SDA 1000-5100 Series
Large Dehumidifying Dryer
AP-1 Control
Part Number: 882.00295.00
Bulletin Number: DH1-615
Effective: 12/01/05
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.
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Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
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 shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given, at the manufacturer’s
discretion. If the item is found to be defective in materials or workmanship, and it was
manufactured by our company, purchased components are covered under their specific
warranty terms.
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Table of Contents
CHAPTER 1: SAFETY................................................................7
1-1
How to Use This Manual .............................................................................................7
Safety Symbols Used in this Manual.....................................................................7
Warnings and Precautions ..........................................................................................8
Responsibility ..............................................................................................................9
General Responsibility...........................................................................................9
Operator Responsibility.........................................................................................9
Maintenance Responsibility.................................................................................10
Reporting a Safety Defect ...................................................................................11
1-2
1-3
CHAPTER 2: FUNCTIONAL DESCRIPTION...........................12
2-1
2-2
Models Covered in This Manual................................................................................12
General Description...................................................................................................12
Specifying a Drying System ................................................................................12
What is Desiccant?..............................................................................................12
The Closed Loop Drying System.........................................................................12
The Process/Regeneration Cycle........................................................................13
Sequence of Operation .......................................................................................13
Standard Features.....................................................................................................14
Auto Start Timer ..................................................................................................14
Mechanical Features...........................................................................................14
Electrical Features...............................................................................................14
Options......................................................................................................................15
Dewpoint Extend .................................................................................................15
Closed-Loop Regeneration .................................................................................15
Drawings and Diagrams............................................................................................16
Process Aftercooler.............................................................................................18
Aftercooler Design Specifications........................................................................18
Process Air Dust Collector...................................................................................18
Material Overdrying Protection............................................................................20
Mechanical Options.............................................................................................21
Electrical Options ................................................................................................21
Controller Options ...............................................................................................21
Safety Devices and Interlocks...................................................................................22
2-3
2-4
2-5
2-6
Dimensions and Specifications
......................................................................24
Mechanical Options ......................................................................................24
Electrical Features...............................................................................................25
Electrical Options ................................................................................................25
CHAPTER 3: MECHANICAL INSTALLATION ........................26
3-1
3-2
3-3
3-4
3-5
3-6
Uncrating the Equipment...........................................................................................26
Rigging and Placing Unit...........................................................................................26
Making Electrical Connections ..................................................................................26
Making Gas Line Connections (Gas-Fired Models Only)..........................................27
Checking for Proper Blower Rotation........................................................................28
Making Dryer/Drying Hopper Process Air Connections ............................................29
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3-7
3-8
Connecting Aftercooler/Precooler Cooling Water (Optional).....................................32
Using the Drying Hopper Air Trap .............................................................................33
CHAPTER 4: CONTROLS........................................................34
4-1
4-2
Controller Description................................................................................................34
Identifying Control Panel Components for the AP-1 Optional Controller...................35
Disconnect Switch...............................................................................................35
Control Power Switch..........................................................................................35
Touch Screen......................................................................................................35
Alarm Horn & Light..............................................................................................35
Process Air Temperature and Conveying Process Controller...................................35
Identifying Controller Screens ...................................................................................36
Redundant Safety Controller Display ........................................................................49
Setting the Redundant Safety Controller...................................................................50
4-3
4-4
4-5
4-6
CHAPTER 5: OPERATION.......................................................52
5-1
5-2
5-3
5-4
5-5
Start-up......................................................................................................................52
Using the Dryer Status Screen..................................................................................53
Alarms .......................................................................................................................54
Alarm Descriptions ....................................................................................................54
Shutdown ..................................................................................................................55
CHAPTER 6: MAINTENANCE .................................................56
6-1
6-2
Maintenance Schedule..............................................................................................56
Preventative Maintenance.........................................................................................57
Cleaning or Replacing the Process Air Filters.....................................................57
Cleaning or Replacing the Regeneration Filter....................................................58
Calibrating the Dirty Filter Alarm..........................................................................58
Checking the Dewpoint Control System..............................................................59
Corrective Maintenance ............................................................................................60
Symptoms of Worn Out Desiccant ......................................................................60
Replacing the Desiccant......................................................................................60
Replacing the Process Heater (Electric Dryers)..................................................61
Replacing the Regeneration Heater (Electric Dryers) .........................................62
6-3
CHAPTER 7: TROUBLESHOOTING .......................................64
7-1
7-2
7-3
Introduction................................................................................................................64
Basic Troubleshooting...............................................................................................64
Determining Temperature Controller Errors or Sensor Errors...................................66
Using a Thermocouple ........................................................................................66
Using a Platinum Resistance Thermometer........................................................66
CHAPTER 8: APPENDIX..........................................................67
8-1
8-2
Warranty....................................................................................................................67
Technical Specifications............................................................................................68
Annex B Information............................................................................................68
Spare Parts List.........................................................................................................69
Dryer Identification (Serial Number) Tag...................................................................70
Technical Assistance.................................................................................................72
8-3
8-4
8-5
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Parts Department ................................................................................................72
Service Department.............................................................................................72
Sales Department................................................................................................72
Contract Department...........................................................................................72
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Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining the large
dehumidifying dryer. The purpose is to assist you in applying efficient, proven techniques
that enhance equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the 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 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 the dehumidifying dryer provides excellent,
long service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING! WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
Caution!
CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property damage.
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Dryer Safety Tags
Tag Description
Tag
Description
Read Operation &
Installation Manual
High Voltage Inside
Enclosure
Hot!
Lifting Point
Earth Ground
Protected Earth
Ground
PE
1-2 Warnings and Precautions
Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes. This may include, but
is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international
regulations.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:
; 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.
; 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 you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
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; Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the 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 a
negative way following an accident. The following are some of the ways that accidents can
affect your production:
• Loss of a skilled operator (temporarily or permanently)
• Breakdown of shop morale
• Costly damage to equipment
• Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group from
the management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.
Hold daily equipment inspections in addition to regular maintenance checks. You will keep
your equipment safe for production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.
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
Large Dehumidifying Dryers
Safety
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employer probably has established a set of safety rules in your workplace. Those rules, this
manual, or any other safety information will not keep you from being injured while operating
your equipment.
Learn and always use safe operation. Cooperate with co-workers to promote safe practices.
Immediately report any potentially dangerous situation to your supervisor.
;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:
• 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.
;When changing control settings to perform a different mode of operation, be sure
selector switches are correctly positioned. Locking selector switches should only be
adjusted by authorized personnel and the keys removed after setting.
;Report the following occurrences IMMEDIATELY:
• unsafe operation or condition
• unusual dryer action
• leakage
• improper maintenance
• NEVER stand or sit where you could slip or stumble into the
dehumidifying dryer while working on it.
;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.
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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.
If you need to repair a large component, use appropriate handling equipment. Before you use
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)
be sure the load does not exceed the capacity of the handling equipment or cause it to become
unstable.
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using
them to lift a load.
Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.
When you have completed the repair or maintenance procedure, check your work and remove
your tools, rigging, and handling equipment.
Do not restore power to the 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.
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Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for 600-3000 cfm
Large Dehumidifying Dryers with AP1 control. These dryers are available with electric
heaters or gas burners. Gas dryers are indicated with a “G” in the model number. Model
numbers are listed on the serial tag. Make sure you know the model and serial number of
your equipment before contacting the manufacturer for parts or service.
Our dehumidifying dryers are designed to generate heated, dehumidified air at carefully
controlled temperatures for use in closed-loop plastic drying systems. Dehumidifying dryers
are sized to meet the specific requirements stated by the Customer at the time of purchase.
2-2 General Description
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 by the plastics industry to generate very low dewpoint
air that is heated to a controlled temperature for drying plastic pellets and regrind.
The drying system consists of a dry air source and drying hoppers with process heating
controls. The dry air source controls two primary sub-systems, the process air and the
regeneration circuit. Each dryer has a left and a right desiccant bed so that one bed can
regenerate while the other is in use. 2000-3000 cfm dryers feature two sets of desiccant beds,
for a total of four desiccant beds.
The drying system can be configured for one drying hopper or for as many as 20 hoppers.
The process air heater can be located on the dryer or on each individual drying hopper.
Heaters that are located on the drying hoppers can be set up with their own independent
controls or can be controlled centrally using the main dryer controller.
Specifying a Drying System
There were many variables considered in the selection of your drying system, including: type
of materials, residence time, throughput of the extruder or injection molding machine,
ambient air moisture and temperature, and the altitude at the processing site. Should your
operating environment change, we can advise you on necessary equipment, process time and
temperature modifications.
What is Desiccant?
Desiccant is a material that attracts and holds (absorbs) water from the air. The desiccant our
dryers use is a synthetic crystalline metal aluminosilicate that is blended with a clay binder
and formed into beads.
Absorbed water is driven from saturated desiccant by heating it to a high temperature
(reducing the desiccant's capacity to hold water) and forcing air through it. This moisture
removal process is called "regeneration".
The Closed Loop Drying System
These 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,
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Functional Description
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moisture is stripped from the air by a desiccant bed. The dried process air is then re-heated
and delivered back into the drying hopper to dry material again.
This system is a "closed loop", because ambient (outside) air is never introduced into the
process air. The closed loop system is used by the manufacturer 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.
The Process/Regeneration Cycle
There are two desiccant beds in a dryer up to 1500 cfm. Larger dryers have four beds (two
left and two right beds). While one desiccant bed is on-line in the process air loop, the other
is off-line being regenerated (see Figure 1).
When a desiccant bed is on-line, it absorbs moisture from the process air. The desiccant will
become saturated with moisture and need to be regenerated. The dryer automatically redirects
the process airflow to the second bed and starts regenerating the first bed.
During regeneration, air is heated to approximately 550°F and forced through the saturated
desiccant. The moisture driven off the desiccant is bled to the atmosphere. The regeneration
heater is then turned off while the regeneration blower continues to blow air through the
desiccant bed until it is cooled.
Figure 1: Regeneration Cycle
AD600-AD1500
Dryer Flow Schematic
Right Desiccant in
Regeneration
AD600-AD1500
Dryer Flow Schematic
Left Desiccant in
Regeneration
Regeneration
Blower
Regeneration
Blower
Regeneration
Filter
Dryer Valve
Regeneration
Filter
Dryer Valve
Insulated
Drying
Hopper
Insulated
Drying
Hopper
Regeneration
Heaters
Regeneration
Heaters
Process
Heater
Process
Heater
Regeneration
Exhaust
Process
Filter
Regeneration
Exhaust
Process
Filter
Left Desiccant
Right Desiccant
Left Desiccant
Right Desiccant
Process
Blower
Process
Blower
Sequence of Operation
When the dryer is started, the main air valve rotates 360º and then moves to place the last
successfully regenerated desiccant bed online. If the dryer was powered off using the main
power disconnect or E-stopped, then the regenerating bed is placed back into regeneration,
and the regeneration cycle is started over. The main air valve is allowed a period of time to
move from one position to the other. If the main air valve does not complete positioning
within the allotted time, then a “Main Air Valve Fail” alarm is generated and the dryer stops
the process air blower and disables the drying hoppers and regeneration circuit.
If the closed loop regeneration option is enabled, the regeneration closed loop valve moves to
the open loop position. The system always begins the cooling phase for a regeneration cycle
using ambient (open loop) air. The closed loop regeneration valve is allowed a period of time
to move from the closed to the open loop position and a “Closed Loop Valve” alarm is
generated if the valve fails to reach the commanded position within this time. This alarm will
disable the regeneration circuit but does not stop the process air system or drying hoppers.
Large Dehumidifying Dryers
Functional Description
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Once the main air valve and closed loop regeneration valve are in place, the process air
blower starts. The system monitors the process air blower’s overload, starter auxiliary contact
feedback and air pressure. Loss of any of these items when the process air blower is running
will cause the process air blower and the drying hopper’s process heaters to shut down.
The process air heaters (or gas burners, on gas-fired dryers) will turn on after a delay to allow
the process air blower to accelerate the operating speed.
During normal operation, one set of desiccant beds is connected to the process air circuit
while the other set is being regenerated. When the offline beds are done regenerating, they
will be switched into the process air circuit and the other beds will be regenerated. The
default bed switch setting is based on time. If the Dewpoint Switch option is enabled, the
beds will switch when the process air dewpoint reaches the dewpoint switch point. The
dewpoint option will automatically disable itself and an alarm will be generated if the
dewpoint sensor or related electronics fail.
2-3 Standard Features
Auto Start Timer
The autostart timer is used to automatically start and stop the dryer at the time you specify. It
can be programmed for one start and/or stop event per day for a week. When the Auto Start
Timer is enabled, the dryer will automatically start and stop at pre-programmed times. If the
dryer is stopped due to the Auto Start Timer, the DRYER STATUS message will indicate
that the Auto Start timer is active.
Mechanical Features
; 180ºF – 250ºF Drying temperature range
; High regeneration temperature control safeties
; 13X desiccant (molecular sieve)
; Easy to access process, regeneration, and combustion air filters.
; High pressure centrifugal blower
; Dew point +15º F to –40º F
Electrical Features
; Electrically-actuated air valve
; NFPA79, UL & CUL machinery electrical standards (Electric Dryers) includes:
•
•
•
•
•
•
•
NEMA 12 controls, components & enclosure
Non-fused electrical disconnect
Solid state relays for heater control
Branch fusing
Lockable power disconnects
Regeneration temperature control
“Process high temp” indication light and audible alarm
• 7 day timer
Large Dehumidifying Dryers
Functional Description
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•
Sequence shutdown switch
; NFPA86, UL, AGA & CGA machinery electrical standards (Gas Dryers)
; Available supply voltages of 208, 230, 460, 575/3/60 and 400/3/60
2-4 Options
Dewpoint Extend
The Dewpoint Extend option measures the temperature of the moist air as it is bled to the
atmosphere after regeneration. After a period of time, the bleed temperature will rise. This
condition, called "bed breakthrough" indicates that the bed is dry. At bed breakthrough, the
bleed air temperature peaks between 350°F and 400°F.
The regeneration heaters turn off automatically on bed breakthrough for additional energy
savings. A 550°F regeneration temperature will dry the desiccant beds sufficiently to produce
process air dewpoint of -40°F. In a properly sized system, this ultra-low humidity level will
be more than adequate to dry plastics to as little as .003% moisture.
Closed-Loop Regeneration
An optional regeneration closed-loop valve and heat exchanger can be used to close the
regeneration loop during the cooling portion of the regeneration cycle. If this option is
enabled on the dryer, air will be bled to the atmosphere until the heating portion of the
regeneration cycle is finished. Then, the regeneration closed loop valve will direct air through
a water-cooled heat exchanger and back into the regeneration loop (see Figure 2).
Figure 2: Closed Loop Regeneration
Regeneration
Blower
Regeneration
Blower
AD600-AD1500
Dryer Flow Schematic
Regeneration Heating is
Activated
AD600-AD1500
Dryer Flow Schematic Dryer Valve
Regeneration Closed Loop
Cooling is Activated
Dryer Valve
Regeneration
Filter
Regeneration
Filter
Optional
Optional
Regeneration
Closed Loop
Cooler
Regeneration
Closed Loop
Regeneration
Cooler
Regeneration
Heaters
Heaters
Regenerarion
Exhaust
Regeneration
Exhaust
Optional
Regeneration
Closed Loop
Valve
Optional
Regeneration
Closed Loop
Valve
Left Desiccant
Left Desiccant
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Functional Description
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2-5 Drawings and Diagrams
Regeneration
Blower
Insulated
Drying
Hopper
Regen.
Filter
Process
Air Filter
Process
Heater
Optional
Regeneration
Closed Loop
Cooler
Regen.
Exhaust
Optional
Regeneration
Closed Loop
Valve
Optional
After-cooler
Right Desiccants
Left Desiccants
Dryer Valve
Process
Blower
Airflow Schematic: 2000-3000 cfm dryers (4 desiccant beds). Left desiccant beds are
regenerating—closed loop regeneration is activated.
Regeneration
Blower
Insulated
Drying
Hopper
Regen.
Filter
Process
Air Filter
Process
Heater
Optional
Regeneration
Closed Loop
Cooler
Regen.
Exhaust
Optional
Regeneration
Closed Loop
Valve
Optional
After-cooler
Right Desiccants
Left Desiccants
Dryer Valve
Process
Blower
Airflow Schematic: 2000-3000 cfm dryers (4 desiccant bed). Left desiccant beds are
regenerating in open-loop regeneration mode.
Large Dehumidifying Dryers
Functional Description
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Filter Check
Gage
Differential
Pressure
Switch
Thumb Screws
PS
Cartridge Filter
Dust Shroud
Filter Retainer
Slide Gate
Clamp
Dust Pan
Dust Level
Indicator
Optional dryer dust collector
Large Dehumidifying Dryers
Functional Description
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Process Aftercooler
The optional aftercooler cools the moist air returning to the dryer from the drying hopper.
The aftercooler can cool the return air from 250ºF to about 150ºF. This maintains the dryer’s
efficiency and condenses the unwanted plasticizer from the air stream. The aftercooler
requires a cooling water connection (see Figure and page 25).
Figure 3: Process Aftercooler
Mounting
Brackets
Mounting Brackets
High
Temperature
Gasket
Cooling Coil
Cooling Coil
Pipe Gasket
Stainless Steel Cooler
Housing
Stainless Steel
Cooler Housing
High
Temperature
Gasket
Cooling Coil
Cooling Coil
Cover Plate
Cooling Coil
Cover Plate
Cooling Coil
Pipe Gasket
Aftercooler Design Specifications
Entering water temp.
ºF
ºC
85ºF
29ºC
Process Air Dust Collector
The optional process air dust collector consists of a filter, dust can, pressure gauge, and
optional pressure switch (see Figure). The gauge will let you know whether it is time to clean
out your filters. The optional dirty filter alarm will be activated if the filter is dirty.
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Figure 4: Process Air Dust Collector
Filter Check
Gage
Differential
Pressure
Switch
Thumb Screws
PS
Cartridge Filter
Dust Shroud
Filter Retainer
Slide Gate
Clamp
Dust Pan
Dust Level
Indicator
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Material Overdrying Protection
Material Overdrying Protection is an automatic system used to reduce the chance of over-
drying, and possibly melting, the resin in the drying hopper. Material Overdrying Protection
activates when the return temperature is above a set value, indicating that all the resin in the
hopper is dry.
The control system monitors the return air temperature and automatically changes the process
air setpoint to the SET BACK SETPOINT value when the return air temperature rises above
the set back temperature. The process air setpoint returns to normal when the return air
temperature falls below the SETUP TEMPERATURE value. The target values for
changing the process air setpoint can be adjusted on the Mat Protect screen.
Recommended Temperature Settings
Drying Temperature (ºF) 160 180 200 220 240 260 280 300 320 340 360
Setpoint
120 125 130 135 135 140 150 160 170 180 200
Figure 5: Material Miser/Air Balance Valve
Temperature
Probe
Valve
Proofing
Coupling
Switch
Drying
Hopper
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Mechanical Options
; Low temperature operation (120°F to 250°F)
; High temperature operation (250°F to 400°F)
; Precooler (Required for temperatures below 180°F, used with low temperature
operation)
; Aftercooler (Required for temperatures above 250°F, used with high temperature
operation)
; Plasticizer trap / Aftercooler w/filter
; Temperature Set Back
; Automatic airflow reduction valve (not for gas dryers)
; 13X desiccant
; Closed loop cooling valve
; Dew point +15°F to -80°F
; Sound insulation for under 85 DBA noise level
; Dust collector
Electrical Options
; Hopper mounting of the process heater box
; Remote operator interface (with standard controller only)
; Ethernet module for remote communication w/data logging
; CSA approval
; UL rating
; 400/3/50 supply voltage (includes CE compliance)
Controller Options
; Dew point meter w/regeneration on demand
; Phase detection
; Airflow monitoring
; Temperature setback
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2-6 Safety Devices and Interlocks
This section includes information on safety devices and procedures that are inherent to the
large dehumidifying dryer. This manual is not intended to supersede or alter safety standards
established by the user of this equipment. Instead, the material contained in this section is
recommended to supplement these procedures in order to provide a safer working
environment.
At the completion of this section, the operator and maintenance personnel will be able to do
the following:
•
•
•
Identify and locate specific safety devices.
Understand the proper use of the safety devices provided.
Describe the function of the safety device.
Safety 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 large
dehumidifying dryer; however, it is the responsibility of the personnel operating and
maintaining the equipment to familiarize themselves with the safety procedures and the
proper use of any safety devices.
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch
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 the large dehumidifying dryer 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 machines.
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.
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In addition to the safety devices listed above, these dehumidifying dryers are equipped with a
line cord plug. This allows the operator or maintenance personnel to unplug the system from
its power source and tag it out. The plug can then be tagged with any number of approved
electrical lockout tags available at most electrical supply stores.
WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning the dehumidifying dryer. Failure to do so may
result in serious injury. No one but the person who installed the lockout may remove it.
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Dimensions and Specifications
9 Denotes availability
CFM
600 850 1000 1250 1500 2000 2500 3000
(Electric Dryer w/ Basic Control)
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
(Electric Dryer High Performance)
(Gas Dryer option in lieu of Electric- 180°F to 250°F)
Gas dryer 250°F -400°F temp. range, includes aftercooler,
insulated drying hose, & high temp. return air hose
Gas central dryer (no process gas heater)
Dimension and Specifications
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
(Gas & Electric Dryer)
Air inlet/outlet: OD, in inches (mm)
8(203)
10(254)
12(305)
Gas Flow Requirement (Gas Dryers)
Low Heat Gas Flow Rate (CFH)
High Heat Gas Flow Rate (CFH)
Exhaust Duct Sizes in inches (MM)
Comb. Flue Air Flow (CFM)
159 225 265 331 397 528 661 793
227 322 378 473 568 756 945 1,134
3(76)
87 123 145 182 218 290 363 436
Overall Dimensions (Electric Dryers)
4(102)
5(127)
6(152)
Dimensions (in inches)
Height
Depth
Width
67
96
63
81
118
83
150
73
Shipping Weight (in lbs.)
Dimensions (in inches)
2100 2200 2950 4350 4700 6500 7300 8450
Overall Dimensions (Gas Dryers)
Height
Depth
Width
67
96
63
83
118
85
150
73
Shipping Weight (in lbs.)
2950 3050 3800 5150 5800 8125 8875 9050
Mechanical Options
9 Denotes availability
CFM
Option Description
600 850 1000 1250 1500 2000 2500 3000
Low temp operation 120°F to 180o F. (Electric dryers only)
High temp operation for the electrical dryers, 180°F to 400o F.
High temp operation for the Gas dryers, 250°F to 400o F.
Plasticizer trap/ After Cooler w/Filter
Aftercooler
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
Over Drying Protection
Temperature Set Back
Automatic airflow reduction valve. (Not for gas dryers)
13X Desiccant
9
9
9
9
STD
Closed Loop Cooling Valve
(Std. w/high performance)
9
9
9
9
Dew Point +15°F to –40°F
Dew Point + 15°F to -80°F
9 (Not with high performance)
9 (Standard with high performance)
Sound Insulation Package for under 85 DBA Noise Level
Dust Collector ADC
Process Heater 180°F to 250°F
Process Heater 180°F to 400°F
Not Required
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
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Electrical Features
CFM
Dryer AMP Draw
600 850 1000 1250 1500 2000 2500 3000
Full load Amps
152 217 249 314 378
Standard voltage Low Heat (Electric Dryers)
208v/3/60Hz.
230v/3/60Hz.
N/A
137 196 225 284 342
400v/3/50Hz.
79 113 129 163 197 270 339 424
460v/3/60Hz.
575v/3/60Hz.
Standard voltage High Heat (Electric Dryers)
208v/3/60Hz.
230v/3/60Hz.
69
55
98 112 142 171 234 294 370
78
90 114 137 188 236 295
Full load Amps
207 296 342 430
187 267 309 389
N/A
400v/3/50Hz.
108 154 178 224 269 366
N/A
460v/3/60Hz.
575v/3/60Hz.
Standard voltage (Gas Dryers)
208v/3/60Hz.
230v/3/60Hz.
400v/3/50Hz.
460v/3/60Hz.
575v/3/60Hz.
94 134 154 194 234 318 399 494
75 107 123 156 187 254 319 395
Full load Amps
36
33
19
16
13
47
43
48
44
61
55
32
28
22
75 120 150 191
67 109 136 173
25
22
17
39
34
27
62
54
43
78
67
54
99
87
69
Electrical Options
9 Denotes availability
CFM
Option Description
600 850 1000 1250 1500 2000 2500 3000
AP1 control
(Includes: 4”x2” touch screen and dew point monitoring, 7
day timer, dirty filter indication, & temperature setback.)
Hopper mounting of the process heater box
Remote operator interface
9
9
9
CF
Redundant process temperature safety
Ethernet module for remote communication w/ Data logging
CSA approval
9 (Standard w/High Performance)
9
9
UL rating
9
Supply voltages 400/3/50 (includes CE compliance)
Audible & Visual Alarm
9
9 (Standard w/High Performance)
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Chapter 3: Mechanical Installation
3-1 Uncrating the Equipment
The large 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 1’ x 4’ wood supports. Cut the steel banding.
2. Use a pry bar to remove the blocks securing the unit to the skid.
3. Lift unit from sides, inserting forklift under the base. The forks must be equidistant
from the centerline of the unit and the unit must be balanced on the forks. Lift slowly
and only high enough to clear the skid. Use a pry bar if necessary to carefully remove
the skid from the unit.
4. Lower slowly.
5. Remove the temporary hardware that has been installed to prevent the side panels
from shifting in transit. Retain the crating material for reshipping the components in
case hidden shipping damage is found.
3-2 Rigging and Placing Unit
As with all equipment installations, follow all applicable codes and regulations.
„ Locate close to the process to reduce piping expense.
„ Locate adjacent to drain and city water sources (If equipped with aftercooler).
„ Consult a structural engineer to assure that the floor, mounting pad or structural steel
support is of adequate strength.
„ Allow for required service clearances necessary for maintenance and easy access to all
components.
3-3 Making Electrical Connections
Refer to local electrical codes, the schematic, and connection diagrams supplied with this unit
and the serial tag for wiring considerations. Run all wiring in conduit if codes require it.
Label all wiring to make any future troubleshooting easier.
When making electrical connections to your dryer, ensure that you take into consideration
and make arrangements for the following:
; A qualified electrician should make all electrical connections.
; The serial tag lists voltage, phase, and amp draw information. 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%).
; 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.
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; Make sure all electrical connections are tight.
3-4 Making Gas Line Connections (Gas-Fired Models Only)
Connect a gas line to the dryer’s gas inlet. See Figure 6 for a detailed schematic of the gas
system.
Figure 6: Gas Flow Schematic
Gas Dryers Air
Fuel Train
9
10
7
24
25
6
8
5
PS
PS
11
18
4
C
B
19
15
PS
4
12
23
13
3
1
2
16
15
PS
PS
16
14
3
17
16
3
P
S
3
PS
20
20
20
20
21
21
21
21
22
22
22
22
Fume
Exhaust
Item
1
2
3
4
5
6
7
8
Description
Manual gas shut off valve
Gas regulator
Gas pressure switch
Process gas solenoid valve
Manual adjustable butterfly valve
Process gas proportionator
Process air actuator
Item
14
15
16
17
18
19
20
21
22
23
24
25
Description
Regeneration gas regulator
Regeneration air solenoid valve
Regeneration gas solenoid valve
Regeneration gas proportionator
Regeneration butterfly orifice valve
Regeneration air actuator
Adjustable gas orifice
Regeneration thermocouple
Regeneration SER burner
Air pressure switch
9
Process ratiomatic burner
Process gas heat exchanger
Gas pressure switch
Process combustion air blower
Process combustion air filter
10
11
12
13
Regeneration & combustion air filter
Combustion air blower
Air pressure switch
DANGER! Natural gas burners are started, stopped, and monitored independently of
the dryer controls using EclipseTM Bi-Flame burner controls. Read and
follow the burner control manufacturer’s operating and safety instructions
and applicable NFPA© (National Fire Protection Association) codes in
addition to your local rules and regulations. The Eclipse Bi-Flame model
6500 Dual Burner Monitoring System (instruction manual no. 826, 05/03)
should be included with the dryer. It is also available online at
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3-5 Checking for Proper Blower Rotation
After the electrical connections have been made, check the process and regeneration blowers
for proper blower rotation. Check blower rotation before making process air connections
between the dryer and hoppers, and before connecting cooling water (for the optional
aftercooler).
Blowers should rotate in a clockwise direction opposite shaft end. See Figure.
The blowers are rotating properly when air flows from the delivery outlet.
Incorrect phasing of power leads will cause backward rotation of blower motors and
contamination of the desiccant.
If both blowers are rotating improperly, reverse any two wires at the fused disconnect outside
the dryer or at the disconnect/terminal in the control enclosure. This assures that both blowers
will be rotating in the proper direction.
If just one blower is rotating incorrectly, reverse the wires at the motor starters.
Figure 7: Checking Blower Rotation
Process Blower
Regeneration Blower
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3-6 Making Dryer/Drying Hopper Process Air Connections
When making process air connections to your dryer, ensure that you take into consideration
and make arrangements for the following:
; Use high-temperature flexible dryer hose or rigid tubing to connect the dryer to the
drying hopper.
; Keep the delivery (to the drying hopper) hose as short as possible to minimize heat
loss. Insulated hose is recommended and available for maximum energy savings.
; Do not use insulated hose on the return (from the drying hopper)
; Do not shorten the return hose. The return air to the blower must be 150°F or below.
; Make sure the hoses are not kinked.
; Drying hopper air inlet and outlet locations vary, but always connect the hoses so the
dry process air from the dryer enters the bottom of the drying hopper and flows out
the top to return to the dryer inlet.
Figure 8: Dryer/Drying Hopper Process Air Connections
Return air
thermocouple
(Do not insulate)
location
Process Air Heater on Dryer
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Return air
thermocouple
location
Process Air Heater on Drying
Hopper
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Return air
thermocouple
location
Drying System with Dust Collector
and Process Air Heater on Dryer
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3-7 Connecting Aftercooler/Precooler Cooling Water (Optional)
Support both sides of the fitting when making the cooling water connections to prevent
damage to the aftercooler coil. See Figure.
Connect 85°F water to the inlet closest to the exiting air side of the aftercooler coil. This will
cool the process air about 100°F and raise the water-out temperature about 10°F. The table
below lists available aftercooler models and their flow rates.
Figure 9: Aftercooler Components & Flow Rates
Mounting Brackets
Cooling Coil
Cooling Coil
Pipe Gasket
Stainless Steel Cooler
Housing
High
Temperature
Gasket
Cooling Coil
Cover Plate
Mounting
Brackets
High
Temperature
Gasket
After cooler
Water Flow
Model
(GPM)
600
10
850
10
1000
1250
15
15
20
1500
2000
25
Stainless Steel
Cooler Housing
2500
30
Cooling Coil
3000
35
Cooling Coil
Cover Plate
Cooling Coil
Pipe Gasket
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3-8 Using the Drying Hopper Air Trap
Our exclusive air trap assembly in the top of the drying hopper prevents ambient air from
contaminating the material being dried. To ensure that air does not enter the drying system,
do the following (See Figure):
; Keep the material level above the bottom edge of the air trap for maximum
efficiency.
; Use a hopper loader or vacuum conveying system to maintain the proper material
level.
Figure 10: Drying Hopper Air Trap
Flapper Valve
of the loader
Suggested material level
for the optimum
efficiency.
Return air from the
drying hopper.
Air Trap
Insulation
Delivery low dew point,
heated air to the drying
hopper.
Recommended process
temperature control
thermocouple location.
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Chapter 4: Controls
4-1 Controller Description
The AP1 control package uses a PLC with a touch screen interface to control the operation of
the dryer. See for descriptions of each screen.
Figure 11: Controller Screen Descriptions
Main Menu. The main navigational screen. Used to access status and set-up screens.
Dryer Status Screen. Displays actual dryer temperature and temperature setpoint, as well as
actual dewpoint.
Dryer Menu. Navigational screen for dryer status, setup and other options
Dryer Setup Screen. Used to set high and low temperature alarms. Also used to enable or
disable closed-loop drying. Closed-loop drying is not available on single blower dryers.
Over-Dry Protect Screen. Used to enable/disable and configure material overdrying
protection. Also displays actual return temperature.
Autotune Screen. Used to start and stop autotuning. Also displays PID settings.
Dew Pt Setup Screen. Used to configure dewpoint alarms. Also used to enable/disable
dewpoint switching.
Autostart Screen. Used to configure the autostart timer.
System Menu. Navigational screen for system settings.
Setup Screen. Used to configure alarm duration and passwords.
Set Clock Screen. Used to configure the system clocks.
Hour Meter Screen. Used to view and reset the hour meters for the dryer, machine blower,
and dryer blower.
I/O Status Screen. Used to view the status of inputs and outputs used by the dryer’s
controller.
System Backup. This screen is used to save and restore the dryer settings.
Service Menu. This screen is password protected and meant for the manufacturer’s service
personnel use only.
Alarm History Screen. Used to scroll through the alarm history.
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4-2 Identifying Control Panel Components for the AP-1 Optional
Controller
Disconnect Switch
The Disconnect Switch is located in the front upper right hand corner of the control
enclosure. It allows the user to disconnect power to the dryer for emergency shutdown,
service or long periods of inactivity.
Control Power Switch
The Control Power Switch is located on the front of the control enclosure below the touch
screen. The switch energizes the control circuit (PLC, touch screen, relays, etc.) within the
control enclosure.
Touch Screen
The Touch Screen is located in the center of the control enclosure. Once the disconnect is
on and the control circuit is energized, the machine can be started and parameters can be
adjusted through the touch screen.
Alarm Horn & Light
The Alarm Horn and the Alarm Light are located on the top of the enclosure. These
devices give an audible and visual indication that there is a malfunction with the system.
4-3 Process Air Temperature and Conveying Process Controller
AEC dryers equipped with the “AP-1” control package use a PLC with a touch screen
interface to control the operation of the dryer system. This section of the manual will address
those parameters that allow the user to optimize the drying/conveying system for specific
applications.
(Dryer Status Screen)
(Startup Screen)
The screen shown above provides the operator with the following information:
• Dryer Model Number
• Temperature units (In Celsius or Fahrenheit)
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• Copyright Information
• PLC Version
• Display Version
After approximately 10-12 seconds the controller will flash to the Dryer Status Screen shown
on the previous page.
4-4 Identifying Controller Screens
Main Menu Screen
(Main Menu Screen)
The MAIN MENU provides information on the following system parameters:
• DRYER
• ALARMS
• HELP
• SYSTEM
• LOG OFF
Press the DRYER MENU button to return to the next section of dryer functions.
Typical Dryer Screens
(Dryer Status Screen)
(Shown at Controller Power Up)
(Looking at the screen from Left to Right)
The SETPOINT button allows the operator to set the process air
temperature.
The ACTUAL value will give you a reading of what the actual
process air temperature is entering the drying hopper.
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The DEW POINT value will give you a reading of what the actual
process air dew point is.
The area in the lower left portion of the touch screen conveys two
lines of information relating to the overall operation of the dryer.
The following is a list of typical machine/dryer summary status
line text messages:
1. Dryer Off
2. Left Bed In Process
3. Right Bed In Process
4. Valve Changing Position
5. Autostart Timer Enabled
6. Autotune in Progress
7. Over-dry Protect Active
8. Left Bed Heat
9. Left Bed Cool
10. Left Bed Ready
11. Left Bed Failure
12. Left Bed Process Failure
13. Right Bed Heat
14. Right Bed Cool
15. Right Bed Ready
16. Right Bed Failure
17. Right Bed Process Failure
18. Dyer is Shutting Down
19. Process Offline
The START BUTTON allows the user to stop and start the dryer manually. When
the start button is pressed, the dryer begins to operate. The text in the button will
change from START to SHUTDOWN. The next time the button is pressed, the
dryer will go into a sequence shutdown and the button text will change to
RESTART. The process heater will shut off, the current bed regeneration will be
completed and then the blower will stop. If sequence shutdown is not desired,
turning the POWER SWITCH off will turn off all components of the dryer
immediately and the optional conveying system will be turned off also.
When the button shows ALARM, the process temperature is too hot to start the
dryer. When the process air temperature falls below the setpoint, the button changes
to either START or RESTART, you may begin dryer operation.
SETTING VALUES
By pressing and holding the numbers in the SETPOINT button, the following screen will be
displayed:
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Enter the values you would like to set in the screen by pressing the number keys. Press ENT
(Enter) when you are finished to set the new values or CLR (Clear) to erase the current
values and reenter new ones. To set the values in the next field, press ENT (Enter) to close
the screen shown above. Then select the next number field to enter new values.
For fields with a decimal point (X.X) enter the number assuming there is a decimal point
present. For instance, to enter a 5.8 into an X.X field simply enter "58."
DRYER MENU
Pressing this button will take the user to another screen where more machine parameters can
be viewed and adjusted.
(Dryer Menu Screen)
The screen shown above will allow the operator to set/review operating parameters for the
following:
•
•
•
•
•
•
•
•
DRYER STATUS
DRYER SETUP
OVER DRY PROTECT
ALARMS
AUTO TUNE
DEW PT SETUP (Dew Point Setup)
AUTO START
MAIN MENU
Pressing the DRYER STATUS button will take the operator back to the original status
screen shown on page 35.
Pressing MAIN MENU will return you back to the menu screen.
Dryer Setup
There are four (4) dryer setup pages. Use the MORE and BACK buttons to switch between
the dryer setup screens.
(Dryer Setup Screen - 1 of 4)
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By pressing the LOW TEMP or HIGH TEMP alarm buttons, the operator can enter the
desired values to enable the alarm to go off at a specific deviation from setpoint (on the high
or low side).
When these settings have been made, the operator now has a choice of returning to the
DRYER MENU or entering the MAIN MENU screen.
(Dryer Setup Screen – 2 of 4)
The dryer temperature values can be switched between reading in Fahrenheit and
reading in Celsius. The dryer will continue to run using the new temperature
units if the dryer is running when the temperature units are changed. Check all
temperature related values to ensure that they are correct after changing the
temperature units.
(Dryer Setup Screen – 3 of 4)
The third dryer setup page contains process return and supply air temperature offset
values. The values can be used to bring the dryers temperature readings into agreement
with a reference source such as a calibrated lab thermometer. The user can adjust these
values +/- 10 degrees (F or C). Any number other than zero is added to the supply/return
temperature reading before it is used by the system. For instance, if the user enters an -8.0
for a process temperature offset then the original temperature reading, 165°F, would be
displayed as 157°F.
(Dryer Setup Screen – 4 of 4)
If CLOSED LOOP COOLING is ENABLED then after a pre-set amount of time has
elapsed in open loop cooling, the dryer will close the optional closed loop cooling
valve and finish the cooling portion of the regeneration cycle in closed loop. Closed
loop cooling uses an air to water heat exchanger instead of ambient air to cool the
regenerating bed.
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OVERDRY PROTECTION
(Overdry Protection Screen - 1 of 2)
This feature is used to prevent the overdrying of the plastic resin in the drying hopper.
RETURN TEMP provides the actual temperature of the process air leaving the drying
hopper.
Press the MORE button located in the top right corner of the Over-Dry Protection screen.
By pressing the MATERIAL OVER-DRY OPTION button, the operator can enable or
disable this feature.
(Overdry Protection Screen - 2 of 2)
The SET BACK SETPOINT is the lower process air temperature that will keep the
material ready for processing but not damage it over an extended period of time.
The SET BACK DELAY button prevents the control from going to the SET BACK
SETPOINT until the subject time period has elapsed.
When the return air temperature reading is above the SET BACK TEMPERATURE
the SET BACK SETPOINT is used on the process air setpoint.
When the return air temperature reading is below the SETUP TEMPERATURE, the
process air setpoint returns to normal.
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ALARMS
(Alarm History Screen)
This screen allows the operator to review the number and type of issues that the dryer has
encountered during its operation.
Problems can be viewed by Date, Hour, and Comment.
Because of the size of the screen, only three (3) comments/alarms can be viewed at a
time. Alarm history is not resetable. (Display holds up to 100 messages).
To view alarms not visible on the screen, press the DOWN button.
To return to a particular alarm, press the UP button to scroll upward in the alarm history.
Pressing DRYER in this screen will take the operator to the DRYER STATUS of the
system.
Pressing MAIN will take you to the main screen.
At this point, the operator can return back to the DRYER MENU or MAIN MENU by
touching the appropriate button on the screen.
AUTOTUNE
(Process AutoTune Screen)
This screen allows the operator to automatically tune the process air temperature control
algorithm to a specific drying application. The autotune sequence should be initiated if the
user feels there are unacceptable fluctuations in the process air temperature. The calculated
P, I, and D variables are shown for reference purposes.
The autotune feature can be activated by pressing the START/STOP button located
in the center of the screen. After autotuning is done, it will automatically stop and
give new P, I, and D variables.
AUTOTUNE IN PROGRESS or PROCESS NOT ACTIVE will inform the operator of
the current status of this feature.
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DEW POINT SETUP
(Dew Point Setup Screen)
This screen allows the operator to set the dew point.
The HIGH DEW PT ALARM is an audible/visual alarm that will sound when the process air
dewpoint rises to this value. Values can be set between –40 through +30 degrees. The
dewpoint sensor only reads to a maximum of +15. Set the high alarm value to +30 to disable
high dewpoint alarms.
Used to configure the dewpoint switch. Regeneration will switch sides when the dewpoint
reaches the switch value. If this option is disabled, regeneration will switch sides after a set
period of time.
Used to switch regeneration at this time if dewpoint does not rise above bed switch point.
Press this button to enable or disable the SWITCH ON DEW POINT feature.
AUTO START
(Autostart Timer Screen)
This screen allows the operator to set the time and day that the dryer will start
Automatically.
Pressing PREV DAY allows the operator to scroll backward through the days of the
week to select the day they desire the dryer to start.
Pressing NEXT DAY allows the operator to scroll forward through the days of the week
to select the day they desire the dryer to start.
By touching the ON TIME and OFF TIME sections on the screen, the operator can
enter the values for the time they wish the dryer to turn on and off. The time is on a 24
hour schedule (1:00pm = 13:00). If you do not want to turn the dryer on or off, enter
0:00.
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This button enables and disables the AutoStart Timer.
HELP MENU
(Help Menu Screen)
The DRYER ALARMS button shows Help menus for Dryer Alarms.
MAIN MENU
(Main Menu Screen)
This screen allows you to jump to the different areas of the controller to set, monitor, and
operate different features of the dryer.
System Screens
SYSTEM MENU
(System Menu Screen)
The screen shown above will allow the operator to set/review operating parameters for the
following:
•
•
•
•
•
SYSTEM SETUP
SET CLOCK
HOUR METERS
ALARM HISTORY
I/O STATUS
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•
•
•
SYSTEM BACKUP
SERVICE MENU
MAIN MENU
SYSTEM SETUP
(System Setup Screen)
This screen allows the operator to set alarm and password features.
ALARM OFF DUR is the amount of time (0-99 minutes) that the alarm and horn will stay
off after the alarm silence button is pushed. (When this function is set to 0, this feature will
never turn off. When it is set to 99, it will stay off until another alarm occurs.)
OPER PW is the four (4) digit number that allows access to the station and pump status
screen and the station operator screen. (When this feature is set to 0000 these screens are
not password protected.)
OPER PW DUR is the amount of time (5-99 minutes) the password will allow access to
the associated screens. The screen changes to the station status screen when the time
expires.
SETUP PW is the four (4) digit number that allows access to the setup screens. (When
this is set to 0000 there is no password protection).
Note: Factory default is Supervisor security enabled. Supervisor password is 1234.
SETUP PW DUR is the amount of time (5-99) the password will allow access to the
associated screens. When the time expires, the screen changes to the station status screen.
LOW LEVEL DETECTION SETUP
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The AP1 control system can detect and alarm a low material level condition in up to three (3)
material hoppers. The material hopper assignments on the display are “Machine Hopper 1,”
“Machine Hopper 2,” and “Drying Hopper.” Although your naming conventions may vary,
the low material level detection capability of the AP1 can still be exploited. Refer to the
provided electrical diagram for the proper wiring of the required level detection hardware.
Low material level detection will not be performed for this hopper.
Low material level detection will be performed on this hopper provided that the dryer is
running.
SET CLOCK
(Clock Menu Screen)
This menu allows the operator to set the AUTOSTART CLOCK and the ALARM CLOCK.
The Autostart clock controls the 7-day timer, which can be programmed to start or stop the
dryer automatically. An internal battery backup holds the settings in memory when the dryer
is de-energized. From the Clock Menu screen, press the SET AUTOSTART button to
access the Autostart clock.
Use the following procedure to set the Autostart clock:
1. Press the Month field on the Set Clock screen and use the keypad to enter in the
current month. Pres the ENTER button to save the value.
2. Press the Date field on the Set Clock screen and use the keypad to enter in the current
date. Press the ENTER button to save the value.
3. Press the Year field on the Set Clock screen and use the keypad to enter in the current
year. Press the ENTER button to save the value.
4. Press the Hour field on the Set Clock screen and use the keypad to enter in the
current hour. Press the ENTER button to save the value.
5. Press the Minutes on the Set Clock screen and use the keypad to enter in the current
minutes. Press the ENTER button to save the value.
6. Press the SET TIME button to save the information.
(Autostart Clock Screen)
In this screen the user can set the variables that are used to time and date stamp alarms. This
feature works in conjunction with the ALARM screen (see Page 43 ) to notify the user of
issues that the dryer had encountered during its operation.
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Press the SYSTEM MENU button to return back to the system menu screen and the next set
of programmable features.
HOUR METERS
(Hour Meter Screen)
This screen monitors the number of hours that the dryer has operated.
In addition to monitoring the total number of hours of equipment operation, it also has a
resetable field that allows the operator to set the counter back to zero. This is useful for
monitoring hours between equipment maintenance periods.
Press the DRYER button to reset the counters.
INPUT STATUS
(Input Status Screen)
This screen allows the operator to view the status of the variables contributing to the input of
material into the drying system. It also is useful in troubleshooting system issues (i.e. a dirty
filter or low material level in a hopper).
Press the OUTPUTS button to see the outputs of the dryer.
OUTPUT STATUS
(Output Status)
This screen allows the operator to view the status of the dryer.
Press the INPUTS button to see the inputs of the dryer.
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(System Backup Screen)
ACS Dryer control version 2.000 introduces a system backup feature.
Pressing SAVE SETTINGS will save the system variables for later recall.
Pressing RESTORE SETTINGS will restore previously saved values.
Pressing RESTORE FACTORY DEFAULTS will return the dryer to its factory default
state, namely:
CONVEYING:
NO CONVEYING UNITS AVAILABLE - CONVEYING DISABLED
DRYER OPTIONS:
TEMPERATURE IN FAHRENHEIT
STANDARD HEAT
OVERDRY PROTECTION DISABLED
AUTO START TIMER DISABLED
DRYER VALUES:
ALARM SILENCE DURATION
PASSWORD - OPERATOR
99 MIN
0000
PASSWORD SUPERVISOR
1234
PASSWORD OPERATOR DURATION
PASSWORD SUPERVISOR DURATION
DEWPOINT HIGH LIMIT ALARM VALUE
10 MIN
10 MIN
30 DEGF
(ALARM DISABLED)
OVERDRY SET BACK TEMPERATURE
OVERDRY SET BACK SETPOINT
OVERDRY SET UP TEMPERATURE
PROCESS AIR TEMP. SETPOINT
PROCESS AIR HI DEVIATION VALUE
PROCESS AIR LO DEVIATION VALUE
REGENERATION AIR SETPOINT
PROCESS ACTUAL VALUE OFFSET
REGEN ACTUAL VALUE OFFSET
170 DEGF
100 DEGF
90 DEGF
180 DEGF
35 DEGF
-35 DEGF
450 DEGF
0.0 DEGF
0.0 DEGF
SERVICE
(Service Menu Screen)
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This service menu screen is PASSWORD PROTECTED and meant for ACS personnel use
only.
Press the RETURN key to go back to the SYSTEM MENU.
Touching the MAIN MENU button in the SYSTEM MENU screen, will return the operator
back to the overall menu screen. In this screen, the operator will be able to select the button
that displays the ALARMS screen.
Alarm Screens
ALARMS
(Alarm History Screen)
This screen allows the operator to review the number and type of issues that the dryer has
encountered during its operation.
Problems can be viewed by Date, Hour, and Comment. Because of the size of the screen,
only three (3) comments/alarms can be viewed at a time.
To view alarms not visible on the screen, press the DOWN button.
To return to a particular alarm, press the UP button to scroll upward in the alarm
history.
At this point the operator can return back to the DRYER MENU or MAIN
MENU by touching the appropriate button on the screen.
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Alarm Screen Example
This is an example of what a typical Alarm screen looks like. The user will see the message
causing the alarm in the top half of the display with an ALARM SILENCE button in the
lower half.
To turn off the alarm, the user must press the ALARM SILENCE button. This will cancel
the alarm.
See Section 7-4: Alarms on p. 57 for alarm descriptions.
4-5 Redundant Safety Controller Display
Optional
The Redundant Safety Controller limits the process air temperature from exceeding specific
temperatures in case of a catastrophic failure of the primary PLC process air temperature
control system. 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 is necessary.
Figure 12: Typical Redundant Safety Controller Display
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4-6
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 is 150°F (-23°C).
Always put your set point to 30°F above set point.
To set the redundant safety controller:
1. Press the P button.
2. The controller will ask for a password. Press the Up
get to 10.
button until you
3. Press the Up
button until you get to your desired temperature.
4. Press P again until you get to Run.
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Chapter 5: Operation
5-1 Start-up
There are two possible methods of starting the dryer system: manually, by pressing the Start
button on the Dryer Status screens, and automatically through use of the Auto Start Timer
built into the dryer control system.
Before operating the dryer, make sure all electrical connections are tight and that the
blowers rotate in the right direction.
Use the following procedure to start the dryer manually:
1. Close the slide gate at the bottom of the drying hopper.
2. Turn on the disconnect switch in your power drop, then turn on the one on the dryer.
3. Turn the system ON/OFF switch to ON to energize the display panel.
4. On the Dryer Status screen, press the START button to start the dryer. The process
blower starts.
5. If the dryer has an aftercooler, make sure there is proper flow of cooling water
through the coil and bleed any trapped air from the system.
6. On the Dryer Status screen, press the SETPOINT button, and use the keypad to enter
the process set point value. Press the ENTER button to save the value.
7. 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, the material level in
the hopper should be maintained at a full level.
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5-2 Using the Dryer Status Screen
From the Main Menu screen, press the DRYER button to access the Dryer Status screen.
The Dryer Status screen displays the set point and actual process temperature as well as the
actual dewpoint.
(Dryer Status Screen)
The area in the lower left portion of the screen displays two lines of information relating to
the overall operation of the dryer. Typical messages include the following:
„ Dryer Off
„ Left Bed In Process
„ Right Bed In Process
„ Valve Changing Position
„ Autostart Timer Enabled
„ Autotune in Progress
„ Over-dry Protect Active
„ Left Bed Heat
„ Left Bed Cool
„ Left Bed Ready
„ Left Bed Failure
„ Left Bed Process Failure
„ Right Bed Heat
„ Right Bed Cool
„ Right Bed Ready
„ Right Bed Failure
„ Right Bed Process Failure
„ Dyer is Shutting Down
„ Process Offline
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5-3 Alarms
Use the Alarm History screen to monitor system alarms. From the Main Menu screen, press
the Alarms button to access the Alarm History screen. The three most recent alarms appear at
the top of the Alarm History screen. Use the DOWN and UP buttons to scroll through the
alarms.
(Alarm History Screen)
5-4 Alarm Descriptions
Alarm
Comment
Alarm
Description
Alarm
Effect
The Main Air Valve did not maintain
position.
Possible Motor or Limit Switch Failure.
The Main Air Valve did not find
position.
Possible Motor or Limit Switch Failure.
The Main Air Valves expected and actual
positions do not match.
VALVE
POSITION
Immediate
Shut Down
VALVE
MTR
OVERRIDE
Immediate
Shut Down
VALVE
MOTOR FAIL
Immediate
Shut Down
Possible Motor or Limit Switch Failure.
The process supply air temperature
thermocouple is out of range.
Possible thermocouple failure.
The regeneration air temperature
thermocouple is out of range.
Possible thermocouple failure.
Process air temperature deviation is
above high limit value.
PROCESS
SENSOR FAIL
Process
Shut Down
REGEN
SENSOR FAIL
Regeneration
Shut Down
PROCESS
HIGH TEMP
Process
Shut Down
Possible solid state relay failure.
Process air temperature deviation is
below low limit value.
PROCESS
LOW TEMP
Alert Only
Possible heater failure.
Process air temperature control loop is
unable to maintain the process air
temperature set point.
Possible Missing thermocouple, Failed
heater, Failed solid state relay.
PROCESS
LOOP BREAK
Process
Shut Down
REGEN
HIGH TEMP
Regeneration air temperature deviation is Regeneration
above high limit value. Shut Down
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Alarm
Comment
Alarm
Description
Alarm
Effect
Regeneration air temperature deviation is
below low limit value.
Possible heater failure.
REGEN
LOW TEMP
Alert Only
The dew point sensor is out of range.
Possible transducer or electronics
failure.
Disables
Switch on
Dew Point
DEWPOINT
SENSOR
The dew point value is above the high
limit value. Faulty sensor or PC board.
Possible ambient air contamination or
failed regeneration cycle.
Process blower is not running.
HIGH
DEWPOINT
Alert Only
PROCESS
Process
BLOWER FAIL Possible overload fault, contactor fault.
Shut Down
Process heaters are not active.
PROCESS
Process Shut
Down
Possible surface switch trip, redundant
HEATER FAIL
temperature safety trip.
REGEN
Regeneration blower is not running.
Regeneration
Shut Down
Immediate
Shut Down
Alert Only
Disables
BLOWER FAIL Possible overload fault, contactor fault.
REGEN
HEATER FAIL
DIRTY FILTER Monitored filter(s) require cleaning.
Regeneration heaters are not active.
Possible surface switch trip.
The process return air temperature
P RETURN
thermocouple is out of range.
SENSOR FAIL
Over dry
Protection
Possible thermocouple failure.
5-5 Shutdown
To prolong the life of the process air heaters and desiccant beds, the following procedure
should always be used to shut down the dryer. In an emergency situation, turning off the main
power disconnect will have the immediate effect of stopping all of the dryer’s systems, but
this is not the preferred method for shutting down the system.
1. On the Dryer Status screen, press the SHUT DOWN button to shut down the dryer.
The process heater will shut off. The process blower will shut off after ??? minutes
and the regeneration blower will shut down. The bed regeneration process will be
completed. When the dryer is re-started, the process air will be directed through the
bed that was regenerated last.
2. When processing is complete, close the hopper slide gate and shut down any in-line
companion equipment, such as aftercoolers.
3. Empty the drying hopper, if desired.
If the dryer is turned off manually (by turning off the dryer without using the above shut-
down procedure), the dryer will stop immediately. When the dryer is re-started, the process
air will be directed through the last bed that was being used when the dryer control switch
was turned off. If a bed was being regenerated when the dryer control switch was turned off,
the regeneration process will start over on the same bed. This may cause the dewpoint to
become bad for that desiccant tank.
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Chapter 6: Maintenance
6-1 Maintenance Schedule
The checklist below contains a list of items that should be inspected and/or replaced to keep
your Large Dehumidifying Dryer operating at peak efficiency. Perform each inspection at
the regular intervals listed below.
Dryer Model #
Serial #
Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/
EVERY WEEK
By
By
By
By
By
By
By
By
By
By
By
By
By
Inspect all filters for wear,
replace/clean if dirty or
worn
EVERY MONTH Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
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
Inspection
Actual Inspection
Date/By
Next Scheduled
Inspection
Actual Inspection
Date/By
EVERY YEAR
Inspect desiccant. Replace
if brown or broken
- Photocopy this page for your maintenance records -
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6-2 Preventative Maintenance
Cleaning or Replacing the Process Air Filters
Regular filter cleaning will keep your dryer operating at peak efficiency. The process air
filters protect the centrifugal blowers from plastic fines being drawn in from the drying
hopper. Filters should be cleaned when airflow restriction trips the dirty filter alarm. Filters
should be replaced at least once a year.
Caution!
Operating the dryer without the process air filters installed will void the
warranty.
On 600-1500 cfm dryers, there is a single high-temperature (up to 350ºF) filter mounted
above the process blower on the rear of the dryer. On 2000-3000 cfm dryers, there are two
high-temperature (up to 350ºF) filters located in the housing under the blower platform on the
left rear corner of the dryer.
Vacuuming. Vacuum cleaning is the preferred method for cleaning the process air filters
because compressed air or high-pressure washing can damage the filter. Vacuuming removes
most large particles and surface contaminant. Use a commercial duty vacuum cleaner and
vacuum the filter from the air intake (dirty) side only.
Compressed Air Cleaning. Blow clean, dry compressed air up and down the pleats, blowing
out the filter from the clean side. Do not shoot the air in a criss-cross motion against the grain
of the pleats—this won’t clean the filter, and it may damage it. Compressed air should be less
than 100 psi—use a 1/8 diameter nozzle at least 2 inches away from the filter.
Figure 13: Process Filter Housing
High
Temeprature
Gasket
Stainless Steel
Filter Housing
High
Temperature
Cartridge Filter
High
Temperature
Cartridge Filter
Stainless Steel
Filter Housing
Stainless Steel
Filter Housing
Cover
Filter Housing
Cover Latches
Filter Housing
Cover Latches
High
Temeprature
Gasket
High
Temeprature
Gasket
Stainless Steel
Filter Housing
Cover
600-1500 cfm dryers
2000-3000 cfm dryers
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Use the following procedure to clean or replace the filter cartridges:
1. Turn off and/or lock out electrical power to the dryer.
2. Remove the hand knobs or clamps securing the filter access cover and remove the
cover.
3. Remove the nut on the center retaining rod to remove a filter cartridge.
4. Vacuum, blow out, or wash the filter.
5. Inspect the filter - a damaged filter should not be reused. Check the following:
„ Hold a light bulb behind the filter element to find holes,
tears, fatigued paper or residual dirt.
„ Inspect the end plates—damage here could allow air to
bypass the filter.
„ Look for rust on the end plates and metal core—rust
particles could flake off and contaminate the dryer and resin.
„ Check the gasket for damage—a damaged gasket will allow
contaminants into the process. Replace if needed.
6. Return the filter cartridge to its original position and tighten the nut on the center
retaining rod to secure the filter cartridge.
7. Secure the filter access cover with the hand knobs or threaded fasteners.
Cleaning or Replacing the Regeneration Filter
Large dryers are equipped with a filter in the regeneration air loop located at the back of the
dryer. Regular filter cleaning will keep your dryer operating at peak efficiency.
Caution!
Operating the dryer without the regeneration air filters installed will void
the warranty.
1. Turn off and/or lock out electrical power to the dryer.
2. Remove the knob securing the filter.
3. Remove the filter from the post..
4. Vacuum or carefully blow out the filter with compressed air. If the filter is worn or
can't be cleaned, replace it.
5. Slide the filter back onto its post and tighten knob back on the filter.
Calibrating the Dirty Filter Alarm
Your dryer may be equipped with a Dirty Filter alarm. When the alarm sounds, it is time to
clean or change the filter. The Dirty Filter alarm is tested and calibrated at the factory, but it
can be adjusted in the field. Be sure that your filter is clean, and use the following procedure
to calibrate the alarm.
1. Remove the process air return filter element from its housing.
2. Block off approximately 50% of the filter’s surface area to simulate a dirty filter.
3. Reinstall the cartridge and secure the cover.
4. While the process blower is operating, adjust the trim screw on the differential
pressure switch until the alarm light just comes on.
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5. Remove the restricted filter cartridge from the housing again. The alarm light should
stay off when the process blower operates if the switch is adjusted correctly.
6. Re-install the obstructed cartridge filter. The alarm light should go on again if the
switch is adjusted correctly.
7. Fine tune the switch setting so it consistently warns of a blocked filter and does not
falsely indicate a blockage of a clean filter.
8. Remove the restriction from the filter element and re-install the clean filter. The
alarm light should remain off.
Checking the Dewpoint Control System
The Dewpoint Switch option on dryers depends on the proper operation of the dewpoint
sensor and its control board. The dewpoint sensor is in the process air stream and is therefore
susceptible to contamination.
Dewpoint sensor life is dependent 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 dewpoint sensor readings and establish a
periodic replacement schedule as needed.
Caution! Do not attempt to check the continuity or resistance of a dewpoint sensor. The
sensor will be destroyed.
If you suspect that the dewpoint readings on the dewpoint meter are incorrect, a dewpoint
simulation calibrator is available from the manufacturer. This device simulates various
dewpoint outputs. It can confirm proper operation of the dewpoint sensor and dewpoint
system control board.
Use the following procedure to check the dewpoint sensor and dewpoint control board:
1. Remove the sensor cable from the sensor hex nut adapter.
2. Connect the cable to the plug on the rear of the simulator.
3. Turn the rotary knob on the simulator to each position and note the readings on the
dewpoint meter on the dryer's control panel. The readings should correspond within a
degree or two across the entire range.
4. If the readings agree, the control board is OK. Dewpoint sensor replacement is
recommended. If the readings do not agree, replace the control board and run the test
again to rule out the possibility of a bad sensor.
Note: Do not attempt to make any adjustments to the components on the dewpoint
control board.
5. When testing is finished, re-connect the control cable to the sensor adapter.
Large Dehumidifying Dryers
Maintenance
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6-3 Corrective Maintenance
Symptoms of Worn Out Desiccant
The moisture adsorption capacity of the desiccant used in Large Dehumidifying Dryers
degrades after an indefinite period of time. Useful life depends on variables such as material
moisture content, plasticizer vapors in the return air and number of regeneration cycles.
Your dryer may need new desiccant if it exhibits any of the following symptoms:
• The plastic material is not being dried sufficiently (high scrap/reject rate).
• The air temperature at the top of the regenerating desiccant bed rapidly climbs to
350°F or more shortly after the start of regeneration, even though a saturated bed has
just started heating.
• The process air dewpoint, measured with a portable dewpoint monitor, is higher than
-10°F throughout the process drying cycle.
• Smoke or dust is being blown out of the process air outlet.
• Noticeable amounts of desiccant in the beds is a medium-brown color, or darker.
If any of these signs are noticed, the desiccant in the desiccant beds should be replaced.
Desiccant replacement kits are available from the Parts Department. If you wish, the
desiccant beds can be repacked at your site by a service technician.
WARNING! DESICCANT MATERIAL CAUSES EYE IRRITATION
BREATHING MAY BE HARMFUL/MAY CAUSE SKIN IRRITATION!
• Do not get in eyes.
• Avoid prolonged contact with skin.
• Use with adequate ventilation.
• Wash thoroughly after handling.
FIRST AID:
In case of eye contact, immediately flush eyes with plenty of water for
at least 15 minutes. If irritation persists, see a physician.
Replacing the Desiccant
Follow the procedure below to change the desiccant. See Figure 14 below for desiccant
tower components.
1. Disconnect electrical power to the dryer.
2. Remove the bolts and nuts securing the covers of each desiccant canister. Remove
the covers and set them aside.
3. With a shop vacuum that has a 4 micron HEPA filter, carefully remove all desiccant
from each tower.
4. Inspect all screens for tears or burn-through spots.
5. Fill each canister with 13X, 8 x 12 bead desiccant.
Large Dehumidifying Dryers
Maintenance
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6. Inspect the gaskets on each of the covers. Replace if necessary.
7. Re-install the covers.
Figure 14: Desiccant Tower Assembly
High
Temperature
Gaskets.
Regeneration
Heater Cover.
Regeneration
Heaters
Heater Element
Mounting Plate.
Viewing Glass, for
checking the status of
the desiccant inside.
Access cover can be
removed in order to
replace desiccant.
High
Temperature
Gaskets.
Stainless Steel
Hollow Core
Desiccant Tank
Desiccant Tank
Mounting
Platform
Figure 15: Desiccant Replacement Amounts
Dryer
CFM
Desiccant Required per Tower
“13 X”, 8 x 12 Bead
Total
350
600
850
175
175
300
300
300
300
300
300
350
600
600
600
1000
1250
1500
2000
2500
3000
1200
1200
1200
Replacing the Process Heater (Electric Dryers)
Large Dryers have a number of single phase Calrod-type heater elements wired in a delta
formation. They are mounted on top of the dryer or to the drying hopper. The number and
wattage of the heaters varies with model, voltage, temperature range, etc., but the
replacement procedure is the same.
DANGER! Disconnect and lock out power before heater replacement.
Large Dehumidifying Dryers
Maintenance
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1. Remove the bolts securing the process heater access cover.
2. Sketch the heater wiring configuration so the heaters may be re-wired properly.
Heaters are mounted on a common plate of three or six for easy maintenance.
3. Remove the jumper bars and wires for the heater plate assembly(ies) being removed
or replaced.
4. Remove the bolts securing the heater plate assembly and slide out the assembly.
Avoid damaging the gaskets.
5. Remove individual heaters for replacement by removing the large brass nuts and
washers.
6. Re-install the heaters and heater plate assemblies in reverse order, replacing gaskets
if necessary.
Caution!
Heater loops should not touch each other. "Hot spots" will lead to
premature heater failure.
7. Re-install the jumper wires and bars according to the sketch made earlier.
8. Re-secure the process heater access cover.
Stainless Steel
Heater Housing
Figure 16: Process Heater Box Assembly
Cover
High
Temperature
Gasket
Heater Elements
Double Wall
Stainless Steel
Heater
Housing
Heater Elements
High
Temperature
Gasket
Heater Element
Mounting Plate
Heater Element
Mounting Plate
Double Wall
Stainless Steel
Heater
Housing
High
Temperature
Gasket
Heater Assembly
Gude Bars
Heater Assembly
Gude Bars
Stainless Steel
Heater Housing
Cover
Hex Nut For
Securing the Heater
Wire
Heater Element
Mounting Hex Nut
Heater Element
High Temperature
Washer / Gasket
Washer
Heater Wire with
Crimped on Closed
Loop Connector
Heater Assembly
Guide Bar
Heater Element
Bulkhead Fitting
Heater Mounting
Plate
Replacing the Regeneration Heater (Electric Dryers)
The regeneration heaters are wired in the delta formation, mounted in the core of the
desiccant tanks.
DANGER! Disconnect and lock out power before heater replacement.
Large Dehumidifying Dryers
Maintenance
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1. Access the desiccant canisters by removing the panels on the dryer.
2. Remove the Regeneration Heater Cover.
3. Unscrew the six (6) screws on the Heater Element Mounting Plate.
4. Slide out the heater assembly, taking care to not damage the gaskets.
5. Unscrew the heater loops that need to be replaced.
6. Re-install the new heaters. Securely tighten all fasteners.
Caution!
The heater loops should not touch each other. This will create "hot spots"
and lead to premature heater failure.
7. Insert the heater assembly back into the desiccant canister.
8. Fasten the six (6) screws on the Heater Element Mounting Plate.
9. Re-secure the Regeneration Heater Cover.
10. Re-install the dryer panels.
Figure 17: Regeneration Heater Box Assembly
High
Temperature
Gaskets.
Regeneration
Heater Cover.
Regeneration
Heaters
Heater Element
Mounting Plate.
Viewing Glass, for
checking the status of
the desiccant inside.
Access cover can be
removed in order to
replace desiccant.
High
Temperature
Gaskets.
Stainless Steel
Hollow Core
Desiccant Tank
Desiccant Tank
Mounting
Platform
Large Dehumidifying Dryers
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Chapter 7: Troubleshooting
7-1 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.
Before making haphazard substitutions and repairs when defective electrical components are
malfunctioning, we recommend that you check the associated circuitry and assemblies for
other defective devices. It is common to replace the obviously damaged component without
actually locating the real cause of the trouble. Such hasty substitutions will only destroy the
new component. Refer to wiring diagrams and schematics.
7-2 Basic Troubleshooting
Problem
Little or no air
coming from
process delivery
tube.
Possible Cause
Dirty Filters
Desiccant beds contaminated by
material or plasticizer leaking
into the system. See Sec. 6-6.
Corrective Action
Clean or replace filters.
Replace desiccant
Blower fuse(s) blown.
Overload tripped.
Fix problem and Replace fuse(s).
Fix problem and reset the
overload.
Wrong motor rotation.
Turn off power. Reverse
incoming power.
Blower fins filled with dust or
contaminants.
Remove blower side plate, clean
baffles, replace.
Suction in delivery
tube, pressure from
the return tube.
Phase is reversed on power drop
coming into the dryer.
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. Never change the phase at
the motor starters unless only one
of the two blowers is rotating
improperly.
Loss or reduction of Process heaters are faulty.
process air
temperature.
Check for open or shorted heaters.
Replace if required. Check the
fuses.
Solid-state temperature controller Replace.
faulty.
Process temperature was adjusted
in error by plant personnel.
Make sure that plant personnel are
aware of the proper temperature
set point. A sign posted next to the
control would be helpful.
Large Dehumidifying Dryers
Troubleshooting
64
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Problem
Possible Cause
Corrective Action
Replace.
Desiccant beds are contaminated. Replace desiccant.
Loss or reduction in Process heaters are faulty.
drying capacity.
Material being dried differs from
material specified at the time of
purchase.
Drying systems are designed for
the material that was originally
specified. Different materials may
need a longer residence time or
different drying temperature.
Inspect for air leaks; replace if
necessary.
Break in flex hose to/from drying
hopper.
Blower fins filled with dust or
contaminants.
Remove blower side plate, clean
baffles, replace. Replace filter
elements.
Material in drying
hopper cakes, or
meltdown occurs.
Process temperature set too high
due to operator error.
Check resin manufacturer's data
sheet for proper drying
temperature. Make sure plant
personnel are aware of the correct
process temperature Set Point.
See Section “Temperature Screen
Setup” on page 34.
High temperature alarm not set
properly.
Process set point is out of
acceptable range.
Restore temperature controller to
factory pre-sets. Auto-Tune if
necessary.
Poor Dew Point
Performance.
Burned out regeneration heater.
Contaminated or worn out
desiccant.
Repair or replace.
Replace.
Leaking process air hoses.
Repair or replace.
Dryer is being operated beyond its Check dryer and drying hopper
capacity.
sizing.
Bad dew point sensor.
Replace.
Fouled dew point sensor manifold. Clear obstruction. Air should flow
freely through sensor.
Large Dehumidifying Dryers
Troubleshooting
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7-3 Determining Temperature Controller Errors or Sensor Errors
Using a Thermocouple
If the controller displays a temperature that is close to room temperature (70ºF/21ºC) 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 (32ºF) 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.
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Troubleshooting
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Chapter 8: Appendix
8-1 Warranty
The manufacturer warrants all equipment manufactured by it to be free from defects in
workmanship and material when used under recommended conditions. The company’s
obligation is limited to repair or replace FOB the factory any parts that are returned prepaid
within one year of equipment shipment to the original purchaser, and which, in the
company’s opinion, are defective. Any replacement part assumes the unused portion of this
warranty.
This parts warranty does not cover any labor charges for 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. If the serial number has been
defaced or removed from the component, the warranty on that component is void.
Defective parts become the property of the warrantor and are to be returned.
The company is not liable for any incidental, consequential, or special damages or expenses.
The company’s obligation for parts not furnished, as components of its manufactured
equipment is limited to the warranty of the manufacturers of said parts.
Any sales, use, excise, or other tax incident to the replacement of parts under this warranty is
the responsibility of the purchaser.
The company neither assumes nor authorizes any other persons to assume for it any liability
in connection with the sale of its equipment not expressed in this warranty.
Many types of the manufacturer’s equipment carry an additional one-year service policy.
Consult your sales representative for specific details.
Large Dehumidifying Dryers
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8-2 Technical Specifications
Annex B Information
The following design information is provided for your reference:
1. No modifications are allowed to this equipment that could alter the CE compliance
2. Ambient temperature:
3. Humidity range:
4. Altitude:
0 degrees Celsius – Maximum (104 degrees Fahrenheit)
50% relative humidity
Sea level
5. Environment:
6. Radiation:
Clean and non-explosive
None
7. Vibration:
Minimal, i.e. machine mounting
8. Allowable voltage fluctuation:
9. Allowable frequency fluctuation:
+/- 10%
Continuous
Intermittent
+/- 1%
+/- 2%
10. 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)
12. Power supply should include a ground connection.
13. Over-current protection is supplied in the dryer, but additional protection should be
supplied by the user.
14. The door-mounted disconnect serves as the electrical disconnect device.
15. Dryer is not equipped with local lighting.
16. Functional identification
17. Dryer is equipped with a CE mark
18. Dryer is supplied with an operating manual in the language of the destination
country.
19. Cable support may be required for power cord, depending on final installation.
20. 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.
21. Doors can be opened with a screwdriver, but no keys are required.
22. Two-hand control is not required or provided.
23. All dryers should be moved around and set in a place with a lift truck or equivalent.
24. There are no frequent repetitive cycles that require manual controlrepetitive
functions are automatic while the dryer is operating.
25. An inspection report detailing the functional test is included with the dryer.
26. The machine is not equipped with cableless controls.
27. Color-coded (harmonized) power cord is sufficient for proper installation.
Large Dehumidifying Dryers
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8-3 Spare Parts List
LARGE DRYER SPARE PARTS LIST 600,850,1000,
1250,1500,2000,2500, AND 3000
LEVEL 1 ( Electrical Components )
PART #
SIZE Description
A0536474
A0536471
A0534846
A0545343
A0538001
A0538017
A0538005
A0534842
A0540997
A0540995
A0542207
50
35
20
Fuse, Process Heater Elements
Fuse, Regen Heater Elements
Fuse, Process Blower
3
3
3
3
2
1
2
1
1
2
1
3.5 Fuse, Regen Blower
3.2 Transformer, Control Primary
6
5
10
1
Transformer, Control Secondary
Transformer, Valve Motor Primary
Transformer, Valve Motor Secondary
Fuse, Control, PLC
0.75 Fuse, Control, Output/Power Supply
Fuse, Control, Power Supply Out
3
LEVEL 1 ( Mechanical Components )
PART #
SIZE Description
Dew Point Sensor Insert
W00015435
A0548556
A0568271
A0566467
A0570595
A0568062
A0566531
A0572408
W00018051
W00013983
A0566564
A0572479
A0566676
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Dew Point Sensor
Dew Point Sensor Cable
Valve switch
Process Air Filter 600-850 CFM
Process Air Filter 1000-3000 CFM
Regeneration Air Filter 600-850 CFM
Regeneration Air Filter 1000-3000 CFM
13X molecular Sieve Desiccant ( 8 X 12 Beads )
High Temperature Gasket (15 Ft Roll)
Desiccant Tank Sight Glass
1
1
1
2
2
2
1
1
1
1
1
1
1
1
350 Lbs.
350 Lbs.
600 Lbs.
600 Lbs.
600 Lbs.
1200 Lbs.
1200 Lbs.
1200 Lbs.
2.25 Rolls
2.25 Rolls
2.75 Rolls
3.0 Rolls
3.0 Rolls
4.5 Rolls
4.5 Rolls
4.5 Rolls
2
2
3
2
2
3
2
2
3
2
2
3
2
2
3
4
4
5
4
4
5
4
4
5
Desiccant Tank Sight Glass Gasket
High Temperature Snap Switch.
LARGE DRYER SPARE PARTS LIST 600,850,1000,1250,
1500,2000,2500, AND 3000
LEVEL 2 ( Electrical Components )
PART #
SIZE Description
A0558000
A0558002
A0558004
A0558040
A0558079
A0569887
A0569895
A0505417
A0567058
A0554555
A0548556
9A Contactor, IEC
16A Contactor, IEC
32A Contactor, IEC
1
1
1
1
1
1
1
1
1
1
1
Overload, IEC, 12-32A
Overload, IEC, 1 - 2.9A
Overload, IEC, 5 - 15A
48A Relay, Solid State
Relay, 4PDT, Regeneration T'Couple
Relay, SPDT
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
*
*
Circuit Board, Dew Point
Sensor, Dew Point
LEVEL 2 ( Mechanical Components )
PART #
SIZE
Description
3500 Watts Heater Element 208/220 Volts
3500 Watts Heater Element 230 Volts
3500 Watts Heater Element 400 Volts
3500 Watts Heater Element 460 Volts
3500 Watts Heater Element 575 Volts
Heater Element Gasket
A0566544
A0566547
A0566549
A0566549
A0566549
A0566415
A0566682
21
30
39
39
45
21
30
39
39
45
21
42
30
60
39
78
39
78
45
90
66
78
90
21
30
39
39
45
66
78
90
21
30
39
39
45
66
78
90
120
158
180
1/4" OD Teflon Tube.
18 Feet
18 Feet
18 Feet
18 Feet
18 Feet
18 Feet
18 Feet
18 Feet
Large Dehumidifying Dryers
Appendix
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LARGE DRYER SPARE PARTS LIST 600,850,1000,1250,
1500,2000,2500, AND 3000
LEVEL 3 ( Electrical Components )
PART #
SIZE
Description
A0567930
A0567932
A0569896
A0567933
A0563932
A0568961
PLC, Controller
PLC, Temperature Control Module
PLC, Analog Input Module
PLC, Touch Screen
Power Supply, 24VDC
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Redundant Temperature Safety Controller
LEVEL 3 ( Mechanical Components )
PART #
SIZE
Description
8" O.D. by 12 Ft Long Hi Temp Hose.
3" O.D. by 12 Ft Long Hi Temp Hose.
Return Air Cooling Coil 600-850 CFM
Return Air Cooling Coil 1000-1500 CFM
Return Air Cooling Coil 2000-3000 CFM
Closed Loop Cooling Coil
A0542302
A0571107
A0570519
A0566849
A0568147
A0568233
A0546119
A0562555
A0565900
A0572510
A0572509
A0572511
A0559792
A0559903
A0559998
A0553766
A0572513
A0572512
A0572514
A0572516
A0572515
A0572517
A0559815
A0568211
A0560003
W00015335
A0548558
W00015436
A0572502
A0566879
A0565249
A0565250
A0566466
A0547006
A0537908
A0568205
A0542231
A0571107
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
208-230/460 Volt Blower, 600 CFM
575 Volt Blower, 600 CFM
208-230/460 Volt Blower, 850 CFM
380 Volt Blower, 1000 CFM
230/460 Volt Blower, 1000 CFM
575 Volt Blower, 1000 CFM
380 Volt Blower, 1250 CFM
230/460 Volt Blower, 1250 CFM
575 Volt Blower, 1250 CFM
230/460 Volt Blower, 1500 CFM
380 Volt Blower, 2000 CFM
230/460 Volt Blower, 2000 CFM
575 Volt Blower, 2000 CFM
380 Volt Blower, 2500 CFM
230/460 Volt Blower, 2500 CFM
575 Volt Blower, 2500 CFM
380 Volt Blower, 3000 CFM
230/460 Volt Blower, 3000 CFM
575 Volt Blower, 3000 CFM
Dew Point Sensor Manifold
Gasket for the Dew Point Sensor
Plastic Nut for the Dew Point Sensor
O-Ring for Main Valve
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3.2 Feet
3.2 Feet
3.2 Feet
3.2 Feet
3.2 Feet
3.2 Feet
3.2 Feet
3.2 Feet
Main Valve Motor
Filter housing Latch
Filter Housing Strike
Closed Loop Cooling Valve Motor
Knob for the Regeneration Filter
Handle for Panels.
Latch for Panels
8" Hose Clamp
1
4
1
4
1
4
1
4
1
4
1
4
1
4
1
4
4
4
4
4
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
8
12
36
16
6
12
36
16
6
12
36
16
6
16
48
32
6
16
48
32
6
16
48
32
6
24
16
6
24
16
6
3" Hose Clamp
Large Dehumidifying Dryers
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8-5
Dryer Identification (Serial Number) Tag
(Located on back of Dryer)
XXX Series Dryer
Model Number XXX-15
Max Drying Capacity HR
460V
1
Serial Number 060701R
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 lbs/(180 KG)
Electrical Diagrams &
Pneumatic Diagram
Street Address
City, State Zip Code
Telephone Number
Large Dehumidifying Dryers
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8-5 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 expediting your phone or fax order, please have the model and serial
number of your unit when you contact us. A customer replacement parts list is included in this manual
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing
excellent customer service.
Service Department
[
]
[
]
Call toll-free 8am–5pm CST 800 233-4819 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 worldwide 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.
Large Dehumidifying Dryers
Appendix
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