PERSISTS Replacing Worn Desiccant Caution DESICCANT BEDS ARE HOT DURING OPERATION To avoid burn hazard make sure desiccant beds are sufficiently cool before replacing worn desiccant To access the Desiccant Bed 1 Disconnect electrical power to the dryer 2 Using a 1 8 Allen wrench remove t
32. e right direction 4 Fill the drying hopper with material 5 Turn the dryer ON switch to START to start the dryer The process blower starts 6 If your dryer has a water cooled aftercooler make sure that sufficient cooling water 3gpm at 85 F or lower flows properly through the coil and that you have bled any trapped air from the system Make sure the aftercooler has the proper supply water temperature 7 Set the process set point on the temperature controller After the proper pre drying time for the initial hopper fill has elapsed fully open the drying hopper slide gate 9 Turn on the machine convey ON OFF switch to ON and set the convey timer for the proper conveying time Note To allow proper residence time during continuous processing maintain the material level in the hopper at the midpoint of the air trap assembly Dehumidifying Dryers Chapter 4 Operation 24 of 59 4 2 Controller Description and Operation Identifying Control Panel Indicator Lights and Switches for the Standard Controller Switches System OFF ON START Switch This switch energizes or de energizes control power to the indicator panel and starts the dryer The controller can be energized without the dryer running Optional Alarm Silence Switch Press this switch to silence the horn when a high temperature process regeneration or blower failure alarm activates Indicator Lights Alarm Light This feature works in conjunction with the alarm ho
33. eed a longer residence time or a different drying temperature Break in flex hose to from Inspect for air leaks replace as drying hopper needed Airflow valve sticking or failing Check for proper ODETEHOD of valve actuators Repair or to shift replace if necessary Blower fins filled with dust or Remove Do ersioe Date clean baffles replace Insufficient power to PLC Check power supply and power PLC Regeneration Bed LED Power LED is off wiring to PLC temperature Material being dried differs from material specified at the time of purchase Loss or reduction in drying capacity tami ts R Replace filter elements ad Faulty PLC PLC Power light is dicators both off asi ae ME on Run light is off and or Error Replace PLC 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 both OH E off Insufficient power to PLC Check power supply and power l Power light is off wiring to PLC Faulty PLC PLC Power light is on Run light is off and or Error Replace PLC light is on Dehumidifying Dryers Chapter 6 Troubleshooting 49 of 59 Problem Possible cause Corrective action Check resin manufacturer s data sheet for proper drying Process temperature set too high temperature Make sure plant due to operator error personnel are aware of the correct process temperature set point
34. ened with a screwdriver but no keys are required Two hand control is not required or provided All dryers should be moved around and set in a place with a lift truck or equivalent There are no frequent repetitive cycles that require manual control repetitive functions are automatic while the dryer is operating An inspection report detailing the functional test is included with the dryer The machine is not equipped with cableless controls Color coded harmonized power cord is sufficient for proper installation Dehumidifying Dryers Chapter 7 Appendix 54 of 59 Aftercooler Design Specifications Entering water temp a H C 7 4 Drawings and Diagrams 7 5 Spare Parts List Figure 18 Level 1 Spare Parts List Electrical amp Mechanical 15CFM 220V 50 HZ 3PH 15CFM 15CFM 230V 3PH 400V 50 HZ 3PH 15CFM eov 3PH 15CFM MINI DRYER SPARE PARTS LIST AD15 AD30 AD60 208V 3PH LEVEL 1 Electrical Components SIZE A0568932 2 Fuse for the Heater Elements A0568933 2 5 Fuse for the Heater Elements A0568934 3 A0534039 Fuse for the Heater Elements 0534040 0534041 0534042 A0534043 Fuse for the Heater Elements A0534044 A0534046 A0534047 Fuse for the Heater Elements A0534048 A0534049 A0568936 Fuse for the Heater Elements A0434051 A0568909 1 A0568910 1 125 Fuse for the Process Blower A0568911 1 25 Fuse for the Process Blower F A0534804 2 use for the Process Blower A0568917 2 5 Fuse for t
35. ensure that you take into consideration and make arrangements for the following e A qualified electrician should make all electrical connections e Fulfill all national state and local safety and electrical code requirements e The serial tag lists voltage phase and amp draw information e Line voltage must be within plus or minus ten percent 10 of the voltage listed on the serial tag or damage may occur Phase imbalance must be less than two percent 2 e Connect main power to the dryer at the disconnect or terminals in the upper right corner of the control enclosure e Install a fused disconnect with a lockout feature in the power main leading to the dryer e The power drop must include a ground wire e Make sure all electrical connections are tight Dehumidifying Dryers Chapter 3 Installation 19 of 59 3 4 Setup Procedures This section provides the procedures necessary for configuring your Dehumidifying Dryer Configuration of your dryer includes checking for proper blower rotation making dryer drying hopper process air connections and the optional aftercooler on 60 cfm models We recommend that you carry out these procedures in the order given here Note Before carrying out these procedures install all equipment as described in this section Checking for Proper Blower Rotation Three Phase Models Caution In three phase models incorrect phasing of power leads can cause backward rotation of blower motors a
36. er safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment At the completion of this section the operator and maintenance personnel will be able to do the following Dehumidifying Dryers Chapter 2 Functional Description 13 of 59 e Identify and locate specific safety devices e Understand the proper use of the safety devices provided e Describe the function of the safety device Safety Circuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards into the design of the dryer however it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices Fail Safe Operation If a safety device or circuit should fail the design must be
37. ess the OK key to accept the value and write to the relay memory OR d Press the ESC key to cancel the changes Note A change will NOT take effect until step 12 c is done 13 The dryer is shut off by turning the control power switch to the OFF position 14 Refer to Schematic drawing A0566087 enclosed in the control enclosure Dehumidifying Dryers Chapter 4 Operation 38 of 59 Alarm Display Messages Note The relay screen which contains the Alarm Display Messages is located inside the controller enclosure WARNING Do not attempt to check the Alarms on the Controller located within the unit enclosure unless you are a qualified electrician The following is a list of Alarm Display Messages which can be found on the relay screen Temperature Controller Alarm and or Regen Heater Temp Switch and or HIGH TEMP Process Heater Temp Switch and or Redundant Temp Safety PROC BLWR Blower Overload VALVE MTR Valve Motor Time Out PROC BLWR Multiple Alarms HIGH TEMP VALVE MTR HEAT 35 COOL 30 SYSTEM NORMAL No Alarms Dehumidifying Dryers Chapter 4 Operation 39 of 59 4 4 Ama Hung the Dryer For Auto tuning press the beige button once The AT screen will show with the setting OFF 2 Press the UP arrow to change the setting to ON 3 Press the beige button again to go back to the Temperature Screen Your actual temperature will start to flash for about 10 20 minutes with the temperature fluctuating up
38. expressed in this warranty No person agent manufacturer distributor dealer installer or company is authorized to change modify or extend the terms of this warranty in any manner whatsoever The time within which an action must be commenced to enforce any obligation of the Company s arising under this warranty or under any statute or law of the United States or any state thereof is hereby limited to the duration of this warranty Some states do not permit this limitation so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For transactions involving the potential applicability of international law or that of a foreign country this warranty policy and the procedures hereunder shall be governed by applicable federal and state law but not by the United Nations Convention on Contracts for the Sale of Goods Customer Responsibilities Any sales use or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser 7 2 Optional Components The following is a list of options which your Dehumidifying Dryer may have been equipped with e Dew Point Monitor e Audible Alarm with Silence Button e High Temperature Option with Aftercooler e Casters e AP1 PLC Control System Dehumidifying Dryers Chapter 7 Appendix 53 of 59 7 3 Technical Specifications Annex B Information The following design in
39. formation is provided for your reference l ROE T N Sy a a 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature 0 degrees Celsius Maximum 104 degrees Fahrenheit Humidity range 50 relative humidity Altitude Sea level Environment Clean dust free and non explosive Radiation None Vibration Minimal i e machine mounting Allowable voltage fluctuation 10 Allowable frequency fluctuation Continuous 1 Intermittent 2 Nominal supply voltage 460 3 60 Verify on serial number tag 11 Earth ground type TN system has one point directly earthed through a protective conductor Power supply should include a ground connection Over current protection is supplied in the dryer but additional protection should be supplied by the user The door mounted disconnect serves as the electrical disconnect device Dryer is not equipped with local lighting Functional identification Dryer is equipped with a CE mark Dryer is supplied with an operating manual in the language of the destination country Cable support may be required for power cord depending on final installation No one is required to be in the interior of the electrical enclosure during the normal operation of the unit Only skilled electricians should be inside the enclosure for maintenance Doors can be op
40. g your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 233 4819 or call 630 595 1060 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Sales Department Call 630 595 1060 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 630 595 1060 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations Dehumidifying Dryers Chapter 7 Appendix 59 of 59
41. ge 39 4 A JAuto T ring The Dryer oe ete echten aste epu tuse tres ltalfetdutali dtu id 40 4 5 Shutting Down the DEPVer cutie decet ied drmet x cadet tet ains hee tbe dites puc ntu bd but duae VTO 159 40 CHAPTER 5 MAINTENANCE eeeeeeeeeeeee nnne 41 5 1 Preventative Maintenance Schedule see eee 41 5 2 JPreventauveMallllernarice ocaeca inci pa bestie utet eb heaters ur eid 42 Servicing Process Air Filters esses sss E aeia AE EE 42 Servicing the Dew Point Monitor sies se einen hine 43 b 3 Corrective Maintenance sese eee eee eee 44 Symptoms OF Worn Doeslccarnt otro sinter ra d ur rueda tei pe 44 Replacing Worm DESICCANT sae isis bob eade de edens 45 Replacing the Process Healer scoop t e Oe Fa ue diga qutt adt 47 CHAPTER 6 TROUBLESHOOTING 48 9 1 IntlOductiQtes oio epe eiie ta nas petet odit tisse E R e ea teach a 48 6 2 Determining Temperature Controller Errors or Sensor Errors 51 Using a TCT IO COUN srera a eue eate Rede pda Dal Ee ee d 51 Using a Platinum Resistance Thermometer essen 51 CHAPTER 7 APPENDIX rri sees ennenen eenn 52 UMS uci mmt 52 Warranty Speciticatlone sedie tes Foro Terre tua eR n redes 52 Warranty Restriction S scissioni einginn SR PAN UE Rel E SURE raids 52 Warranty Be sao n e etudiant tere duse ctae 53 Customer Responsibilities sese ee eee eee eee 53 52
42. he Process Blower A0550577 3 A0568919 Fuse for the Process Blower A0568921 0550593 0538062 A0568922 6 25 Fuse for the Process Blower A0568923 7 A0568926 A0538069 1 Fuse for the Process Blower A0536892 25 Fuse for the transformer A0536894 2 Fuse for the transformer A0536895 E Fuse for the transformer A0538001 Fuse for the transformer A0538002 ER Fuse for the transformer 0568941 2 A0558078 3 1 Motor Overload A0558079 2 1 6 5 LEVEL 1 Mechanical Components SIZE ir Fi i i aras nz aen sce EMAAR 220V 50 HZ 3PH 30CFM ol a N wo N Oojo N w N 6 a AJ a N o oo T eel A A Oy l o N z Z gm A m g eo co N L e A0548556 Process Air Filter 13X molecular Sieve Desiccant 8 X 12 Beads 4 75 Lbs W00013983 High Temperature Gasket 135 Inches High Temperature Snap Switch gt Re o SISI EE ASS al al SiSia B S S a eS elll al al R S el Z oo Oa BY p se ISIS laid 1 e Kan gt N co a ol bsov apu lacz Co LL del del laa 50 HZ 3PH 30CFM LIES LLL EL LS EL LELEL LE LLL lel Lieb Lp ean aan foce LEE EE TTT EISE TELE LEE Tel lal frv oo nz sen socru ATS EE TT fel Pol TT ET LLL pes sen poer ol TT IE TTT fel PET TET TT fed fel PET T T T pov sonz sen fooce el LET TTT T le js TTT TT TTY T Psov se foocen 60CFM 400V 50 HZ 3PH 460V 3PH Figure 19 Level 2 amp 3 Spare Par
43. he four 4 10 32 button head screws holding the Dessicant Cap to the Regeneration Heater 3 Remove the Desiccant Cap 4 With a shop vacuum carefully remove all desiccant from each tower Dehumidifying Dryers Chapter 5 Maintenance 45 of 59 Figure 11 Desiccant Bed Location and Disassembly Undo 4 10 32 Button Head Screws using 1 8 Allen Wrench Desiccant Cap 1 Wide x 1 8 Thick Silicon Strip and Stick Gasket 13X Molecular Sieve 8x12 Beads Pi Regeneration Heater Regeneration Thermocouple 16 Mesh 0 028 Diameter Wire Stainless Steel Screen B 1 Wide x 1 8 Thick High Temperature Gasket 2 4 40 screws Hi Temperature Snap Switch Caution You should properly dispose of any discarded desiccant Consult local disposal regulations for more information Inspect each lower desiccant screen for tears or holes where desiccant burned through Replace as needed After cleaning each chamber add a level layer of half the 8 x 12 bead desiccant on top of the screen Next carefully add the full amount of bead desiccant specified per bed Amounts are listed in the Desiccant Amounts Table below Smooth the top level and finally add another layer of the remaining bead desiccant to the top Make sure this layer is level and smooth Repeat the previous step for
44. ion Again provide additional support to hold the dryer securely on the machine For 60 cfm dryer units you must provide additional support to stabilize these units and to protect personnel when installing on machine throats Use caution and observe safety rules when lifting and placing your dryer Dehumidifying Dryers Chapter 3 Installation 15 of 59 Figure 16 Machine Mount Dryer Dimensions Mounting flange C MEN p 1 p lt L E Diameter hole F Notes Hopper mounting flanges on 0 75 and l and 1 5 cu ft 20 amp 40 liter hoppers are supplied blank so the customer 1 j can drill to match existing machine throat 3 0 cu ft 80 liter hoppers and larger are not supplied with a cast flange as shown 15 30 60 cfm machine mount dimensions in inches cm I PE FE 0 7 ft 20 liters 1 5 ft 40 liters 1 5 ft 40 liters 3 0 ft 80 liters 4 0 ft 120 liters 6 0 ft 160 liters in cm in cm in cm j in cm in cm cm pat 104 45 109 49 109 46 1H 56 75 86 sm 35 89 35 89 4575 116 45 2 7 8 7 l Fr ns ss 15 38 15 38 2 sty 51 in 56 75 30 76 30 76 34 86 34 45 75 7 2 Dehumidifying Dryers Chapter 3 Installation 16 of 59 Figure 17 Floor Mount Dryer Dimensions 1S cfm in 325 30 30
45. lled or city water as warm as 85 F 29 C Recommended flow rate is three 3 gpm gallons per minute 11 liters per minute Dehumidifying Dryers Chapter 3 Installation 21 of 59 3 5 Initial Start up Pre Startup Checks M Check the process and return hoses for tight connections M Check all companion equipment such as the drying hopper verify that the loading system is ready for operation M Verify that all dryer electrical connections are tight Starting Up the Dryer l Turn on energize the disconnect switch in your power drop then turn on the one on the dryer Turn the system ON OFF switch to ON to energize the display panel Close the slidegate at the bottom of the drying hopper Make sure that the blowers turn in the right direction Fill the drying hopper with material Turn the dryer ON switch to START to start the dryer The process blower starts If your dryer has a water cooled aftercooler make sure that sufficient cooling water 3gpm at 85 F or lower flows properly through the coil and that you have bled any trapped air from the system Make sure the aftercooler has the proper supply water temperature Set the process set point on the temperature controller After the proper pre drying time for the initial hopper fill has elapsed fully open the drying hopper slide gate Turn on the machine convey ON OFF switch to ON and set the convey timer for the proper conveying time Note To allow proper
46. lown Dehumidifying Dryers Chapter 6 Troubleshooting 50 of 59 No setting change possible on The key protection switch is set Set the key protection switch to temperature controller to ON OFF not obtained is wrong or connection is wrong Properly set the input with the Input type setting is incorrect input type selector rotary switch No compensating lead wires used for extension of the thermocouple Use proper compensating lead wires and terminals Use a dedicated thermocouple Thermocouple and controller are connector If a connector is a connected by wires other than metal different from the proper lead wires thermocouple and controller a Process value is abnormal or temperature error may result Verify that the thermocouple is properly installed in the inlet tube Sensor is broken or short i S Replace with a good sensor circuited Separate input wires as far as possible from the origin of the noise Celsius temperatures used Check Mode selector switch 6 instead of Fahrenheit or vice e ON F versa e OFF C Process value shifted because Set input shift value to 0 or set the input shift function is used mode selector switch 4 to OFF Determining Temperature Controller Errors or Sensor Errors Process thermocouple not in airflow The controller is influenced by noise or other induction Using a Thermocouple If the controller displays a temperature that is close to room temperat
47. ment 675 Vols 0568139 Screen Cover for the Desiccant Tanks 10568140 Screen Cover for the Desiccant Tanks 0568141 Screen Cover for the Desiccant Tanks fAose6682_ __ 1 4 OD Teflon Tube SSCS A0566415 Washer Gasket for the Heater Elements MINI DRYER SPARE PARTS LIST AD15 AD30 AD60 LEVEL 3 Electrical Components PART SIZE AOS69z1 Power Disconnect A0566096 Mitsubishi Programmable Relay Logic Controller A0568961 Redundant Temperature Safety Controller LEVEL 3 Mechanical Components 40534059 2 O D by 12 Ft Long Hi Temp Hose A0534060 2 1 2 O D by 12 Ft Long Hi Temp Hose A0s66535 Return Air Cooling Coil _ _ A0536628 208 460 Volt Process Bower A0536629 575 Volt Process Blower A0534079 208 460 Volt Process Blower _ A0535351 575 Volt Process Blower A0552439 208 460 Volt Process Blower _ A0552440 575 VoltProcessBlowr Dehumidifying Dryers Chapter 7 Appendix CFM CF CFM CF CFM 220V 50 HZ 3P 400V 50 HZ 3P 575V 60 HZ 3P 220V 50 HZ 3P 400V 50 HZ 3P 575V 60 HZ 3P 220V 50 HZ 3P 400V 50 HZ 3P 208V 3PH 230V 3PH 460V 3PH 208V 3PH 230V 3PH 460V 3PH 208V 3PH 230V 3PH 460V 3PH F FM F F 5CFM CF 2 2 2 i 2 2 u i E i wi my my my ey 0 u O19 O O ojojo ojoj o Ql o OC CO Q Domo o umo vj
48. mperature When setting the process air temperature consult with the resin manufacture for the recommended drying temperature To change the process air temperature set point with the dryer running e Press to raise the set point to the temperature you want 2 e Press to lower the set point to the temperature you want Dehumidifying Dryers Chapter 4 Operation 27 of 59 Restoring the Process Air Temperature Controller E5CN to Factory Settings If the preset parameters on the controller have been tampered with and it no longer properly controls temperature and displays dew point you can restore the controllers to the factory setup Call the Service Department for detailed instructions ESCN Operating Parameters The E5CN controller has several mode selections Within each mode are numerous parameters that can be set The factory has set the security level to protect the critical parameters from being accidentally changed Below is an explanation of the operating modes you will have access to and on the following page are the manufacturers default settings Available ESCN Modes Operation Level Indicator Name Description Run Stop Mode When RUN is selected the control is running r S When STOP is selected the control is stopped When the control is stopped the STOP display r 5 lights The default is set to RUN Alarm Value 1 This setting is used to indicate how many degrees
49. n timing sequence is initiated The regen heater is controlled by the E5C2 controller Default timing for regeneration is 35 minutes for HEATING and 30 minutes for COOLING 4 If either the left or right bed safety temperature switch opens a regen heater fault is generated HIGH TEMP is displayed on the relay screen The alarm horn and light are activated The process heater regen heater and process regen blower are turned off Pressing the ALARM RESET pushbutton will deactivate the alarm horn and light Turn the Off On Start switch to the START position to restart the dryer If the switch is still open the dryer will not restart Dehumidifying Dryers Chapter 4 Operation 37 of 59 5 Ifthe OMRON controller faults the optional redundant high temperature safety device opens or the process heater safety switch opens a process heater fault is generated HIGH TEMP is displayed on the relay screen The alarm horn and light are activated The process heater regen heater and process regen blower are turned off Pressing the ALARM RESET pushbutton will deactivate the alarm horn and light Turn the Off On Start switch to the START position to restart the dryer If the fault condition still exists the dryer will not restart 6 Ifthe process blower overload trips a process blower fault is generated PROC BLWR is displayed on the relay screen The alarm horn and light are activated The process heater regen heater and process
50. nd CONTAMINATION OF THE DESICCANT Always check blower rotation before putting material in the drying hopper The blower is rotating properly when air flows from the delivery outlet Note Holding your hand in front of the air return will also indicate if the blower rotates in the proper direction If the three phase blower rotates improperly reverse any two wires at the fused disconnect outside the dryer or at the disconnect terminal in the control enclosure This assures that the blower rotates in the proper direction Making Dryer Drying Hopper Process Air Connections Floor Mount Models When making process air connections to your floor mounted dryer ensure that you take into consideration and make arrangements for the following e Use high temperature flexible dryer hose or rigid tubing to connect the dryer to the drying hopper e Keep the delivery hose to the drying hopper as short as possible to minimize heat loss We strongly recommend insulated hose for maximum energy savings e Do not use insulated hose on the return from the drying hopper e The return air to the blower must be 150 F 66 C or below If the return air temperature is not below this point you should purchase and install the optional aftercooler to remove excessive heat Consult the manufacturer for more information Aftercooler considerations also apply to machine mount models e Make sure that hoses are not kinked or collapsed e Drying hopper air inlet
51. oil Allen Wrench Note To clean the cooling coil use compressed air or a steam cleaner to blow the dust off or clean any oily residue on the coil Servicing the Dew Point Monitor The accuracy of the dew point monitor on mini dryer systems depends on proper operation of the dew point sensor and the control board The dew point sensor is in the process air stream and is therefore susceptible to contamination Dehumidifying Dryers Chapter 5 Maintenance 43 of 59 Dew point sensor life depends on e Air temperature and flow passing over the sensor e The amount of fines dust in the process air e The amount of plasticizer vapor in the process air Once every six months the dryer operator should monitor the initial dew point sensor readings and establish a periodic replacement schedule as needed Caution Do not attempt to check the continuity or resistance of the dew point sensor The sensor will be destroyed 5 3 Corrective Maintenance This section provides you with the information necessary to correct or repair any issues which might appear during the normal operation of your dehumidifying dryer Although we have listed how to perform these procedures it is recommended that you call the Service Department to have any in depth maintenance performed Symptoms of Worn Desiccant The moisture absorption capacity of the desiccant used in your dehumidifying dryer degrades after an indefinite period of time Useful life depen
52. pped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty terms 7 7 Safety Tag Information Dryer Safety Tags Hot Read Operation and Installation Manual High Voltage Earth Ground Inside Enclosure Protected Earth Lifting Point Ground Dehumidifying Dryers Chapter 7 Appendix 57 of 59 7 8 Dryer Identification Serial Number Tag Located on back of Dryer Company Logo C XXX Series Dryer Model Number XXX 15 Max Drying Capacity HR 460V Serial Number 060701R 16 Date of Manufacture 06 2003 4 5A Over current Protection Device s 4 5A Total Frequency 50 60Hz Compressed air supply None Dryer Mass 400 Ibs 180 KG Electrical Diagrams amp Street Address City State Zip Code Telephone Number Dehumidifying Dryers Chapter 7 Appendix 58 of 59 7 9 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 630 595 1060 Fax 630 475 7005 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expeditin
53. quipment 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 Dehumidifying Dryers Chapter 1 Safety vii 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 operating your equipment Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your super
54. r cartridge Figure 10 Air Filter Location and Disassembly Process Return z Air Filter 1 Wide x 1 8 Thick High Temperature Gasket 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 Dehumidifying Dryers Chapter 5 Maintenance 42 of 59 Cleaning with Compressed Air Blow clean dry compressed air up and down the pleats blowing out the filter from the inside out Remove loose dirt from the filter with compressed air or vaccum from the outside Caution DO NOT clean wash filter with water After each cleaning e Inspect the filter element Briefly hold a light bulb behind the element and look for any fatigued paper or residual dirt Inspect for holes and tears by looking though the filter toward a bright light Check for damaged gaskets or dented metal parts Do not re use a damaged filter e Check the gasket for damage A damaged gasket allows contaminants into the process Replace as needed Figure Cooling Coil Location and Disassembly 1 Wide x 1 8 Thick High Temperature Gasket Use compressed air or a steam cleaner to blow the dust off or clean Undo 4 10 32 Button Head Screws using Y any oily residue on the c
55. r display and PAGE will appear in the lower display C 2 Press the Advance Key to move through the parameter prompts 3 Press the Up J or Down J keys to change the parameter value 4 Press the RESET Key at any time to return to the Home Page display Figure 9 Setting List for Redundant Safety Controller WATLOW Part No A0555757 SEn Sensor Type 0 3 Lin Thermocouple Linearization 0 10 Temperature Units Fahrenheit Celsius C F Temp Decimal Places 0 0 0 IS En INFOSENSE Yes No Process Scale Low 4 00 to 20 00 mA 4 00 mA 1 00 to 10 00V 1 00V Process Scale High 4 00 to 20 00 mA 20 00 mA 1 00 to 10 00V 5 00 V Calibration Offset 999 to 999 0 Input Filter Off DiSP Cont both OFF Output 1 Function Limit 2 2 Output 1 Limit Sides Both High Low Both Limit 1 Hysteresis 0 0 to 999 0 1 0 Output 2 Function Off Process Alarm Limit 2 OFF Output 2 Sides Both high low Both None Process Value Limit 1 Low Set Limit 1 High Set Limit 2 Low Set Limit Upper Display Look 2 High Set Alarm 2 Low Set Alarm 2 Process High Set Limit 3 Low Set Limit 3 High Set Alarm 3 Low Set Alarm 3 High Set None Process Value Limit 1 Low Set Limit 1 High Set Limit 2 Low Set Limit Lower Display Look 2 High Set Alarm 2 Low Set Alarm 2 High Set Limit 3 Low Set Limit 3 High Set Alarm 3 Low Set Alarm 3 High Set 0 no lockout 1 Programming and Setup Page Locked 2 Limit Set Points are the only Operation
56. residence time during continuous processing maintain the material level in the hopper at the midpoint of the air trap assembly Auto Tuning the Dryer l For Auto tuning press the beige button once The AT screen will show with the setting OFF Press the UP arrow to change the setting to ON Press the beige button again to go back to the Temperature Screen Your actual temperature will start to flash for about 10 20 minutes with the temperature fluctuating up and down during that period After the flashing stops it means auto tuning has finished Dehumidifying Dryers Chapter 3 Installation 22 of 59 Shutting Down the Dryer l ON CAL US 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 OFF Turn the system ON OFF switch to OFF If needed empty the drying hopper For maintenance or a long term shutdown open de energize the electrical disconnects at the dryer and at the power drop Dehumidifying Dryers Chapter 3 Installation 23 of 59 Chapter 4 Operation 4 1 Start up 1 Turn on energize the disconnect switch in your power drop then turn on the one on the dryer 2 Turn the system ON OFF switch to ON to energize the display panel 3 Close the slidegate at the bottom of the drying hopper Make sure that the blowers turn in th
57. rn to warn the operator of a high bed safety temperature a regeneration heater fault or a blower failure This warning is reset by pressing the alarm silence button Figure 4 Typical Dryer Control Panel PROCESS TEMPERATURE PN N uua ESCN ALARM HORN A Dehumidifying Dryers Chapter 4 Operation 25 of 59 Process Air Temperature Controller Our 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 are factory set and adjusted normally no field adjustment to the internal controls is necessary Figure 5 Typical Process Air Temperature Controller Temperature indicators Identifying Process Air Temperature Controller LED Indicators Indicator Name Description PV Process Value During normal operation the process value PV ane Numeric LED numeric LED indicator displays the process Bee temperature at the To Process thermocouple It also lists parameters during setup and error messages if any errors occur SV Set Value During normal operation the set value SV anaa Numeric LED numeric LED indicator displays the process set 2209 point temperature selected for the dryer The dryer then maintains this set point temperature This LED indicator also displays parameter and pre set function v
58. s eee eee 22 Staring Updhe Dryer iieitet aecenas And qd caedis a SA DEAD bua 22 Auto Tut ng the Dryel usos cocer odora e den oda bee Roe oe 22 Shutting Down the DIyeF ua iei ett uidet Gta uie ode eee set RunC 23 CHAPTER 4 OPERATION sss sese cc cost uoc doin au caia xa dria vnu acp 24 Aad Y StartUp zd Ere torte ei E A dee decode seed eve eee De EY e 24 4 2 Controller Description and Operation eee 25 Identifying Control Panel Indicator Lights and Switches for the Standard CONTONG E MED 25 Process Air Temperature Controller sisse 26 Setting the Process Air Temperature eee eee 27 Dehumidifying Dryers ii Restoring the Process Air Temperature Controller E5CN to Factory Settings 28 Process Air Dew Point DISDIGy sace eee 31 Setting the High Dew Point AIS sees eee eee eee 31 Restoring the Process Air Dew Point Meter E5CK to Factory Setup 31 Redundant Safety Controller Display eee eee 32 Setting the Redundant Safety Controller sess 32 Restoring the WATLOW Redundant Safety Controller to Factory Setup 32 4 3 Dryer Operation Procedures tesi oerte retur t essen buta icis bti nenen 34 Controller Operation Without Optional Alarm Horn amp Reset Button 34 Controller Operation With Optional Alarm Horn amp Reset Button 37 Alarm Display Messages aee bites UL da od sagen deus xiu Re pu ade do
59. sor based controller for limiting the process air temperature The controller is a modular self contained unit removable from the mounting housing All parameters are factory set and adjusted normally no field adjustment to the internal controls are necessary Figure 8 Typical Redundant Safety Controller Display Setting the Redundant Safety Controller The Redundant Safety Controller alarm setting is changed by pressing the up and down keys to input the alarm value The upper display reading indicates the Process Value while the lower display indicates the High Point Setting alarm value The factory setting for the High Point Alarm Value Z 4 is 150 F 23 C Restoring the WATLOW Redundant Safety Controller to Factory Setup If the preset parameters on the controller have been tampered with and it no longer functions properly call the Service Department This controller is not meant to be modified WATLOW Operating Parameters The WATLOW controller has only one mode selection ALARM The factory sets the security level to protect the critical parameters from being accidentally changed Below is an explanation of the modes you will have access to and the manufacturer default settings Dehumidifying Dryers Chapter 4 Operation 32 of 59 Entering Operating Parameters to Select Modes To enter the display 1 Press both the Up LJ and Down keys for three seconds from the home page The word SEE will appear in the uppe
60. the other bed Inspect the gaskets on the valve assembly Replace if necessary Re install the valve and reconnect actuator wiring Figure 12 Required Desiccant Amounts Dryer 8 x 12 bead Total model Partno lbs Kg W00018051 12 25 Dehumidifying Dryers Chapter 5 Maintenance 46 of 59 Replacing the Process Heater The dehumidifying dryers utilize a single phase Calrod type heater element This heater element is mounted in the center compartment below the desiccant beds Although the replacement procedure is the same for each heater the wattage varies by model voltage temperature range etc WARNING Hazardous electrical current present Disconnect and lock out power before you replace heater elements Figure 13 Process Heater Location and Disassembly Undo 6 10 32 Butto Head Screws using 1 8 Allen Wrench 1 Wide x 1 8 Thick High Temperature Gasket 7 2 4 40 screws Hi Temperature Snap Switch Procedures 1 Remo s ms suroj as e ae ce a ee mv pav SESS heater access cover using a 1 8 Allen wrench 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 two 2 4 40 screws 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
61. ts List Electrical amp Mechanical 2 2 2 2 w ui Ji ui fa wi oy my my ey i iL O O O O O ojojo ojoj o o Doo quo o o oll S S S el el Q 9 S S SIS f l ajl avj aj oO oO v oj G S GO MINI DRYER SPARE PARTS LIST AD15 AD30 AD60 LEVEL 2 Electrical Components A0556000 MotrStater ooo A0530042 Mercury Heater Contactor 0567917 Process Air Temperature Controler 0544089 Regeneration Air Temperature Controler 0505417 Regeneration T Coupe Relay LEVEL 2 Mechanical Components 0548621 Ceramic Cap for the End of Heater Elements 0566478 750 Watts Heater element 208 220 Volts 0566479 750 Watts Heater element 230 Vots 0566480 750 Watts Heater element 400 Vols A0566481 750 Watts Heater element 460 Vols io566482 750 Watts Heaterelement575 Vols 0566483 1280 Watts Heater Element 208 220 Vols A0566484 1250 Watts Heater Element 230 Vols A0566485 1280 Watts Heater Element 400 Vols 0566486 1280 Watts Heater Element 460 Volts 0566487 1250 Watts Heater Element 675 Vots A0566601 2800 Watts Heater Element 208 220 Vols 0566602 2500 Watts Heater Element 230 Vols 0566603 2500 Watts Heater Element 400 Volts 0566604 2500 Watts Heater Element 460 Vots A0566605 2800 Watts Heater Ele
62. ure 70 F 21 C when you short circuit controller input terminals the controller is normal and the sensor is probably broken short circuited or incorrectly wired Using a Platinum Resistance Thermometer If the controller displays a temperature of about 0 0 C 32 F when you insert a 100 ohm resistor between terminals A and B of the controller and you short circuit controller terminals B and B the controller is normal and the sensor is probably broken short circuited or incorrectly wired Other service problems or questions can be answered by contacting the Service Department Dehumidifying Dryers Chapter 6 Troubleshooting 5 of 59 Chapter 7 Appendix 7 1 Warranty Unless otherwise specified this product includes a Standard ONE YEAR PARTS WARRANTY Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions as set forth in the operating manuals for such equipment THE FOREGOING EXPRESS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES GUARANTIEES AGREEMENTS AND SIMILAR OBLIGATIONS OF THE COMPANY AND OR MANUFACTURER UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE PAGE OR LIMITED BY THE MANUFACTURERS WARRANTY FOR PARTS The Company s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to
63. urer for parts or service Our dehumidifying mini dryers are designed to generate heated dehumidified air at carefully controlled temperatures for use in plastic drying systems Drying systems are sized to meet the specific requirements stated by the Customer at the time of purchase 2 2 General Description Dehumidifying dryers are used to generate very low dew point air heated to a controlled temperature for drying plastic pellets and regrind Our dryers force hot dry air through resin in a drying hopper where air picks up moisture from the material and draws it back to the dryer In the dryer a desiccant bed strips moisture from the air The dried process air is then re heated and delivered back into the drying hopper to continue to remove moisture Figure 15 Typical Dryer Air Flow Schematic Moisture Exhaust x High pressure 4 prepheral blower Valve Drying Hopper Filter Separates ust Ambient Air Flow Dehumidifying Dryers Chapter 2 Functional Description 11 of 59 A small amount of ambient air is introduced into the process air stream to make up for the air lost during the bed regeneration Because the process air is typically much drier than the ambient air the air mixture maintains drying efficiency at a consistently high level This air is heated to 500 F 260 C before entering
64. ve 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 Dehumidifying Dryers Chapter 1 Safety vi 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No mater who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production e Loss ofa skilled operator temporarily or permanently e Breakdown of shop morale e Costly damage to e
65. visor or appropriate person REMEMBER e NEVER place your hands or any part of your body in any dangerous location e NEVER operate service or adjust the dryer without appropriate training and first reading and understanding this manual e NEVER try to pull material out of the dryer with your hands while it is running e Before you start the dryer check the following e Remove all tools from the dryer e Be sure no objects tools nuts bolts clamps bars are laying in the hopper area e If your dryer has been inoperative or unattended check all settings before starting the unit e At the beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly e Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment e When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting e Report the following occurrences IMMEDIATELY e unsafe operation or condition e unusual dryer action e leakage e improper maintenance e NEVER stand or sit where you could slip or stumble into the dryer while working on it s DO NOT wear loose clothing or jewelry which can be caught while
66. wer and pneumatic i e compressed air sources prior to servicing or cleaning the dryer Failure to do so may result in serious injury No one but the person who installed the lockout may remove it Dehumidifying Dryers Chapter 2 Functional Description 14 of 59 Chapter 3 Installation 3 1 Uncrating the Equipment Dehumidifying Dryers are shipped mounted on a skid enclosed in a plastic wrapper and contained in a cardboard box 1 Pry the crating away from the skid Note Remove the nails holding the box to the skid and lift the box off carefully avoiding staples in the I x 4 wood supports Cut the steel banding 2 Use a pry bar to remove the blocks securing the unit to the skid 3 Lift unit from sides Use a pry bar if necessary to carefully remove the skid from the unit 4 Lower slowly 3 2 Rigging and Placing the Dryer Take care when rigging and placing the dryer Figures 1 2 and 3 on the following pages show a suggested safe rigging diagram It lets you lift the dryer hopper unit vertically for installation on the machine throat Adjust chain lengths at the center sling bracket before you lift the unit Your dryer has built in lifting lugs Caution If you are mounting a machine mount dryer with a magnet or transition adaptor on the machine throat you must provide additional support to hold the dryer securely on the machine Be aware that off center static and dynamic hopper loading can occur with machine vibrat
67. working on a dryer In addition cover or tie back long hair Dehumidifying Dryers Chapter 1 Safety viii e Clean the dryer and surrounding area DAILY and inspect the machine for loose missing or broken parts e Shut off power to the dryer when it is not in use Turn the switch to the OFF position or unplug it from the power source Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning tags to the disconnect switch When you need to perform maintenance or repair work on a dryer above floor level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk on your dryer use it The work platform should have secure footing and a place for tools and parts DO NOT climb on dryers machines or work from ladders If you need to repair a large component use appropriate handling equipment Before you use handling equipment portable A frames electric boom trucks fork trucks overhead cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable Carefully test the condition of lifting cables chains ropes slings and hooks

Sterling SDAA 25-100 Dehumidifier User Manual

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