AEC AP Series Large Dehumidifying Dryer User Manual

Large AP1+ Control

Dehumidifying Dryer

Part Number: 882.00202.00

Bulletin Number: XX1-670

Effective: 09/01/05

Write Down Your Serial Numbers Here For Future Reference:

_________________________ _________________________

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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.

Please note that our address and phone information has changed.
Please reference this page for updated contact information.

These manuals are obsolete and are provided only for their technical information, data and capacities.
Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance
and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied
upon. Please contact the ACS Group for more current information about these manuals and their
warnings and precautions.

Parts and Service Department

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.

For immediate assistance, please contact:

• North, Central and South America, 8am – 5pm CST [phone] for drying, conveying, heating and cooling
and automation. For size reduction: [phone].
North America, emergencies after 5pm CST [phone]

North America email: [e-mail]

• Mexico, Central & South America
Email: [e-mail]

• Europe, Middle East & Africa [phone]

Email: [e-mail]

• India [phone]

Email: [e-mail]

• Asia/Australia [phone]

Email: [e-mail]

Sales and Contracting Department

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.

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.

For assistance with your sales or system contracting needs please Call:

North, Central and South America [phone] or [phone] Monday–Friday, 8am–5pm CST

Europe/Middle East/Africa [phone]
India [phone]
Asia/Australia [phone]

Facilities:

ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at
www.acscorporate.com

United States:

ACS Schaumburg – Corporate Offices

1100 E. Woodfield Road
Suite 588
Schaumburg, IL 60173
Phone: + 1 847 273 7700
Fax: + 1 847 273 7804

ACS New Berlin – Manufacturing Facility

2900 S. 160th Street
New Berlin, WI 53151
Phone : [phone]
Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP
Suzhou, China 215126
Phone: + 86 8717 1919
Fax: [phone]

Europe/Middle East/Africa:

ACS Warsaw

Ul. Działkowa 115
02-234 Warszawa
Phone: + 48 22 390 9720
Fax: [phone]

India

ACS India

Gat No. 191/1, Sandbhor Complex
Mhalunge, Chakan, Tal Khed,
Dist. Pune 410501, India
Phone: [phone]
Fax: + 91 20 40147576

Shipping Info

Unpacking and Inspection

You should inspect the large dehumidifying 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 the packing list. You should have:

; Large 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.

Large Dehumidifying Dryers ii

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.

returned material purchased from the manufacturer returned is subject to 15% ($75.00

ALL
minimum) restocking charge.

returns are to be shipped prepaid.

ALL

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

to the return of any material, authorization must be given by the manufacturer. A

Prior
RMA number will be assigned for the equipment to be returned.

Reason for requesting the return must be given.

returns are to be shipped prepaid.

All

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
manufactured by our company, purchased components are covered under their specific
warranty terms.

the item is found to be defective in materials or workmanship, and it was

Large Dehumidifying Dryers iii

Table of Contents

CHAPTER 1: SAFETY................................................................ 7

1-1 How to Use This Manual ............................................................................................. 7

Safety Symbols Used in this Manual.....................................................................7

1-2 Warnings and Precautions .......................................................................................... 8

1-3 Responsibility .............................................................................................................. 9

General Responsibility...........................................................................................9

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

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

Reporting a Safety Defect ................................................................................... 11

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

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

2-2 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

2-3 Standard Features..................................................................................................... 14

Auto Start Timer .................................................................................................. 14

Mechanical Features ...........................................................................................14

Electrical Features............................................................................................... 14

2-4 Options ...................................................................................................................... 15

Dewpoint Extend ................................................................................................. 15

Closed-Loop Regeneration .................................................................................15

2-5 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

2-6 Safety Devices and Interlocks ................................................................................... 22

Dimensions and Specifications 9 Denotes availability..................................24

Mechanical Options 9 Denotes availability ..................................................24

Electrical Features............................................................................................... 25

Electrical Options ................................................................................................25

CHAPTER 3: MECHANICAL INSTALLATION ........................26

3-1 Uncrating the Equipment...........................................................................................26

3-2 Rigging and Placing Unit ........................................................................................... 26

3-3 Making Electrical Connections .................................................................................. 26

3-4 Making Gas Line Connections (Gas-Fired Models Only) .......................................... 27

3-5 Checking for Proper Blower Rotation ........................................................................ 28

3-6 Making Dryer/Drying Hopper Process Air Connections ............................................29

Large Dehumidifying Dryers iv

Connecting Aftercooler/Precooler Cooling Water (Optional).....................................32

3-7

3-8 Using the Drying Hopper Air Trap ............................................................................. 33

CHAPTER 4: CONTROLS........................................................ 34

4-1 Controller Description................................................................................................34

4-2 Operating the Dryer................................................................................................... 35

4-3 AP1+ Data Entry ....................................................................................................... 37

4-4 Dryer Setup ............................................................................................................... 39

4-5 Drying Hopper Setup................................................................................................. 40

4-6 AP1+ Data Monitoring and Navigation ...................................................................... 42

System Menu ......................................................................................................56

4-7 Program Upgrade Procedures ..................................................................................62

PLC Program Upgrade........................................................................................62

Touch Screen Program Upgrade.........................................................................63

4-8 Security .....................................................................................................................64

4-9 Dryer & Drying Hopper Faults ................................................................................... 65

Alarm List ............................................................................................................66

Alarm Text Abbreviations .................................................................................... 78

Temperature Alarms............................................................................................ 78

Common Text Descriptions .................................................................................79

4-10 Troubleshooting......................................................................................................... 80

PLC Faults........................................................................................................... 80

PLC Module Faults..............................................................................................81

DeviceNet I/O Faults ........................................................................................... 82

Touch Screen Faults ........................................................................................... 82

CHAPTER 5: MAINTENANCE .................................................83

5-1 Maintenance Schedule..............................................................................................83

5-2 Preventative Maintenance......................................................................................... 84

Cleaning or Replacing the Process Air Filters.....................................................84

Cleaning or Replacing the Regeneration Filter....................................................85

Calibrating the Dirty Filter Alarm..........................................................................85

Checking the Dewpoint Control System..............................................................86

5-3 Corrective Maintenance ............................................................................................87

Symptoms of Worn Out Desiccant ......................................................................87

Replacing the Desiccant...................................................................................... 87

Replacing the Process Heater (Electric Dryers)..................................................88

Replacing the Regeneration Heater (Electric Dryers) .........................................89

CHAPTER 6: TROUBLESHOOTING .......................................91

6-1 Introduction................................................................................................................ 91

6-2 Basic Troubleshooting...............................................................................................91

6-3 Determining Temperature Controller Errors or Sensor Errors................................... 93

Using a Thermocouple ........................................................................................ 93

Using a Platinum Resistance Thermometer........................................................93

CHAPTER 7: APPENDIX.......................................................... 94

7-1 Warranty....................................................................................................................94

7-2 Technical Specifications............................................................................................95

Large Dehumidifying Dryers v

Annex B Information............................................................................................95

7-3 Spare Parts List.........................................................................................................96

7-4 8-4 Dryer Identification (Serial Number) Tag............................................................. 97

7-4 8-4 Dryer Identification (Serial Number) Tag............................................................. 98

7-5 Technical Assistance................................................................................................. 99

Parts Department ................................................................................................ 99

Service Department............................................................................................. 99

Sales Department................................................................................................ 99

Contract Department ...........................................................................................99

Large Dehumidifying Dryers vi

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, pre­operational 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.

Large Dehumidifying Dryers Safety 7

Dryer Safety Tags

Tag Description Tag Description

Read Operation &
Installation Manual

PE

Hot!

Protected Earth
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.

High Voltage Inside
Enclosure

Lifting Point

Earth Ground

; 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.

Large Dehumidifying Dryers Safety 8

; 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:

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.

• Loss of a skilled operator (temporarily or permanently)

• Breakdown of shop morale

• Costly damage to equipment

• Downtime

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 9

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.

Large Dehumidifying Dryers Safety 10

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.

Large Dehumidifying Dryers Safety 11

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,

Large Dehumidifying Dryers Functional Description 12

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

Dryer Valve

Regeneration

Regeneration

Blower

Filter

Insulated

Drying

Hopper

AD600-AD1500

Dryer Flow Schematic

Left Desiccant in

Regeneration

Dryer Valve

Regeneration

Blower

Regeneration

Filter

Insulated

Drying

Hopper

Regeneration

Heaters

Left Desiccant

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.

Regeneration

Exhaust

Process

Heater

Right Desiccant

Process

Process

Blower

Filter

Regeneration

Heaters

Left Desiccant

Regeneration

Exhaust

Process

Right Desiccant

Heater

Process

Process

Blower

Filter

Large Dehumidifying Dryers Functional Description 13

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 14

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).

AD600-AD1500

Dryer Flow Schematic

Regeneration Closed Loop

Cooling is Activated

Regeneration

Heaters

Left Desiccant

Figure 2: Closed Loop Regeneration

Regeneration

Blower

AD600-AD1500

Dryer Valve

Optional
Regeneration
Closed Loop

Cooler

Regeneration

Regenerarion

Exhaust

Optional

Regeneration

Closed Loop

Valve

Filter

Dryer Flow Schematic

Regeneration Heating is

Activated

Regeneration

Heaters

Left Desiccant

Dryer Valve

Optional

Regeneration

Closed Loop

Cooler

Regeneration

Blower

Regeneration

Exhaust

Optional

Regeneration

Closed Loop

Valve

Regeneration

Filter

Large Dehumidifying Dryers Functional Description 15

2-5 Drawings and Diagrams

Process

Heater

Optional

Regeneration

Closed Loop

Cooler

Optional

Regeneration

Closed Loop

Valve

Regen.

Exhaust

Regeneration

Regen.

Filter

Blower

Insulated

Drying

Hopper

Process
Air Filter

Optional

After-cooler

Left Desiccants

Dryer Valve

Right Desiccants

Process

Blower

Airflow Schematic: 2000-3000 cfm dryers (4 desiccant beds). Left desiccant beds are
regenerating—closed loop regeneration is activated.

Regeneration

Process

Heater

Optional

Regeneration

Closed Loop

Cooler

Optional

Regeneration

Closed Loop

Valve

Regen.

Exhaust

Regen.

Filter

Blower

Insulated

Drying

Hopper

Process
Air Filter

Optional

After-cooler

Left Desiccants

Dryer Valve

Right Desiccants

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 16

Filter Check

Gage

Differential

Pressure

Switch

PS

Thumb Screws

Cartridge Filter

Dust Shroud

Filter Retainer

F

E

Dust Level

Indicator

Optional dryer dust collector

Slide Gate

Clamp

Dust Pan

Large Dehumidifying Dryers Functional Description 17

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).

Mounting
Brackets

Figure 3: Process Aftercooler

High

Temperature

Gasket

Cooling Coil

Mounting Brackets

Stainless Steel

Cooler Housing

Cooling Coil

Cooling Coil
Cover Plate

Cooling Coil

Pipe Gasket

Aftercooler Design Specifications

Entering water temp.

ºF ºC

85ºF 29ºC

Cooling Coil
Pipe Gasket

Cooling Coil
Cover Plate

High

Temperature

Gasket

Stainless Steel Cooler

Housing

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.

Large Dehumidifying Dryers Functional Description 18

Filter Check

Gage

Differential

Pressure

Switch

Figure 4: Process Air Dust Collector

Thumb Screws

PS

Cartridge Filter

Dust Shroud

Filter Retainer

F

Dust Level

Indicator

E

Slide Gate

Clamp

Dust Pan

Large Dehumidifying Dryers Functional Description 19

Material Overdrying Protection

Material Overdrying Protection is an automatic system used to reduce the chance of over­drying, 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

Valve

Proofing

Switch

Coupling

Temperature

Probe

Drying

Hopper

Large Dehumidifying Dryers Functional Description 20

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

Large Dehumidifying Dryers Functional Description 21

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.

Large Dehumidifying Dryers Functional Description 22

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.

Large Dehumidifying Dryers Functional Description 23

Dimensions and Specifications

CFM 600 850 1000 1250 1500 2000 2500 3000

(Electric Dryer w/ Basic Control)
(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

(Gas & Electric Dryer)
Air inlet/outlet: OD, in inches (mm)

Gas Flow Requirement (Gas Dryers)
Low Heat Gas Flow Rate (CFH) 159 225 265 331 397 528 661 793
High Heat Gas Flow Rate (CFH) 227 322 378 473 568 756 945 1,134
Exhaust Duct Sizes in inches (MM) 3(76) 4(102) 5(127) 6(152)
Comb. Flue Air Flow (CFM) 87 123 145 182 218 290 363 436

Overall Dimensions (Electric Dryers)

Dimensions (in inches)

Shipping Weight (in lbs.) 2100 2200 2950 4350 4700 6500 7300 8450

Overall Dimensions (Gas Dryers)

Dimensions (in inches)

Shipping Weight (in lbs.) 2950 3050 3800 5150 5800 8125 8875 9050

9

Denotes availability

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 9 9 9 9 9

9 9 9 9 9 9 9 9

8(203) 10(254) 12(305)

Height 67 81 83

Depth 96 118 150
Width 63 73

Height 67 83 85

Depth 96 118 150
Width 63 73

Mechanical Options 9 Denotes availability

Option Description

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

Over Drying Protection

Temperature Set Back
Automatic airflow reduction valve. (Not for gas dryers)

13X Desiccant STD

Closed Loop Cooling Valve
(Std. w/high performance)
Dew Point +15°F to –40°F 9 (Not with high performance)
Dew Point + 15°F to -80°F 9 (Standard with high performance)

Sound Insulation Package for under 85 DBA Noise Level Not Required
Dust Collector ADC
Process Heater 180°F to 250°F
Process Heater 180°F to 400°F

600 850 1000 1250 1500 2000 2500 3000

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

9 9 9 9

9 9 9
9 9 9 9 9 9 9 9
9 9 9 9 9 9 9 9

CFM

9 9

9

Large Dehumidifying Dryers Functional Description 24

Electrical Features

Dryer AMP Draw

Standard voltage Low Heat (Electric Dryers)

208v/3/60Hz. 152 217 249 314 378
230v/3/60Hz. 137 196 225 284 342
400v/3/50Hz. 79 113 129 163 197 270 339 424
460v/3/60Hz. 69 98 112 142 171 234 294 370
575v/3/60Hz. 55 78 90 114 137 188 236 295

Standard voltage High Heat (Electric Dryers)

208v/3/60Hz. 207 296 342 430
230v/3/60Hz. 187 267 309 389
400v/3/50Hz. 108 154 178 224 269 366 N/A
460v/3/60Hz. 94 134 154 194 234 318 399 494
575v/3/60Hz. 75 107 123 156 187 254 319 395

Standard voltage (Gas Dryers)

208v/3/60Hz. 36 47 48 61 75 120 150 191
230v/3/60Hz. 33 43 44 55 67 109 136 173
400v/3/50Hz. 19 25 32 39 62 78 99
460v/3/60Hz. 16 22 28 34 54 67 87
575v/3/60Hz. 13 17 22 27 43 54 69

Electrical Options

CFM

600 850 1000 1250 1500 2000 2500 3000

Full load Amps

N/A

Full load Amps

N/A

Full load Amps

9 Denotes availability

Option Description

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
Redundant process temperature safety 9 (Standard w/High Performance)
Ethernet module for remote communication w/ Data logging
CSA approval
UL rating
Supply voltages 400/3/50 (includes CE compliance)
Audible & Visual Alarm 9 (Standard w/High Performance)

600 850 1000 1250 1500 2000 2500 3000

9 9

CFM

9

CF

9
9
9
9

Large Dehumidifying Dryers Functional Description 25

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.

Large Dehumidifying Dryers Mechanical Installation 26

; 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

6

8

11

4

4

1

3

2

PS

21

22

PS

C
B

PS

12

13

PS

14

20

16

3

17

PS

20

21

22

Fume

Exhaust

5

18

19

15

16

3

20

21

22

24

25

PS

23

15

22

16

P

3

S

20

21

Item Description Item Description

1 Manual gas shut off valve 14 Regeneration gas regulator
2 Gas regulator 15 Regeneration air solenoid valve
3 Gas pressure switch 16 Regeneration gas solenoid valve
4 Process gas solenoid valve 17 Regeneration gas proportionator
5 Manual adjustable butterfly valve 18 Regeneration butterfly orifice valve
6 Process gas proportionator 19 Regeneration air actuator
7 Process air actuator 20 Adjustable gas orifice
8 Air pressure switch 21 Regeneration thermocouple
9 Process ratiomatic burner 22 Regeneration SER burner
10 Process gas heat exchanger 23 Regeneration & combustion air filter
11 Gas pressure switch 24 Combustion air blower
12 Process combustion air blower 25 Air pressure switch
13 Process combustion air filter

DANGER! Natural gas burners are started, stopped, and monitored independently of

the dryer controls using Eclipse

TM

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

http://www.eclipsenet.com/catalog/contents/Documents/08/826IM0503s.pdf

Large Dehumidifying Dryers Mechanical Installation 27

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

Large Dehumidifying Dryers Mechanical Installation 28

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

location

(Do not insulate)

Process Air Heater on Dryer

Large Dehumidifying Dryers Mechanical Installation 29