ACS A0570882 User Manual

15, 30, & 60 cfm

Compact Dehumidifying Dryers

Part Number: A0570882

Bulletin Number: SM1-690.1

Effective: 8/05/04

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 2004
All rights reserved.

15, 30, & 60 cfm Compact Dryers ii

Shipping Information

Unpacking and Inspection

You should inspect your dryer for possible shipping damage.

Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc.

In the Event of Shipping Damage

According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.

Notify the transportation company’s local agent if you discover damage.

Hold the damaged goods and packing material for the examining agent’s inspection. Do not

return any goods before the transportation company’s inspection and authorization.

File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.

Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.

If the Shipment is Not Complete

Check the packing list as back-ordered items are noted on it. You should have:

˛ Dehumidifying Dryer

˛ Bill of lading

˛ Packing list

˛ Operating and Installation packet

˛ Electrical schematic and panel layout drawings

˛ Component instruction manuals

Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the shipping department immediately. For
shipments in the United States and Canada, call 1 [phone]; for all other countries, call
our international desk at [phone]. Have the order number and item number available.
Hold the items until you receive shipping instructions.

Returns

Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.

15, 30, & 60 cfm Compact Dryers iii

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.

15, 30, & 60 cfm Compact Dryers iv

Table of Contents

CHAPTER 1: SAFETY.................................................................... 6

1-1 How to Use This Manual ............................................................................................ 6

Safety Symbols Used in this Manual..................................................................... 6

Dryer Safety Tags ................................................................................................7

1-2 Warnings and Precautions ......................................................................................... 7

1-3 Responsibility............................................................................................................. 8

General Responsibility..........................................................................................8

Operator Responsibility ........................................................................................ 9

Maintenance Responsibility ................................................................................ 10

Reporting a Safety Defect...................................................................................10

1-4 Technical Specifications........................................................................................... 11

Annex B Information........................................................................................... 11

CHAPTER 2: FUNCTIONAL DESCRIPTION .............................. 12

2-1 Models Covered in This Manual ............................................................................... 12

2-2 General Description ................................................................................................. 12

What is desiccant? ............................................................................................. 13

The Process/Regeneration Cycle ....................................................................... 13

2-3 Standard Features ................................................................................................... 13

Mechanical Features .......................................................................................... 13

Electrical Features ............................................................................................. 13

Controller Features............................................................................................. 13

2-4 Options .................................................................................................................... 14

2-5 Safety Devices and Interlocks .................................................................................. 14

CHAPTER 3: INSTALLATION ..................................................... 16

3-1 Uncrating the Equipment.......................................................................................... 16

3-2 Rigging and Placing the Dryer.................................................................................. 16

Recommended Dryer Lifting Hardware ...............................................................17

3-3 Electrical Connections.............................................................................................. 18

3-4 Setup Procedures .................................................................................................... 19

Checking for Proper Blower Rotation..................................................................19

Making Dryer/Drying Hopper Process Air Connections ....................................... 19

Drying Hopper Air Trap Considerations............................................................... 20

Optional Aftercooler............................................................................................ 20

3-5 Initial Start-up........................................................................................................... 20

Pre-Startup Checks............................................................................................ 20

Starting Up the Dryer.......................................................................................... 21

Auto-Tuning the Dryer ........................................................................................ 21

Shutting Down the Dryer ....................................................................................21

CHAPTER 4: OPERATION .......................................................... 22

4-1 Start-up.................................................................................................................... 22

4-2 Controller Description and Operation........................................................................ 23

15, 30, & 60 cfm Compact Dryers v

Identifying Control Panel Indicator Lights and Switches for the Standard

Controller ........................................................................................................... 23

Process Air Temperature Controller.................................................................... 24

Setting the Process Air Temperature ..................................................................25

Restoring the Process Air Temperature Controller (E5CN) to Factory Settings....26

Process Air Dew Point Display ........................................................................... 29

Setting the High Dew Point Alarm.......................................................................29

Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup..................29

4-3 Dryer Operation Procedures..................................................................................... 30

Controller Operation ........................................................................................... 30

Alarm Display Messages .................................................................................... 32

4-4 Auto-Tuning the Dryer.............................................................................................. 33

4-5 Shutting Down the Dryer .......................................................................................... 33

CHAPTER 5: MAINTENANCE..................................................... 34

5-1 Preventative Maintenance Schedule......................................................................... 34

5-2 Preventative Maintenance........................................................................................ 35

Servicing Process Air Filters...............................................................................35

Servicing the Dew Point Monitor.........................................................................36

5-3 Corrective Maintenance ........................................................................................... 37

Symptoms of Worn Desiccant............................................................................. 37

Replacing Worn Desiccant .................................................................................38

Replacing the Process/Regeneration Heater ......................................................40

Replacing/Cleaning the Regeneration Cooling Coils ........................................... 41

CHAPTER 6: TROUBLESHOOTING........................................... 42

6-1 Introduction.............................................................................................................. 42

6-2 Determining Temperature Controller Errors or Sensor Errors.................................... 45

Using a Thermocouple .......................................................................................45

Using a Platinum Resistance Thermometer ........................................................ 45

CHAPTER 7: APPENDIX ............................................................. 46

7-1 Warranty.................................................................................................................. 46

Warranty Specifications..........................................Error! Bookmark not defined.

Warranty Restrictions .............................................Error! Bookmark not defined.

Warranty Liabilities.................................................Error! Bookmark not defined.

Customer Responsibilities ......................................Error! Bookmark not defined.

7-2 Drawings and Diagrams ........................................................................................... 47

Aftercooler Design Specifications ....................................................................... 48

Spare Parts List.................................................................................................................. 50

7-4 Dryer Identification (Serial Number) Tag................................................................... 51

7-5 Technical Assistance ............................................................................................... 51

Parts Department ...............................................................................................51

Service Department............................................................................................ 51

Sales Department .............................................................................................. 51

Contract Department .......................................................................................... 51

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 6 of 51

Chapter 1: Safety

1-1 How to Use This Manual

Use this manual as a guide and reference for installing, operating, and maintaining your
dehumidifying dryer. The purpose is to assist you in applying efficient, proven techniques
that enhance equipment productivity.

This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.

The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre­operational procedures, operation, preventive maintenance, and corrective maintenance.

The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the dehumidifying dryer. We can also provide the assistance of a factory-trained technician
to help train your operator(s) for a nominal charge. This section includes instructions, checks,
and adjustments that should be followed before commencing with operation of the
dehumidifying dryer. These instructions are intended to supplement standard shop
procedures performed at shift, daily, and weekly intervals.

The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the dryer safely and efficiently.

The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your dehumidifying dryer provides
excellent, long service.

The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.

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.

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 7 of 51

Dryer Safety Tags

Hot! Read Operation

and Installation
Manual

High Voltage Earth Ground

Inside Enclosure

PE Protected Earth

Lifting Point Ground

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.

˛ Use EXTEREME CAUTION when working with dryer. HIGH HEAT can be

dangerous. Keep body parts, tools, clothing, and debris away from dryer.

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 8 of 51

˛ When welding or brazing in or around this equipment, make sure VENTILATION is

ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with

sheet metal. An approved FIRE EXTINGUISHER should be close at hand and
ready for use if needed.

˛ Do not restore power until you remove all tools, test equipment, etc., and the

equipment and related components are fully reassembled.

˛ Only PROPERLY TRAINED personnel familiar with the information in this

manual should work on this equipment.

We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.

1-3 Responsibility

These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.

All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.

Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.

Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.

General Responsibility

No mater who you are, safety is important. Owners, operators and maintenance personnel
must realize that every day, safety is a vital part of their jobs.

If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can
affect your production:

• 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.

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 9 of 51

Operator Responsibility

The operator’s responsibility does not end with efficient production. The operator usually has
the most daily contact with the equipment and intimately knows its capabilities and
limitations.

Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or
through a casual attitude toward machinery formed over a period of months or years. Your
employer probably has established a set of safety rules in your workplace. Those rules, this
manual, or any other safety information will not keep you from being injured while operating
your equipment.

Learn and always use safe operation. Cooperate with co-workers to promote safe practices.
Immediately report any potentially dangerous situation to your supervisor or appropriate
person.

REMEMBER:

• NEVER place your hands or any part of your body in any dangerous location.

• NEVER operate, service, or adjust the dryer without appropriate training and first

reading and understanding this manual.

• NEVER try to pull material out of the dryer with your hands while it is running!

• Before you start the dryer check the following:

• Remove all tools from the dryer;

• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the

hopper area;

• If your dryer has been inoperative or unattended, check all settings before starting the

unit.

• At the beginning of your shift and after breaks, verify that the controls and other

auxiliary 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 dryer

while working on it.

• DO NOT wear loose clothing or jewelry, which can be caught while working on a

dryer. In addition, cover or tie back long hair.

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 10 of 51

• Clean the 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
power. Attach warning tags to the disconnect switch.

When you need to perform maintenance or repair work on a dryer above floor level, use a
solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your
dryer, use it. The work platform should have secure footing and a place for tools and parts.
DO NOT climb on dryers, machines, or work from ladders.

If you need to repair a large component, use appropriate handling equipment. Before you use
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)
be sure the load does not exceed the capacity of the handling equipment or cause it to become
unstable.

Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using
them to lift a load.

Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.

When you have completed the repair or maintenance procedure, check your work and remove
your tools, rigging, and handling equipment.

Do not restore power to the dryer until all persons are clear of the area. DO NOT start and
run the dryer until you are sure all parts are functioning correctly.

BEFORE you turn the dryer over to the operator for production, verify all dryer enclosure
panels, guards and safety devices are in place and functioning properly.

Reporting a 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.

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 11 of 51

1-4 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: 0 degrees Celsius – Maximum (104 degrees Fahrenheit)

3. Humidity range: 50% relative humidity

4. Altitude: Sea level

5. Environment: Clean, dust-free and non-explosive

6. Radiation: None

7. Vibration: Minimal, i.e. machine mounting

8. Allowable voltage fluctuation: +/- 10%

9. Allowable frequency fluctuation: Continuous +/- 1%

Intermittent +/- 2%

10. Nominal supply voltage: 115/1/60 (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 for 3 phase

units.

15. Dryer is not equipped with local lighting.

16. Functional identification

17. Dryer is supplied with an operating manual in the language of the destination

country.

18. Cable support may be required for power cord, depending on final installation.

19. 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.

20. Doors can be opened with a screwdriver, but no keys are required.

21. Two-hand control is not required or provided.

22. All dryers should be moved around and set in a place with a lift truck or equivalent.

23. There are no frequent repetitive cycles that require manual controlærepetitive

functions are automatic while the dryer is operating.

24. An inspection report detailing the functional test is included with the dryer.

25. The machine is not equipped with cableless controls.

26. Color-coded (harmonized) power cord is sufficient for proper installation.

15, 30, & 60 cfm Compact Dryers Chapter 2: Functional Description 12 of 51

Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual provides operation, installation, and maintenance instructions for 15, 30, and 60
cfm dehumidifying dryers. Model numbers are listed on the serial tag. Make sure you know
the model and serial number of your equipment before contacting the manufacturer for parts
or service.

Our dehumidifying mini dryers are designed to generate heated dehumidified air at carefully
controlled temperatures for use in plastic drying systems. Drying systems are sized to meet
the specific requirements stated by the Customer at the time of purchase.

2-2 General Description

Dehumidifying dryers are used to generate very low dew point air heated to a controlled
temperature for drying plastic pellets and regrind.

Our dryers force hot, dry air through resin in a drying hopper, where air picks up moisture
from the material and draws it back to the dryer. In the dryer, a desiccant bed strips moisture
from the air. The dried process air is then re-heated and delivered back into the drying
hopper for more moisture removal.

A small amount of ambient air is introduced into the process air stream to make up for the air
lost during the bed regeneration. Because the process air is typically much drier than the
ambient air, the air mixture maintains drying efficiency at a consistently high level. To
compensate for the humidity content in the air, this dryer is supplied with the proper amount
of desiccant.

Figure 1: Typical Dryer Air Flow Schematic

Drying

Hopper

Filter

(Separates Dust )

High Pressure

Peripheral Blower

Regeneration

Make Up Air

Moisture

Exhaust

15, 30, & 60 cfm Compact Dryers Chapter 2: Functional Description 13 of 51

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 blended with a clay binder and
formed into beads.

Absorbed water is driven from saturated desiccant by heating it to a high temperature
(reducing desiccant capacity to hold water) and forcing air through it. This moisture removal
process is called regeneration.

The Process/Regeneration Cycle

Our dryers have two desiccant beds. While one bed is on-line in the process air loop, the
other is off-line, being regenerated.

When a desiccant bed is on-line, it absorbs moisture from the process air. In time, the bed
becomes saturated with moisture and needs to be regenerated. The dryer automatically
redirects the process airflow to the second bed, and starts the regeneration cycle on the first
bed.

During regeneration, the dryer system heats air and forces it through the desiccant bed. The
moisture driven off the bed bleeds to the atmosphere.

2-3 Standard Features

Mechanical Features

• Dual desiccant beds

• Electrically-actuated air valve

• 13X Molecular Sieve

• Single regenerative process blower

• Drying temperature range of 180ºF to 250ºF.

Electrical Features

• Process thermocouple to be connected to drying hopper air inlet.

• Nema 12 control enclosure

• NFPA79 machinery electrical standards

• Non-fused electrical disconnect

• Branch fusing

• Mercury process heater contactor

• Regeneration temperature control

• Process high temperature alarm light

• Process/regeneration heater box

• High temperature safety system (Process/Regeneration)

Controller Features

• Mitsubishi programmable relay controller

15, 30, & 60 cfm Compact Dryers Chapter 2: Functional Description 14 of 51

• Display of process temperature set point and actual settings

2-4 Options

Options marked with “*” indicate options that can be factory installed or retrofitted in the
field.

• Process temperature up to 400ºF (or below 180ºF), including aftercooler on back of

dryer and silicone insulated delivery hose.

Note: For below 160°F, cooler needs to be outside, between dryer and

drying hopper.

• Machine mount adapter to accommodate a dryer and corresponding hopper.

• Drawer magnet, stainless steel construction.

• Casters, two (2) fixed and two (2) swivel.

• Portable carts

• Dew point monitor

• High temperature operation up to 400ºF

• Insulated process air delivery hose

2-5 Safety Devices and Interlocks

This section includes information on safety devices and procedures that are inherent to the
Dryer. This manual is not intended to supersede or 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 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

15, 30, & 60 cfm Compact Dryers Chapter 2: Functional Description 15 of 51

must be held closed with the device it is to protect. If the switch fails, it will go to the open
condition, tripping out the safety circuit.

At no time should the safety device fail and allow the operation to continue. For
example, if a safety switch is guarding a motor, and the safety switch fails, the motor should
not be able to run.

Safety Device Lock-Outs

Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used on these dryers are primarily concerned with electrical power disconnection and the
disabling of moving parts that may need to be accessed during the normal operation of the
machine.

Some of the safety devices utilize a manual activator. This is the method of initiating the
safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable
handle, there may be a location for a padlock. Personnel servicing the equipment should
place a padlock in the lockout handle.

In addition to the safety devices listed above, these dryers are equipped with a line cord plug.
This allows the operator or maintenance personnel to unplug the dryer from its power source
and tag it out. The plug can then be tagged with any number of approved electrical lockout
tags available at most electrical supply stores.

WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)

sources prior to servicing or cleaning the dryer. Failure to do so may result in serious
injury. No one but the person who installed the lockout may remove it.

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 16 of 51

Chapter 3: Installation

3-1 Uncrating the Equipment

Dehumidifying Dryers are shipped mounted on a skid, enclosed in a plastic wrapper, and
contained in a cardboard box.

1. Pry the crating away from the skid.

Note: Remove the nails holding the box to the skid and lift the box

off carefully; avoiding staples in the 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. Use a pry bar if necessary to carefully remove the

skid from the unit.

4. Lower slowly.

3-2 Rigging and Placing the Dryer

Take care when rigging and placing the dryer. Figures 1, 2 and 3 on the following pages show
a suggested safe rigging diagram. It lets you lift the dryer/hopper unit vertically for
installation on the machine throat. Adjust chain lengths at the center sling bracket before you
lift the unit. Your dryer has built-in lifting lugs.

Caution! If you are mounting a machine-mount dryer with a magnet or transition adaptor on the

machine throat, you must provide additional support to hold the dryer securely on the
machine.

Be aware that off-center static and dynamic hopper loading can occur with machine
vibration. Again, provide additional support to hold the dryer securely on the machine.

Use caution and observe safety rules when lifting and placing your dryer!

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 17 of 51

Figure 2: Suggested Lift Rigging for Cart Mounted Dryers

Caution! Do not use a hoist to move or rig your Dryer when it is mounted on a cart!

Moving the Dryer with a hoist will cause it to become unstable and may
cause damage to the Dryer and/or injury to personnel!

Recommended Dryer Lifting Hardware

Item

Quantity

Description

Vendor

Vendor part no.

11Adjustable alloy chain sling

McMaster-Carr

33665T32

22Existing hopper lifting bracket

—

—

31Drop forged steel eye nut

McMaster-Carr

3019T15

41Chain connector

McMaster-Carr

3712T23

Figure 3: Suggested Lift Rigging for Floor Mounted Dryers

Note: Floor Mounted Dryers can be lifted by hoist or fork lift.

PROCESS

TEMPERATURE

DEW POINT

CONTROL
POWER

ON

OFF

ALARM

POWER ON

ON

OFF

PROCESS

TEMPERATURE

DEW POINT

CONTROL
POWER

ON

OFF

ALARM

POWER ON

ON

OFF

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 18 of 51

Figure 4: Suggested Lift Rigging for Machine Mounted Dryers

Caution! When using a hoist to move a machine mounted dryer, ALWAYS attach

chains to the three (3) locations/lifting points on the unit! Moving the
Dryer without the chains attached to all of the lifting points will cause the
unit to become unstable and may cause damage to the Dryer and/or injury
to personnel!

3-3 Electrical Connections

When making electrical connections to your dryer, ensure that you take into consideration
and make arrangements for the following:

• A qualified electrician should make all electrical connections.

• Fulfill all national, state, and local safety and electrical code requirements.

• 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.

• Make sure all electrical connections are tight.

PROCESS

TEMPERATUR

E

DEW POINT

CONT
ROL
POWE

R

ON

OFF

ALARMPOWER ON

ON

OFF

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 19 of 51

3-4 Setup Procedures

This section provides the procedures necessary for configuring your Dehumidifying Dryer.

Configuration of your dryer includes checking for proper blower rotation, making
dryer/drying hopper process air connections and the optional aftercooler (on 15 and 30 cfm
models). We recommend that you carry out these procedures in the order given here.

Note: Before carrying out these procedures, install all equipment as

described in this section.

Checking for Proper Blower Rotation

Three-Phase Models

Caution! In three-phase models, incorrect phasing of power leads can cause

backward rotation of blower motors and CONTAMINATION OF THE
DESICCANT!

Always check blower rotation before putting material in the drying hopper!

The blower is rotating properly when air flows from the delivery outlet.

Note: Holding your hand in front of the air return will also indicate if the

blower rotates in the proper direction.

If the three-phase blower rotates improperly, reverse any two wires at the fused disconnect
outside the dryer or at the disconnect/terminal in the control enclosure. This assures that the
blower rotates in the proper direction.

Making Dryer/Drying Hopper Process Air Connections

Floor Mount Models

When making process air connections to your floor mounted dryer, ensure that you take into
consideration and make arrangements for the following:

• Use high-temperature flexible dryer hose or rigid tubing to connect the dryer to the

drying hopper.

• Keep the delivery hose to the drying hopper as short as possible to minimize heat loss.

We strongly recommend insulated hose for maximum energy savings.

• Do not use insulated hose on the return from the drying hopper.

• The return air to the blower must be 150°F (66ºC) or below. If the return air

temperature is not below this point, you should purchase and install the optional
aftercooler to remove excessive heat. Consult the manufacturer for more information.
Aftercooler considerations also apply to machine-mount models.

• Make sure that hoses are not kinked or collapsed.

• Drying hopper air inlet and outlet locations vary, but always connect hoses so the dry

process air from the dryer enters the bottom of the drying hopper and flows out the top
to return to the dryer inlet.

• Thermocouple is to be installed at drying hopper’s delivery tube.

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 20 of 51

Drying Hopper Air Trap Considerations

Our exclusive air trap assembly on the top of the drying hopper prevents ambient air from
contaminating the material being dried. To ensure that your unit will operate at peak
efficiency, do the following:

• Keep the material level at the mid point of the air trap

This can be achieved by utilizing a hopper loader or vacuum conveying system to
supply material to the drying system.

Optional Aftercooler

Water-cooled 15 and 30 cfm models use a water-to-air heat exchanger as an aftercooler.
Cooling water is required for this design (3 gpm at 85°F or lower). Return air from the
hopper passes through the air filter to trap fines and dust before entering the heat exchanger.

Installing Water Lines

(Hose and Hose Clamp)

When installing the water lines, ensure that the aftercooler utilizes either tower, chilled or city
water up to 85°F (29°C). Recommended flow rate is three (3 gpm) gallons per minute (11
liters per minute).

3-5 Initial Start-up

Pre-Startup Checks

˛ Check the process and return hoses for tight connections.

˛ Check all companion equipment, such as the drying hopper; verify that the loading

system is ready for operation.

˛ Verify that all dryer electrical connections are tight.

Caution! Clean the rust-preventing oil from inside the drying hopper.

Failure to clean the hopper fouls the desiccant and voids your warranty!

˛ Verify that the dryer’s thermocouple is properly connected in the center of the drying

hopper’s delivery tube.

˛ Verify that the temperature control has been configured for your specified scale (ºF

or ºC).

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 21 of 51

Starting Up the Dryer

1. Turn on (energize) the disconnect switch in your power drop, then turn on the

disconnect switch on the dryer (3 phase only).

2. Turn the system ON/OFF switch to ON to start the dryer.

3. Close the slidegate at the bottom of the drying hopper.

Make sure that the blowers turn in the right direction.

4. Fill the drying hopper with material. Dryer performance is compromised if hopper is

not full!

5. If your dryer has a water-cooled aftercooler, make sure that sufficient cooling water

(3gpm at 85°F or lower) flows properly through the coil and that you have bled any
trapped air from the system. Make sure the aftercooler has the proper supply water
temperature.

6. Set the process set point on the temperature controller.

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,

maintain the material level in the hopper at the midpoint of the air trap
assembly.

Auto-Tuning the Dryer

1. For Auto-tuning, press the beige button once. The AT screen will show with the

setting OFF.

2. Press the UP arrow to change the setting to ON.

3. Press the beige button again to go back to the Temperature Screen. Your actual

temperature will start to flash for about 10-20 minutes with the temperature
fluctuating up and down during that period. After the flashing stops, it means auto­tuning has finished.

Shutting Down the Dryer

1. When processing is complete, close the hopper slide gate and shut down any in-line

companion equipment, such as the aftercooler.

2. Turn the Dryer ON/OFF power switch to OFF.

3. Turn the system ON/OFF switch to OFF.

4. If needed, empty the drying hopper.

5. For maintenance or a long term shutdown, open (de-energize) the electrical

disconnects at the dryer and at the power drop.

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 22 of 51

Chapter 4: Operation

4-1 Start-up

1. Turn on (energize) the disconnect switch in your power drop, then turn on the

disconnect switch on the dryer.

2. Turn the system ON/OFF switch to ON to energize the display panel.

The process blower starts.

3. Close the slidegate at the bottom of the drying hopper.

Make sure that the blowers turn in the right direction.

4. Fill the drying hopper with material.

5. If your dryer has a water-cooled aftercooler, make sure that sufficient cooling water

(3gpm at 85°F or lower) flows properly through the coil and that you have bled any
trapped air from the system. Make sure the aftercooler has the proper supply water
temperature.

6. Set the process set point on the temperature controller.

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,

maintain the material level in the hopper at the midpoint of the air trap
assembly.

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 23 of 51

4-2 Controller Description and Operation

Identifying Control Panel Indicator Lights and Switches for the Standard
Controller

Switches

Main Power. This switch allows the dryer to receive power from the main power supply (3

phase only).

Dryer Control ON/OFF Switch. This switch energizes or de-energizes control power to the
indicator panel and starts the dryer. (The controller can be energized without the dryer
running.)

Indicator Lights

Alarm Light. This feature warns the operator of a high bed safety temperature, a

regeneration heater fault, or a blower failure.

Power On. This light illuminates when the main power switch is on, telling the user the
dryer is energized.

Dryer Operating: Indicates the process air blower is on.

Figure 5: Dryer Control Panels

Standard Controller – Standard Single Phase Control Panel shown with Optional Dew Point Monitor

Optional Controller – Optional Three Phase Control Panel shown with Optional Dew Point Monitor

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 24 of 51

Process Air Temperature Controller

Our dryers use a microprocessor-based PID temperature controller for maintaining process air
temperature. The controller is a modular, self-contained unit you can remove from the
mounting housing. All parameters except for the process air set point are factory set and
adjusted; normally, no field adjustment to the internal controls is necessary.

Figure 6: Typical Process Air Temperature Controller

Identifying Process Air Temperature Controller LED Indicators

Indicator

Name

Description

PV

8.8.8.8

Process Value
Numeric LED

During normal operation, the process value (PV)
numeric LED indicator displays the process
temperature at the To Process thermocouple. It
also lists parameters during setup and error
messages if any errors occur.

SV

8.8.8.8

Set Value
Numeric LED

During normal operation, the set value (SV)
numeric LED indicator displays the process set
point temperature selected for the dryer. The dryer
then maintains this set point temperature. This
LED indicator also displays parameter and pre-set
function values during configuration setup.

OUT1

Out 1 LED

Lit when Control Output 1 is on. The Out1
indicator lights when the controller signals the
process heaters to be energized.

OUT2

Out 2 LED

Lit when Control Output 2 is on. Not used in
this application.

AT

AT LED

Flashes during auto-tuning in process value (PV)
screen.

PV

SV

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 25 of 51

Indicator

Name

Description

ALARM1

ALARM 1 LED

Lights in the Operation Indicator Section when
the output function assigned to auxiliary output
1 turns on. The ALARM1 indicator lights when

the process temperature exceeds the set point
temperature by more than the alarm deviation
value. Alarm output de-energizes the heaters.
Heaters re-energize when the temperature falls
within the acceptable range.

Identifying Temperature Controller Keys

Indicator

Name

Description

Mode Key

Press the Mode key to shift the display to the next
set of parameters. The menu screen displays.

Down Key

Press the Down arrow key to lower the process air
set point temperature. During setup, it lets you
decrease the value of the parameter displayed on
the set point LED readout.

Up Key

Press the Up arrow key to raise the process air set
point temperature. During setup, it lets you
increase the value of the parameter displayed on
the set point LED readout.

Setting the Process Air Temperature

When setting the process air temperature, consult with the resin manufacture for the
recommended drying temperature.

To change the process air temperature set point with the dryer running:

• Press the Up Key to raise the set point to the temperature you want.

• Press Down Key to lower the set point to the temperature you want.

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 26 of 51

Restoring the Process Air Temperature Controller (E5CN) to Factory Settings

If the preset parameters on the controller have been tampered with and it no longer properly
controls temperature and displays dew point, you can restore the controllers to the factory
setup. Call the Service Department for detailed instructions.

E5CN Operating Parameters

The E5CN controller has several mode selections. Within each mode are numerous
parameters that can be set.

The factory has set the security level to protect the critical parameters from being accidentally
changed. Below is an explanation of the operating modes you will have access to and on the
following page are the manufacturers’ default settings.

Available E5CN Modes

Operation Level

Indicator

Name

Description

Run/Stop Mode
(r-S)

When “RUN” is selected, the control is running.
When “STOP” is selected, the control is stopped.
When the control is stopped, the STOP display
lights. The default is set to “RUN.”

Alarm Value 1
Mode (AL-1)

This setting is used to indicate how many degrees
the process temperature will be allowed to exceed
the set point temperature. An alarm output will de­energize the heaters.

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 27 of 51

Adjustment Level

Indicator

Name

Description

Auto-Tune Mode
(At)

See Page 19 of Chapter 3 for instructions on how
to Auto-Tune your dryer.

Note: Although the controller is calibrated at

the factory, the manufacturer
recommends that the unit be Auto­Tuned prior to dryer startup.

Temperature Input
Shift Mode (TnS)

This setting is used to offset an error between the
set point and the actual temperature. The entire
input range is shifted by a set figure
preprogrammed by the operator.

Proportional Band
Mode (P)

This setting controls the amount in which the
manipulated variable (MV) is proportionate to the
deviated value or controller error.

Integral Time
Mode (I)

Setting this feature, gives the control an action that
is proportionate to the time integral of the control
error. By using this setting, proportional action is
used in combination with integral action to offset
the control error and the set point will begin to
match the control temperature (PV or process
value).

Derivative Time
Mode (d)

Setting the derivative control provides the
controller with the ability to correct for a future
error in the previously set process output.

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 28 of 51

Entering Operating Parameters to Select Modes

To enter the display:

1. Press the Mode Display key to view the Run/Stop & Alarm 1 Modes.

2. Press the Up Key and the Down Key to set the higher or lower the values of the

parameter or turn that function On or Off.

The SV readout displays the different values for the parameter within a mode.

3. To switch modes within a level, press and hold the Level Display key for one (1)

second.

The PV readout will display the different parameters within each mode.

4. Use short presses on the Mode Display key to display each parameter within a mode.

The SV readout displays the different values for the parameter within a mode.

5. Press the Up Key and the Down Key to set the higher or lower the values of a

parameter or turn that function On or Off.

6. Press the Level Key once to return to the Process Temperature Setting.

Figure 7: Settings for Process Temperature Controller (E5CN), Part No. A0567917

Mode

Parameter

Setting range

Default

Manuf. setting

Run/Stop

Run/Stop

Run

-

Operation

Alarm value 1

-1999 to 9999

0

25

Mode

Parameter

Setting range

Default

Manuf. setting

AT execute/cancel

ON, OFF

OFF

Various

Temperature input shift

-199.9 to 999.9

0.0

-

Proportional Band

0.1 to 999.9

8.0

Various

Integral Time

0 to 3999

233

Various

Adjustment

Derivative Time

0 to 399940Various

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 29 of 51

Process Air Dew Point Display

Optional

The Process Air Dew Point meter indicates the current process air delivery moisture content.
Standard dryers use a microprocessor-based controller for displaying dew point air
temperature. The controller is a modular, self-contained unit removable from the mounting
housing. All parameters are factory set and adjusted; normally, no field adjustment to the
internal controls are necessary.

Figure 8: Typical Dew Point Display Monitor – Part No. A0555757

PV

SV

OUT1

OUT2 MANU STOP RMT AT SUB1

AT

E5CK

OMRON

Note: No field adjustment is required. The dew point meter is meant for

moisture indication only!

Setting the High Dew Point Alarm

The high dew point alarm setting is changed by pressing the up and down keys to input the
alarm value. The factory setting for Alarm Value 1 (AL-1) is -10°F (-23°C).

Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup

If the preset parameters on the controller have been tampered with and it no longer functions
properly, call the Service Department. This controller is not meant to be modified.

Note: The dew point alarm monitors and indicates a deviation from the set

point.

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 30 of 51

4-3 Dryer Operation Procedures

Controller Operation

1. Turn the disconnect (if applicable) on the control panel to the ON position. Power is

applied to the voltage line fuses, line side of the control power switch.

2. Turn the control power switch to the ON position. Power is applied to the

temperature control, programmable relay and dew point controller. The valve will
move to the start position as follows:

a. The valve motor rotates until the cam switch makes 2 transitions.

b. If the cam switch does not make a transition within 10 seconds, a valve

motor fault is generated. “VALVE MTR” is displayed on the relay screen,
the alarm light is activated. The valve motor, heaters, and blower shut off.

To restart the dryer, cycle control power to deactivate the alarm light and
restart the valve motor sequence.

Note: The relay screen which contains the Alarm Display Messages is located

inside the controller enclosure. For a list of Alarm Display Messages,
see Page 32.

WARNING! Do not attempt to check the Alarms on the Controller located within the

unit enclosure unless you are a qualified electrician!

c. The valve will normally complete one full cycle (revolution).

If the drying process shuts down due to an alarm, the dryer has been setup to
have the following operational features:

• The bed in process at power-down will remain in process.

• The bed in regeneration at power-down will remain in regeneration.

• The regeneration timing cycle will restart from the beginning.

3. Once the control power is on and no fault conditions exist, start the dryer as follows:

a. The process/regen blower is started.

b. The process heater is turned on and controlled by the E5CN controller.

c. The regen heater is turned on and the regeneration timing sequence is

initiated. For default timing settings for regeneration, see the table below.

Model

Heating

Cooling

15 cfm

30 cfm

15

45

60 cfm

N/A

N/A

Note: In a humid environment, you may change the setting to 20/45 for better

dew point management.

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 31 of 51

4. If either the left or right bed safety temperature switch opens, a regen heater fault is

generated. “HIGH TEMP” is displayed on the relay screen. The alarm light is
activated. The process heater, regen heater, and process/regen blower are turned off.

5. If the process temperature controller faults or the process heater safety switch opens,

a heater fault is generated. “HIGH TEMP” is displayed on the relay screen. The
alarm light is activated. The process heater, regen heater, and process/regen blower
are turned off.

6. If the process blower overload trips, a process blower fault is generated. “PROC

BLWR” is displayed on the relay screen. The alarm light is activated. The process
heater, regen heater, and process/regen blower are turned off (3 phase only).

7. The valve position limit switch enables the right bed heater and provides an input

signal to the programmable relay when actuated by the cam lobe. When the cam lobe
position is high, the right bed is activated. When the cam lobe position is low, the
left bed is activated. Each heater is ON-OFF controlled.

8. Upon completion of the HEAT portion of the regeneration sequence, the regen

heaters are disabled by the programmable relay and the COOL time begins.

9. Once the Cool time has expired, the valve motor is turned on until the cam switch

makes a transition. Upon making a transition, the timing sequence is restarted for the
new bed.

10. When no fault conditions exist, the display reads “SYSTEM NORMAL”.

11. The top 2 lines of the display show the HEAT and COOL times (in minutes) for the

regeneration sequence. Changes to these times can be made by the operator as
follows:

a. Press the up or down arrow until the cursor is positioned at the number to be

changed.

b. Press the “+” key to increment the number, or the “-“ key to decrement the

number.

c. Press the “OK” key to accept the value and write to the relay memory.

OR

d. Press the “ESC” key to cancel the changes.

Note: A change will NOT take effect until step 11-c is done.

12. The dryer is shut off by turning the control power switch to the OFF position.

13. Refer to Schematic drawing enclosed in the control enclosure.

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 32 of 51

Alarm Display Messages

Note: The relay screen which contains the Alarm Display Messages is located

inside the controller enclosure.

WARNING! Do not attempt to check the Alarms on the Controller located within the

unit enclosure unless you are a qualified electrician!

The following is a list of Alarm Display Messages which can be found on the relay screen:

Temperature Controller Alarm and/or

Regen Heater Temp Switch and/or

Process Heater Temp Switch and/or

Redundant Temp Safety

Valve Motor Time-Out

Multiple Alarms

No Alarms

HIGH TEMP
VALVE MTR

PROC BLWR
HIGH TEMP
VALVE MTR

HEAT 15
COOL 50
SYSTEM
NORMAL

15, 30, & 60 cfm Compact Dryers Chapter 4: Operation 33 of 51

4-4 Auto-Tuning the Dryer

1. For Auto-tuning, press the beige button once. The AT screen will show with the

setting OFF.

2. Press the UP arrow to change the setting to ON.

3. Press the beige button again to go back to the Temperature Screen. Your actual

temperature will start to flash for about 10-20 minutes with the temperature
fluctuating up and down during that period. After the flashing stops, it means auto­tuning has finished.

4-5 Shutting Down the Dryer

1. When processing is complete, close the hopper slide gate and shut down any in-line

companion equipment, such as the aftercooler.

2. Turn the Dryer ON/OFF selector switch to OFF.

3. Turn the system ON/OFF switch to OFF.

4. If needed, empty the drying hopper.

5. For maintenance or a long term shutdown, open (de-energize) the electrical

disconnects at the dryer and at the power drop.

15, 30, & 60 cfm Compact Dryers Chapter 5: Maintenance 34 of 51

Chapter 5: Maintenance

5-1 Preventative Maintenance Schedule

The checklist below contains a list of items which should be inspected and/or replaced to
keep your Dehumidifying Dryer operating at peak efficiency. Perform each inspection at the
regular intervals listed below.

System model #

Serial #

Every week

Date/ByDate/ByDate/ByDate/ByDate/ByDate/ByDate/ByDate/ByDate/ByDate/ByDate/ByDate/ByDate/

By

Inspect all filters for
wear, replace/
clean if dirty or
worn.

Check to make
sure that all hose
conections are
air tight.

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.

Every year

Next scheduled

inspection

Actual inspection

Date/By

Next scheduled

inspection

Actual inspection

Date/By

Inspect desiccant. Replace
if brown or broken.

Every two years

Scheduled

replacement date

Actual replacement
Date/Work done by

Scheduled

replacement date

Actual replacement

Date/Work done by

Replace desiccant.

- Photocopy this page for your maintenance records -

15, 30, & 60 cfm Compact Dryers Chapter 5: Maintenance 35 of 51

5-2 Preventative Maintenance

This section describes maintenance procedures which will increase the longevity and
efficiency of your dehumidifying dryer. Perform them at the regular intervals listed on the
dryer checklist on the previous page.

Servicing Process Air Filters
Caution! Operating the dryer without the process air filter installed voids your

warranty!

Filter cleaning is an important part of your dryer maintenance program.

Dehumidifying dryers have a single cartridge canister-type filter in the process air loop. The
filter protects blowers from plastic fines drawn in from the drying hopper and prevents the
desiccant from being contaminated. Regular filter cleaning is essential to keep your dryer
operating at peak efficiency.

You can blow or vacuum the dirt out of the filter with compressed air, but remember, it could
become damaged from high-pressure blowing.

Recommendations for Cleaning and Replacing Filters

• Turn off and/or lock out electrical power to the dryer.

• Remove the threaded fastener securing the filter access cover, then remove the cover.

• Remove the nut on the center retaining rod to remove the filter cartridge.

Figure 9: Air Filter Location and Disassembly

Process

Air

1" Wide x 1/8" Thick

Temperature

15, 30, & 60 cfm Compact Dryers Chapter 5: Maintenance 36 of 51

Vacuuming

Try vacuum-cleaning a soiled filter first. Vacuuming removes most large particles and
surface contaminants, and may suffice for the first time you clean a filter. Use a commercial­duty (recommended) or household vacuum cleaner. Vacuum the filter from the air intake
(dirty) side only.

Cleaning with Compressed Air

Blow clean, dry compressed air up and down the pleats, blowing out the filter
from the inside out. Remove loose dirt from the filter with compressed air or
vaccum from the outside.

Caution! DO NOT clean/wash filter with water!

After each cleaning:

• Inspect the filter element. Briefly hold a light bulb behind the element

and look for any fatigued paper or residual dirt. Inspect for holes and
tears by looking though the filter toward a bright light. Check for
damaged gaskets or dented metal parts. Do not re-use a damaged
filter!

• Check the gasket for damage. A damaged gasket allows contaminants

into the process. Replace as needed.

Servicing the Dew Point Monitor

The accuracy of the dew point monitor on mini dryer systems depends on proper operation of
the dew point sensor and the control board. The dew point sensor is in the process air stream
and is therefore susceptible to contamination.

Dew point sensor life depends on:

• Air temperature and flow passing over the sensor.

• The amount of fines (dust) in the process air.

• The amount of plasticizer vapor in the process air.

Once every six months, the dryer operator should monitor the initial dew point sensor
readings and establish a periodic replacement schedule as needed.

Caution! Do not attempt to check the continuity or resistance of the dew point

sensor.

The sensor will be destroyed!

15, 30, & 60 cfm Compact Dryers Chapter 5: Maintenance 37 of 51

5-3 Corrective Maintenance

This section provides you with the information necessary to correct or repair any issues
which might appear during the normal operation of your dehumidifying dryer. Although we
have listed how to perform these procedures, it is recommended that you call the Service
Department to have any in-depth maintenance performed.

Symptoms of Worn Desiccant

The moisture absorption capacity of the desiccant used in your dehumidifying dryer degrades
after an indefinite period of time. Useful life 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 process air dew point measured with a portable dew point monitor

is higher than -10°F (-23ºC) throughout the process drying cycle.

• Noticeable amounts of desiccant in the beds is a medium-brown color

or darker.

If you notice any of these signs, replace the desiccant in the desiccant beds. Desiccant
replacement kits are available from the Parts Department. If you want, a technician can
repack desiccant beds at your site.

WARNING! Handling desiccant material is HAZARDOUS.

Wear an N-100 type safety filter mask or equivalent to avoid prolonged
breathing of desiccant dust. Wear safety goggles and gloves to avoid
contact with eyes and skin.

• Handle with adequate ventilation.

• Wash hands thoroughly after handling.

: FIRST AID :

In case of eye contact, immediately flush eyes

with plenty of water for at least 15 minutes.

SEE A PHYSICIAN IMMEDIATELY IF IRRITATION PERSISTS.

15, 30, & 60 cfm Compact Dryers Chapter 5: Maintenance 38 of 51

Replacing Worn Desiccant
Caution! DESICCANT BEDS ARE HOT DURING OPERATION.

To avoid burn hazard, make sure desiccant beds are sufficiently cool
before replacing worn desiccant.

To access the Desiccant Bed:

1. Disconnect electrical power to the dryer.

2. Using a 1/8” Allen wrench, remove the 10-24 button head screws holding the top,

back and side panels to the frame and back of the dryer.

3. Disconnect the three (3) plugs for the valve motor, switch, and blower (15 cfm only)

4. Remove four (4) nuts at each corner of the top casting.

5. Disconnect all hoses and dew point air lines.

6. Pickup and place the top casting in a safe place.

7. Using a 1/8” Allen wrench, remove the four (4) 10-32 button screws holding the

desiccant cover to the canister.

8. Remove the cover.

9. Pickup the desiccant can and turn it upside down over an empty container to remove

all desiccant.

10. Dispose of properly using MSDS sheet.

15, 30, & 60 cfm Compact Dryers Chapter 5: Maintenance 39 of 51

Figure 10: Desiccant Bed Location and Disassembly

Caution! You should properly dispose of any discarded desiccant.

Consult local disposal regulations for more information.

11. Inspect each desiccant screen for tears or holes where desiccant burned-through.

Replace desiccant can if needed.

12. After cleaning each chamber, add the full amount of bead desiccant specified per bed.

Amounts are listed in the Desiccant Amounts Table below. Tap on side of tank to
settle desiccant. Smooth the top level, and finally add another layer of the remaining
bead desiccant to the top. Make sure this layer is level and smooth.

13. Repeat the previous step for the other bed.

14. Inspect the gaskets. Replace if necessary.

15. Re-install all components and reconnect all of the wiring and hoses.

Figure 11: Required Desiccant Amounts (13X Type)

Dryer

8 x 12 bead Total

Model

Part no.

lbs.

Kg

15 cfm

6.5

2.9

30 cfm

9.7

4.4

60 cfm

W00018051

13.5

6.1

Valve & Air

Manifold Casting

Desiccant

Assembly Rod

Regeneration

Heater

Wire Conduit

Assembly

Lower Air Manifold Casting

Gasket

Hollow

Desiccant

Tank

15, 30, & 60 cfm Compact Dryers Chapter 5: Maintenance 40 of 51

Replacing the Process/Regeneration Heater

The dehumidifying dryers utilize a single-phase Calrod-type heater element. This heater
element is mounted in the center compartment in the desiccant beds. Although the
replacement procedure is the same for each heater, the wattage varies by model, voltage,
temperature range, etc.

WARNING! Hazardous electrical current present.

Disconnect and lock out power before you replace heater elements!

Figure 12: Process/Regeneration Heater Location and Disassembly

Valve & Air

Manifold Casting

Desiccant

Assembly Rod

Regeneration

Heater

Wire Conduit

Assembly

Lower Air Manifold Casting

Gasket

Hollow

Desiccant

Tank

15, 30, & 60 cfm Compact Dryers Chapter 5: Maintenance 41 of 51

Procedures

1. Disconnect electrical power to the dryer.

2. Using a 1/8” Allen wrench, remove the 10-24 button head screws holding the top,

back and side panels to the dryer frame.

3. Disconnect the plug for the valve motor, valve switch, and blower (15 only).

4. Remove the four (4) nuts at each corner of the top casting.

5. Pickup and place the top casting in a safe place.

6. Pickup the desiccant can to reveal the heater.

7. Using a 1/8” Allen wrench, remove the four (4) 10-32 screws on the heater plate.

8. Remove the wires to the heater plate assembly being removed or replaced.

9. Remove the two (2) 4-40 screws for the temperature switch.

10. Inspect temperature switch with voltmeter. (Normally closed, ohms). Replace if

faulty.

11. Re-install the heater and heater plate assemblies in reverse order. Install new heater

gaskets and securely tighten all fasteners.

Caution! Heater loops should not touch each other.

“Hot spots” lead to premature heater failure!

Replacing/Cleaning the Regeneration Cooling Coils

Figure 13: Cooling Coil Location and Disassembly

To clean the cooling coil, use compressed air or a steam cleaner to blow the dust off or clean
any oily residue on the coil.

Undo (4) 10-32 Button
Head Screws using 1/8
Allen Wrench

Use compressed air or a steam
cleaner to blow the dust off or clean
any oily residue on the coil.

1" Wide x 1/8" Thick High

Temperature Gasket

15, 30, & 60 cfm Compact Dryers Chapter 6: Troubleshooting 42 of 51

Chapter 6: Troubleshooting

6-1 Introduction

The utmost in safety precautions should be observed at all times when working on or around
the machine and the electrical components. All normal trouble-shooting must be
accomplished with the power off, line fuses removed, and with the machine tagged as out of
service.

The use of good quality test equipment cannot be over-emphasized when troubleshooting is
indicated. Use a good ammeter that can measure at least twice the AC and DC current that
can be encountered for the machine. Be sure that the voltmeter has at least minimum
impedance of 5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales.
Popular combination meters, VOM and VTVM can be selected to provide the necessary
functions.

Before making haphazard substitutions and repairs when defective electrical components are
malfunctioning, we recommend that you check the associated circuitry and assemblies for
other defective devices. It is common to replace the obviously damaged component without
actually locating the real cause of the trouble. Such hasty substitutions will only destroy the
new component. Refer to wiring diagrams and schematics.

Locating mechanical problems, should they occur, is relatively straightforward. When
necessary, refer to the parts catalog section.

Problem

Possible cause

Corrective action

Dirty filter.

Clean or replace filter.
Desiccant beds are contaminated
by material or plasticizer leaking
into the system.

Replace desiccant. See Page 38

for more information.

Blower overload has tripped.

Fix the problem and reset the

overload. Possible open fuse,

loose wire.

Little or no air coming from
the process delivery tube.

Blower fins filled with dust or
contaminants.

Remove blower side plate,

clean baffles, replace.

Phase is reversed on power drop
coming into the dryer. (Only on
3 phase units.)

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.

Suction in delivery tube,
pressure from the return tube.

Wrong delivery and return
connections.

Reverse hoses. See air flow

diagram on Page 12.

15, 30, & 60 cfm Compact Dryers Chapter 6: Troubleshooting 43 of 51

Problem

Possible cause

Corrective action

Process heaters are faulty.

Check for open heaters. Replace

if required.
Solid-state temperature
controller faulty.

Replace.

Loss or reduction of process air
temperature.

Process temperature was
adjusted in error by plant
personnel.

Make sure that plant personnel

are aware of the proper

temperature set point. Post an

appropriate sign next to the

controller.
Process heaters are faulty.

Replace.
Desiccant beds are

contaminated.

Replace desiccant.

Material being dried differs

from material specified at the
time of purchase.

Drying systems are designed for

the material which was

originally specified. Different

materials may need a longer

residence time or a different

drying temperature.
Break in flex hose to/from

drying hopper.

Inspect for air leaks; replace as

needed.

Airflow valve sticking or failing
to shift.

Check for proper operation of

valve actuators. Repair or

replace if necessary.

Remove blower side plate,

clean baffles, replace.

Loss or reduction in drying
capacity.

Blower fins filled with dust or
contaminants.

Replace filter elements.

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.
High temperature alarm not set
properly.

Reset high temperature alarm.

Process set point is out of
acceptable range.

Restore temperature controller

to factory pre-sets.
Function set for degrees Celsius
(ºC), set point at degrees
Fahrenheit (ºF).

Verify correct Celsius or

Fahrenheit settings.

Material in drying hopper cakes,
or meltdown occurs.

Process thermocouple not in
airflow.

Verify that the thermocouple is

properly installed in the inlet

tube.

15, 30, & 60 cfm Compact Dryers Chapter 6: Troubleshooting 44 of 51

Problem

Possible cause

Corrective action

Burned out regeneration heater.

Repair or replace.

Contaminated or worn out
desiccant.

Replace.

Leaking process air hoses.

Repair or replace.

Dryer operates beyond its
capacity.

Check dryer and drying hopper

sizing.

Bad dew point sensor.

Replace.

Fouled dew point sensor
manifold.

Clear obstruction. Air should
flow freely through sensor.

Poor dew point performance.

Dirty filter.

Clean or replace filter element.

The internal mechanism is not
inserted properly into the
housing.

Properly insert the internal
mechanism into the housing.

The power supply is not
connected.

Properly connect the power
supply.

No power is supplied, or the
supplied power is not within the
specified range.

Supply a voltage of 85 to 125
VAC to the power supply
terminals of the controller.

Nothing displays when the
controller is turned on.

Disconnect switch or Control
Power switch not set to ON.
Control Power fuse blown.

Check control power fuse for
continuity. Turn disconnect
switch and control power switch
ON.

Input polarity on thermo-couple
is wrong or connection is wrong.

Properly wire the terminals.

No compensating lead wires
used for extension of the
thermocouple.

Use proper compensating lead
wires and terminals.

Thermocouple and controller are
connected by wires other than
proper lead wires.

Use a dedicated thermocouple

connector. If a connector is a

metal different from the

thermocouple and controller, a

temperature error may result.

Process thermocouple not in
airflow.

Verify that the thermocouple is

properly installed in the inlet

tube.

Sensor is broken or short­circuited.

Replace with a good sensor.

The controller is influenced by
noise or other induction.

Separate input wires as far as
possible from the origin of the
noise.

Process value is abnormal or
not obtained.

Celsius temperatures used
instead of Fahrenheit or vice
versa.

Contact Service Department

15, 30, & 60 cfm Compact Dryers Chapter 6: Troubleshooting 45 of 51

6-2 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, short­circuited, or incorrectly wired.

Other service problems or questions can be answered by contacting the Service
Department.

15, 30, & 60 cfm Compact Dryers Chapter 7: Appendix 46 of 51

Chapter 7: Appendix

7-1 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.

15, 30, & 60 cfm Compact Dryers Chapter 7: Appendix 47 of 51

7-2 Drawings and Diagrams

Figure 14: Machine-Mount Dryer Dimensions

Model

15 cfm

30 cfm

60 cfm

Hopper Size

0.85 ft_/24

liters

1.7 ft_/48 liters

1.7 ft_/48 liters

3.0 ft_/85 liters

3.0 ft_/85 liters

9.0 ft_/255

liters

Dimension

In.

Cm.

In.

Cm.

In.

Cm.

In.

Cm.

In.

Cm.

In.

Cm.

A

30

76.23076.2

34 7/16

87 _

38 7/16

97.4

38 7/16

97.4

38 7/16

97.4

B

37 7/8

96.2

46 7/8

119.1

46 7/8

119.172183

49 7/8

126.7

79

200.6

C

23

58.42358.4

35 5/16

89.7

35 5/16

89.7

35 5/16

89.7

35 5/16

89.7

D

22 7/8

58.1

22 7/8

58.12768.62768.62768.62768.6

E

7

17.8717.8717.8717.8717.8717.8

F

2.5

6.4

2.5

6.4

2.5

6.4

2.5

6.4

2.5

6.4

2.5

6.4

G

5.5145.5145.5145.5145.5145.5

14

Mounting flange

Diameter hole:

E

E

F

G

G

PROCESSTEMPERATUREDEW POINTCONTROLPOWERONOFFALARMPOWER ONONOFF

CBAD

15, 30, & 60 cfm Compact Dryers Chapter 7: Appendix 48 of 51

Figure 15: Cart-Mount Dryer Dimensions

ABCDE

F

In.

Cm.

In.

Cm.

In.

Cm.

In.

Cm.

In.

Cm.

In.

Cm.

15 cfm

27 _

69.92358.4

30 cfm

27 13/16

70.6

60 cfm

36

91.4

36 5/16

92.2

3 7/8

9.8

11 _

29.22258.9

33

83.8

Aftercooler Design Specifications

Entering water temp.

ºF

ºC

85ºF

29ºC

A

PROCESS

TEMPERATURE

DEW POINT

CONTROL

POWER

ON

OFF

ALARM

POWER ON

ON

OFF

B

E

D

C

F

A B C D E F
ASD15
ASD30

15, 30, & 60 cfm Compact Dryers Chapter 7: Appendix 49 of 51

Figure 16: Electrical Drawing

15, 30, & 60 cfm Compact Dryers Chapter 7: Appendix 50 of 51

7-3 Spare Parts List

Figure 17: Spare Parts List (Mechanical)

MINI DRYER SPARE PARTS LIST 15, 30, 60 cfm Models

15CFM

15CFM

15CFM

15CFM

15CFM

15CFM

15CFM

30CFM

30CFM

30CFM

30CFM

30CFM

30CFM

30CFM

60CFM

60CFM

60CFM

60CFM

60CFM

60CFM

LEVEL 1 ( Mechanical Components )

115V 3PH

208V 3PH

220V 50 HZ 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

115V 3PH

208V 3PH

220V 50 HZ 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

220V 50 HZ 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

PART # SIZE Description
W00015435 Dew Point Sensor Insert Cable 1 1 1
A0548556 Dew Point Sensor 1 1 1
A0566467 Valve switch 1 1 1
A0572319 Process Air Filter UP TO 55 CFM 1 1
A0566531 Process Air Filter UP TO 100 CFM 1
W00018051 13X molecular Sieve Desiccant ( 8 X 12 Beads ) 6.5 Lbs. 9.75 Lbs. 14.5 Lbs.
W00013983 High Temperature Gasket. 32 Inches 32 Inches 32 Inches
A0566839 Desiccant Tank Gasket 4 4 4
A0566676 High Temperature Snap Switch. 2 2 2

LEVEL 2 ( Mechanical Components )

PART # SIZE Description
A0568483 500 Watts Heater element 115 Volts 2 0 0
A0568484 500 Watts Heater element 208/220 Volts 2 2 0 0
A0568485 500 Watts Heater element 230 Volts 2 0 0
A0568486 500 Watts Heater element 400 Volts 2 0 0
A0568487 500 Watts Heater element 460 Volts 2 0 0
A0568488 500 Watts Heater element 575 Volts 2 0 0
A0570287 1000 Watts Heater element 115 Volts 0 2 0
A0570288 1000 Watts Heater Element 208/220 Volts 0 2 2 0
A0570289 1000 Watts Heater Element 230 Volts 0 2 0
A0570290 1000 Watts Heater Element 400 Volts 0 2 0
A0570291 1000 Watts Heater Element 460 Volts 0 2 0
A0570292 1000 Watts Heater Element 575 Volts 0 2 0
A0572359 1500 Watts Heater Element 208/220 Volts 0 0 2 2
A0572360 1500 Watts Heater Element 230 Volts 0 0 2
A0572361 1500 Watts Heater Element 400 Volts 0 0 2
A0572362 1500 Watts Heater Element 460 Volts 0 0 2
A0572363 1500 Watts Heater Element 575 Volts 0 0 2
A0566682 1/4" OD Teflon Tube.

3.5 Feet

5 Feet 6 Feet

LEVEL 3 ( Mechanical Components )

PART # SIZE Description
A0572358 1" O.D. by 12 Ft Long Hi Temp Hose. 1 1 1
A0534060 2-1/2" O.D. by 12 Ft Long Hi Temp Hose. 1 1 1
A0566535 Return Air Cooling Coil 1 1 1
A0570437 115 Volt Process Blower. 1 1 1 1 1 1 1
A0570294 115 Volt Process Blower. 1
A0534282 208/460 Volt Process Blower. 1 1 1 1 1
A0535350 575 Volt Process Blower 1
A0552439 208/460 Volt Process Blower. 1 1 1 1 1
A0552440 575 Volt Process Blower 1
W00015335 Dew Point Sensor Manifold 1 1 1
A0548558 Gasket for the Dew Point Sensor 1 1 1
W00015436 Plastic Nut for the Dew Point Sensor 1 1 1
A0568022 Rubber Bumper for the bottom of Dryer 4 4 4

042.00016.00 Swivel Casters 2 2 2

042.00017.00 Rigid Casters 2 2 2
132-00007-00 Handle for The Panels. 2 2 2
A0566466 Valve Motor 1 1 1
A0547006 Knob for the Filter Housing 1 1 1
A0570444 Valve Shaft 1 1 1

15, 30, & 60 cfm Compact Dryers Chapter 7: Appendix 51 of 51

7-4 Dryer Identification (Serial Number) Tag

(Located on back of Dryer)

Company Logo

XXX Series Dryer
Model Number XXX-15

Max Drying Capacity HR

460V Serial Number 060701R
1_ 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

7-5 Technical Assistance

Parts Department

Call toll-free 7am–5pm CST [800] 423-3183 or call

[414]

354-0970, Fax [414] 354-6421
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] 657-4679 or call [414

] 3

54-0970
Emergencies after 5pm CST, call [847] 439-5655
We have a qualified service department ready to help. Service contracts are available for most of our
products.

Sales Department

Call

[414]

354-0970 Monday–Friday, 8am–5pm CST
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales
Department for the name of the sales representative nearest you.

Contract Department

Call [414] 354-0970 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 non­union installations.