AEC AP Series Large Dehumidifying Dryer User Manual

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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:

_________________________ _________________________

We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice.

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 +1 (800) 483-3919 for drying, conveying, heating and cooling and automation. For size reduction: +1 (800) 229-2919. North America, emergencies after 5pm CST (847) 439-5855

North America email: acsuscanadacustserv@corpemail.com

• Mexico, Central & South America Email: acslatinamericacustserv@corpemail.com

• Europe, Middle East & Africa +48 22 390 9720

Email: acseuropecustserv@corpemail.com

• India +91 21 35329112

Email: acsindiacustserv@corpemail.com

• Asia/Australia +86 512 8717 1919

Email: acsasiacustserv@corpemail.com

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 +1 (262) 641-8600 or +1 (847) 273-7700 Monday–Friday, 8am–5pm CST

Europe/Middle East/Africa +48 22 390 9720 India +91 21 35329112 Asia/Australia +86 512 8717 1919

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 : +1 262 641 8600 Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP Suzhou, China 215126 Phone: + 86 8717 1919 Fax: +86 512 8717 1916

Europe/Middle East/Africa:

ACS Warsaw

Ul. Działkowa 115 02-234 Warszawa Phone: + 48 22 390 9720 Fax: +48 22 390 9724

India

ACS India

Gat No. 191/1, Sandbhor Complex Mhalunge, Chakan, Tal Khed, Dist. Pune 410501, India Phone: +91 21 35329112 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 (800) 233-4819; for all other countries, call our international desk at (630) 475-7491. Have the order number and item number available. Hold the items until you receive shipping instructions.

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

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

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

Blower

Filter

Regeneration

Heaters

Left Desiccant

Regeneration

Exhaust

Process

Right Desiccant

Heater

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

Thumb Screws

Cartridge Filter

Dust Shroud

Filter Retainer

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

Cartridge Filter

Dust Shroud

Filter Retainer

Dust Level

Indicator

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

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

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

CFM

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 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

C B

Fume

Exhaust

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

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

Return air

thermocouple

location

Process Air Heater on Drying

Hopper

Large Dehumidifying Dryers Mechanical Installation 30

Return air

thermocouple

location

Drying System with Dust Collector

and Process Air Heater on Dryer

Large Dehumidifying Dryers Mechanical Installation 31

3-7 Connecting Aftercooler/Precooler Cooling Water (Optional)

Support both sides of the fitting when making the cooling water connections to prevent damage to the aftercooler coil. See Figure.

Connect 85°F water to the inlet closest to the exiting air side of the aftercooler coil. This will cool the process air about 100°F and raise the water-out temperature about 10°F. The table below lists available aftercooler models and their flow rates.

Figure 9: Aftercooler Components & Flow Rates

Mounting Brackets

Cooling Coil

Cooling Coil Pipe Gasket

Stainless Steel Cooler

Housing

High

Temperature

Gasket

Cooling Coil

Cover Plate

Stainless Steel

Cooler Housing

Cooling Coil

Mounting

Brackets

Cooling Coil Cover Plate

High

Temperature

Gasket

Cooling Coil Pipe Gasket

After cooler

Model

600 10

AD600 10

850 10

AD850 10

1000 15

AD1000 15

1250 15

AD1250 15

1500 20

AD1500 20

2000 25

AD2000 25

2500 30

AD2500 30

3000 35

AD3000 35

Water Flow

(GPM)

( GPM )

Large Dehumidifying Dryers Mechanical Installation 32

3-8 Using the Drying Hopper Air Trap

Our exclusive air trap assembly in the top of the drying hopper prevents ambient air from contaminating the material being dried. To ensure that air does not enter the drying system, do the following (See Figure):

; Keep the material level above the bottom edge of the air trap for maximum

efficiency.

; Use a hopper loader or vacuum conveying system to maintain the proper material

level.

Figure 10: Drying Hopper Air Trap

Suggested material level

for the optimum

efficiency.

Flapper Valve

of the loader

Return air from the

drying hopper.

Air Trap

Insulation

Delivery low dew point,

heated air to the drying

hopper.

Recommended process

temperature control

thermocouple location.

Large Dehumidifying Dryers Mechanical Installation 33

Chapter 4: Controls

4-1 Controller Description

The AP1+ dryer control system is designed to control ACS cabinet, medium and large dryers. These dryers have separate Process and regeneration blowers and up to four desiccant beds.

The AP1+ dryer control system, or AP1+, includes all of the features of the AP1 control system and adds the following:

• Customer configurable drying hopper identification.

• Enhanced diagnostics for quick troubleshooting.

• Support of Central Drying applications of up to 24 drying hoppers.

• Support for two (2) operator interfaces.

o Standard 5.7” color touch screen. o Optional 12” color touch screen.

• Support for Compact Flash memory cards.

o Use multiple dryer configurations easily. o Save and distribute settings anywhere. o Program upgrades with one button.

• Manufacturer native Ethernet (Optional).

The AP1+ is available in two basic configurations—local I/O and remote I/O.

• Local I/O where the Process heater controls are integral to the dry air source.

o Used for single drying hopper configurations. o All controls are mounted on the dryer.

• Remote I/O, for Central drying applications, where the Process heaters are separate

from the dry air source.

o Used on systems with from 2 to 24 drying hoppers. o Drying hopper I/O is connected to the dryer controls using high speed

DeviceNet.

Large Dehumidifying Dryers Controls 34

4-2 Operating the Dryer

To operate the dryer, access the Overview display and press the “Push to Start Dryer” button.

The main air valve will rotate into position.

• If the left bed finished regeneration then the right bed will be placed into

regeneration and the left bed will be placed into Process.

• If the left bed did not finish regeneration then the left bed will be placed into

regeneration and the right bed will be placed into Process.

The Process blower(s) will start.

• When air flow is verified, all enabled drying hoppers heaters will begin

heating the process supply air to their respective set points.

• There is an adjustable time delay between the Process blowers starting and

the drying hoppers Process supply air heaters starting to allow the Process supply air header to come up to operating pressure.

The drying hoppers can be started in a staggered manner where the AP1+ waits an adjustable time between starting each drying hopper.

ACS recommends that the customer execute an auto-tune cycle on the regeneration beds and drying hoppers if the AP1+ is being placed into service for the first time.

The regeneration blower starts.

• When air flow is verified, the bed in regeneration is brought to the pre-set

regeneration temperature.

• The bed remains at the regeneration temperature until either a pre-set time

has expired or the beds outlet air temperature rises above the “Bed Break” target value at which point the regeneration heaters are turned off and the bed is allowed to cool for either a pre-set time period or until the bed outlet temperature reaches the “Cool Down” target value. If the closed loop regeneration option was purchased, then the closed loop valve will place the cooling bed into closed loop cooling, as opposed to ambient cooling, when the bed outlet temperature reaches the “Closed Loop” target value.

A customer adjustable option allows the beds to switch either when the regeneration cycle completes (“Switch on Time”) or if the dew point rises above a pre-set limit (“Switch on Dew Point”). The “Switch on Dew Point” option will also cause the beds to switch if a side has been on-line for an adjustable amount of time.

ACS recommends that the customer execute an auto-tune cycle on the regeneration beds and drying hoppers if the AP1+ is being placed into service for the first time.

The pattern continues until the dryer is shut down by pressing the “Push to Stop Dryer” button on any overview display or the auto start feature reaches a preprogrammed stop event time. However it is stopped, the AP1+ puts the dryer into a sequenced shutdown.

The Process and regeneration systems start operation in parallel and run independently.

Large Dehumidifying Dryers Controls 35

• The drying hoppers process supply air heaters shut down and then the Process air

blower(s) shutdown after an adjustable delay.

• Any running regeneration cycle is allowed to finish and then the regeneration blower

is shutdown.

• The dryer can be re-started by pressing the “Shutting Down Push to Restart” button

on any overview display.

The Process and regeneration systems run in parallel and independently of each other with the following exceptions.

• The on-line bed’s regeneration heaters will be used as boost heaters for the normal

drying hoppers Process supply air heaters on non-central drying configurations purchased with the high temperature option.

Large Dehumidifying Dryers Controls 36

4-3 AP1+ Data Entry

Values and text are changed using one of 4 different keypads.

• Numbers use the TENKEY keypad

• Text use the KEYBOARD keypad

• Dates use the DATE SETTING keypad

o System Clock Only

• Times use the TIME SETTING keypad

o System time only

Large Dehumidifying Dryers Controls 37

The appropriate keypad appears when a changeable value is pressed.

You are only allowed to change a number to a value that falls between the minimum and maximum limit shown on the TENKEY keypad and that value must fit within the field size.

For instance, a changeable value appears as XXX.X with a maximum limit of 800.0 and a minimum limit of -50.0.

Acceptable entries:

450.0

-40.0

0.0

Unacceptable entries:

900.0 (> maximum limit)

-75.0 (< minimum limit)

1234.5 (>maximum field size of 4 digits)

Large Dehumidifying Dryers Controls 38

4-4 Dryer Setup

The customer can fine-tune the AP1+ by changing values and turning options on or off.

Use the “Dryer Setup” display to

• Select whether temperatures are displayed in Fahrenheit or Celsius.

• Set the high alarm limit value for the dryer exit air temperature alarm.

• Set the high alarm limit value for the dryer’s after- or pre-cooler option.

• Enable or disable the regeneration closed loop cooling option.

• Set the high alarm limit for the regeneration closed loop cooling option.

Use the “Auto-Tune” display to start or stop auto tuning for the regeneration temperature control loops.

Use the “Dew Point Setup” display to

• Select whether the regeneration system switches sides when a regeneration cycle

completes (TIME) or when the dew point is greater than a switch point (DEW POINT).

• Set the high dew point alarm limit value.

• If switch on dew point is selected

Use the “System Setup” display to

o Set the dew point bed switch point value. o Set the maximum allowed bed in Process (Online) time.

• Set the operator level password and duration.

• Set the setup level password and duration.

• Set the klaxon and alarm lamp suppression time.

Use the “Set Clock” display to set the system time. System time is in 24 hour format.

Use the “Auto-Start” display to set up the 7 day programmable timer.

• Midnight (00:00) is treated as a NO-EVENT

• All other times are in 24 hour format

• Example – Set dryer to start at 6am on Monday and stop at 4pm on Friday:

o Monday on time setting = 06:00 o Friday off time setting = 16:00 o All other values = 00:00 o Auto start option button = ON

Use the “Save and Restore Settings” display to save and restore the AP1+ operational parameters. Multiple profiles can be used simply by supplying different compact flash memory cards.

Large Dehumidifying Dryers Controls 39

4-5 Drying Hopper Setup

Use the drying hopper setup display to change the following drying hopper specific parameters.

• Start or stop the drying hoppers Process supply air temperature control loop auto-

tune.

• Select whether a drying hopper low level alarm will

o Never alarm (Disabled) o Only arm when the dryer is running (Dryer)

• Select whether the drying hopper is running at

o FULL capacity – low level probe 1 is used for low level alarm. o ½ capacity – low level probe 2 is used for low level alarm.

• Set an offset value to the dryers supply and return air temperature readings.

• Set the high and low Process supply air temperature deviation alarm values.

• Change the name of the drying hopper.

• Access the Material Miser and air balance setup screen.

Use the “Material Miser and Air Balance Setup Screen” display to control the various available combinations of Material Miser action and optional air damper control.

Material Miser

o Temperature Activated

 Material Miser mode is active when the difference between the supply and return

temperature has been less than the “Set Back Temperature” value for the “Set back Delay” time.

• Set Back Only

o When activated, Material Miser will automatically change the

• Air damper only

o When activated, Material Miser will automatically close the

• Set Back with Air Damper

o In addition to temperature setback, close the optional air damper

o Convey activated

 Material Miser mode is active when the drying hopper senses that it has not

received new material within the “Demand Watchdog” time.

• Set Back Only

o When activated, Material Miser will automatically change the

• Air damper only

o When activated, Material Miser will automatically close the

• Set Back with Air Damper

drying hoppers Process supply air temperature set point to the value set in “Set Back Setpoint.”

optional air damper valve.

valve.

drying hoppers Process supply air temperature set point to the value set in “Set Back Setpoint.”

optional air damper valve.

Large Dehumidifying Dryers Controls 40

Air Balance

o Requires the optional air damper valve. o Opens the air damper valve when the difference between the return air temperature and

o In addition to temperature setback, close the optional air damper

valve.

the “Return Air. Temperature Set point” is less than the “Open Deviation” value and keeps it open until the difference is more than the “Close Deviation” value.

Large Dehumidifying Dryers Controls 41

4-6 AP1+ Data Monitoring and Navigation

Overview Displays

There may be up to 4 overview displays depending on the number of drying hoppers in the system. Each overview display shows, by color, the status of the drying hoppers and of the dryer.

Each drying hopper shows its current supply air temperature value and the dryer shows the current dew point value.

• Press and release a drying hopper to enable or disable it. Press and hold a drying

hopper for 3 seconds to switch to that drying hoppers detailed status display.

• Press and hold the dryer for 3 seconds to switch to a detailed dryer status display.

• Press the “Push to Start” button to start the dryer.

• Press the “Push to Stop” button to stop the dryer.

• Press the “Shutting Down Push to Restart” button to re-start the dryer.

• Press the “Process Fault Push to Restart” button to re-start the dryer after a failure of

the process system.

• Press the “Regen Fault Push to Restart” button to re-start the dryer after a failure of

the regeneration system.

• Press the “Main” button to access the main menu display.

• Press the “Alarms” button to access the alarm history display.

• Press the “Help” button to access the help menu display.

Large Dehumidifying Dryers Controls 42

Drying Hopper Status Displays

The drying hopper status displays show detailed information on the operational status of the drying hopper.

1. Press and release the drying hopper to enable or disable it.

2. Press the “Supply Air Temperature – Setpoint” value to change the drying hopper

process supply air temperature set point.

If the “Air Balance” option is enabled, Press the “Return Air Temperature – Set point” value to change the air balance return air temperature set point. This space will be blank of the “Air Balance” option is disabled.

A bar graph, indicating the material level in the drying hopper (0-100%) and a marker, indicating the demand level set point appear when the optional continuous material level monitoring system is purchased. Press the “Demand” value to change the point at which the AP1+ LDH control can issue a material request to an external conveying system.

Trend

The trend window displays 4 hours worth of values for the process supply air temperature and return air temperature. The trend only collects data while the drying hopper status display is active

The trend colors match the colored line underneath the values description in the main part of the display.

The maximum and minimum values for the trend can be changed by pressing the trend itself and entering new values for the appropriate pens.

• Press the “Back” and “Next” buttons to change to the other available drying hopper

status displays.

• Press the “Overview” button to return to the overview display.

• Press the “Main” button to access the main menu display.

• Press the “Alarms” button to access the alarm history display.

• Press the “Help” button to access the help menu display.

• Press the “Setup” button to access the drying hopper setup display.

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Drying Hopper Setup Displays

The drying hopper setup displays allow the user to change a limited number of parameters associated with the drying hopper.

You may be required to enter the SETUP level password to access this display.

• Press the “Autotune” button to start or stop an auto-tune cycle on the drying hoppers

process supply air temperature control loop.

• Press “Supply TC Offset” or “Return TC Offset” to change the values as needed to

correct for thermocouple drift or to bring the temperature readings into compliance with a reference instrument.

• Press “High Alarm Setpoint” or “Low Alarm Setpoint” to change the values as

needed to alter the point at which a high or low deviation from set point alarm is generated.

• Press “Name Line 1” or “Name Line 2” to uniquely identify the drying hopper. The

names are 2 lines of 4 characters each.

• Press “Low Level Alarm” to either disable the low level alarms or associate it with

the dryer being in operation.

• Press “Capacity” to use either sensor 1 (FULL) or sensor 2 (1/2) as the low level

signal.

• Press the “Back” and “Next” buttons to change to the other available drying hopper

setup displays.

• Press the “Material Miser and Air Balance Setup” button to access the Material Miser

and air balance setup display.

Press “Status” to return to the drying hopper status display.

Press “Help” to access the help menu.

The “Service” button is for authorized ACS service personnel.

Auto-tune is accomplished using the Limit-Cycle method (Astrom & Hagglund, 1994).

The drying hopper name is only used on the displays for identification purposes.

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Material Miser and Air Balance Setup Displays

The Material Miser and Air Balance setup display is used to alter the values and options associated with Material Miser and air balance control.

Press the button to cycle through the available options:

Material Miser Disabled.

Material Miser – Temperature Activated – Set Back Only

Material Miser – Temperature Activated – Air Damper Only

Material Miser – Temperature Activated – Set Back with Air Damper

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Material Miser – Convey Activated – Set Back Only

Material Miser – Convey Activated – Air Damper Only

Material Miser – Convey Activated – Set Back with Air Damper

Air Balance Disabled

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Air Balance Enabled

Both Material Miser and Air Balance use the return air temperature and cannot both be enabled at the same time.

Material Miser seeks to prevent over-drying of material while air balance seeks to maintain a constant air flow through the drying hoppers.

Material Miser can be activated by either the proximity of the return air temperature to the supply air temperature (Temperature Activated) or by the absence of a demand for material (Convey Activated).

Material Miser, once activated, can either automatically change the supply air temperature set point to a lower value (Set Back) or close an optional air damper valve (Air Damper) or both.

Air Balance requires the optional air damper valve to function. The air damper valve will open and close depending on the difference between the return air temperature and the return air temperature set point.

When Material Miser is “Temperature Activated,”

• Press “Set Back Temperature” to change the target value for the return air

temperature at which Material Miser is activated.

• Press “Set Back Delay” to change the time delay for activating Material Miser based

on the return air temperature.

• Press “Set Up Temperature” to change the target value for the return air temperature

at which Material Miser is de-activated.

When Material Miser is “Convey Activated,”

• Press “Demand Watchdog” to change the amount of time the drying hoppers demand

signal is off before Material Miser is activated. Once activated by this method, a valid demand for material will disable Material Miser and return the drying hopper to normal operation.

If Material Miser is using the “Set Back” function,

• Press “Set Back Setpoint” to change the value that will become the new process

supply air temperature set point when Material Miser is activated. The process supply air temperature set point returns to the previous value when Material Miser is de-activated.

When Air Balance is “Enabled,”

• Press “Return Air Temp. SP” to change the value of the return air temperature set

point. This value can also be changed on the drying hopper status display.

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• Press “Open Damper Deviation” to change difference between the return air

temperature and return air temperature set point that will cause the air damper to open.

• Press “Close Damper Deviation” to change difference between the return air

temperature and return air temperature set point that will cause the air damper to close.

Material Miser and Air Balance Setup Displays

• Press the “Back” and “Next” buttons to change to the other available Material Miser

and air balance setup displays.

• Press “Setup” to return to the drying hopper setup display.

• Press “Menu” to access the main menu display.

• Press “Help” to access the help menu.

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Alarm History Display

1. Use the alarm history display to trouble shoot dryer problems.

2. The alarm history display keeps a record of any alarm that occurred on the dryer

since it was first started up to 1000 alarms. The 1001 alarm replaces the first alarm.

3. The alarm history display show the date (MM/DD/YY) and time (HH:MM) that the

alarm occurred as well as a brief description of the alarm.

4. Press “Push to Silence” to turn off the klaxon and lamp for the pre-set repeat intervals

if the alarm banner is not visible.

5. Press “Back” to return to the previous display.

6. Press “Help” to access the help menu.

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Dryer Menu Display

1. Use the dryer menu display to access other displays associated with the operation and

2. Press “Dryer Status” to access the dryer status display.

3. Press “Dryer Setup” to access the dryer setup display.

4. Press “Main Menu” to return to the main menu display.

5. Press “Dryer Auto-Tune” to access the regeneration beds auto-tune display.

6. Press “Dew Point Setup” to access the dew point setup display.

7. Press “Help Menu” to access the help menu display.

8. Press “Alarm History” to access the alarm history display.

9. Press “Press to Logoff” to sign off of all active security levels.

Dryer Status Display

Use the dryer status display to monitor the operation of the dryer and regeneration system.

setup of the dryer.

1. Press “Dryer Trend” to active a trend window.

The trend window displays 2 hours worth of values for the dew point, dryer exit temperature, regeneration heat exchanger temperature and pre-cooler or after-cooler temperature. Press “BIG TREND” to display less information or “SMALL TREND” to display more information.

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The trend colors match the colored line underneath the values description in the main part of the display.

The maximum and minimum values for the trend can be changed by pressing the trend itself and entering new values for the appropriate pens.

2. Press “Regen Trend” to active a trend window.

The trend window displays 4 hours worth of values for the regeneration temperatures. The trend only collects data while the trend display is active

The trend colors match the colored line underneath the values description in the main part of the display.

The maximum and minimum values for the trend can be changed by pressing the trend itself and entering new values for the appropriate pens.

3. Press “Dew Point Switch” to change the value at which the regeneration system

switches sides and begins a new regeneration cycle if the option, switch on dew point, is enabled.

4. Press “Dryer Menu” to return to the dryer menu display.

5. Press “Help” to access the help menu display.

The 2 message bars at the bottom indicate what the regeneration cycle is doing. The upper line is used for the right bed while the lower line is used for the left bed. If a time appears as part of the message, its format is HOURS:MINUTES.

The right bed messages are:

RIGHT BED UNDEFINED RIGHT BED OFF-LINE RIGHT BED OFF-LINE & READY RIGHT BED REGEN-HEAT H:M RIGHT BED COOLING H:M RIGHT BED CLOSED LOOP H:M RIGHT BED IN PROCESS H:M RIGHT BED REGEN FAILURE DRYER SHUT OFF

– Dryer is not functioning

DRYER IS STOPPING IN H:M

– Main Air Valve position is undetermined

– Bed is not in process and requires regeneration

– Bed is not in process and has completed regeneration – Regeneration in progress, heating active – Regeneration in progress ambient air cooling active – Regeneration in progress closed loop cooling active – Bed is being used to dry the process air

– Regeneration failed

– Sequenced shutdown in progress

The left bed messages are:

LEFT BED UNDEFINED LEFT BED OFF-LINE LEFT BED OFF-LINE & READY

– Main Air Valve position is undetermined

– Bed is not in process and requires regeneration

– Bed is not in process and has completed regeneration

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LEFT BED REGEN-HEAT H:M LEFT BED COOLING H:M LEFT BED CLOSED LOOP H:M LEFT BED IN PROCESS H:M LEFT BED REGEN FAILURE DRYER WAITING TO AUTO START

occur.

DRYER IS STOPPING IN H:M

– Regeneration in progress, heating active – Regeneration in progress ambient air cooling active – Regeneration in progress closed loop cooling active – Bed is being used to dry the process air

– Regeneration failed

– Dryer is off and awaiting an automatic startup event to

– Sequenced shutdown in progress

Press “Dryer Menu” to access the dryer menu display.

Press “Help” to access the help menu.

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Dryer Setup Display

1. Press “Temperature FAHRENHEIT” to change the temperature units to Celsius.

2. Press “CELSIUS” to change the temperature units to Fahrenheit.

3. Press “Dryer Exit Temperature High Alarm Setting” to change the high alarm limit

4. Press “Closed Loop Temp. High Alarm Setting” to change the high alarm limit value

value for the dryer exit temperature.

for the regeneration closed loop cooling heat exchanger temperature if it is installed. This space is blank if the regeneration closed loop cooling heat exchanger option is not installed.

5. Press the “Pre-cooler or After-cooler High Alarm Setting” to change the high alarm

limit value for the process air heat exchanger if one is installed. This space is blank if either the pre-cooler or after-cooler option is not installed.

6. Press “Next” to proceed to the blow back filter cleaning setup display if the blow

back filter cleaning option is installed.

7. Press “Main Menu” to access the main menu display.

8. Press “Dryer menu” to return to the dryer menu display.

9. Press “Help” to access the help menu display.

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Blow Back Filter Setup Display

1. Press “Process Blowback Filter” to change the enable status of the blowback filter

cleaning option.

2. Press “Blowback Every” to change how often a blow back cleaning cycle is initiated.

The time is entered in hours.

3. Press “Blowback Pulses” to change how many pulses of air used during a cleaning

cycle.

4. Press “Blowback On Time” to change how long each air blast lasts.

5. Press “Blowback Off Time” to change how long to wait between air blasts.

6. Press “Back” to return to the dryer setup display.

7. Press “Main Menu” to access the main menu display.

8. Press “Dryer Menu” to access the dryer menu display.

9. Press “Help” to access the help menu display.

Dryer Auto-Tune

1. Press the “Autotune” button to start or stop an auto-tune cycle on the drying hoppers

process supply air temperature control loop.

2. Press “Overview” to access the overview display.

3. Press “Main Menu” to access the main menu display.

Auto-tune is accomplished using the Limit-Cycle method (Astrom & Hagglund, 1994).

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4. Press “Dryer Menu” to return to the dryer menu display.

5. Press “Help” to access the help menu display.

Dew Point Setup

1. Press “High Alarm Setting” to change the value for the high dew point alarm limit.

2. Press the “Switch on Time or Dew Point” button to cause the dryer to either

immediately switch beds following the completion of a regeneration cycle (Switch on Time) or switch beds when either the dew point exceeds a pre-set limit or a maximum on-line time has been reached (Switch on Dew Point).

When the switch on dew point option is selected,

3. Press “Bed Switch Point” to change the dew point value at which the beds will switch

sides.

4. Press “Bed Online Time” to change the time a bed is allowed to be online even if the

dew point is low.

Auto-Start Timer Option Setup

The AP1+ includes a 7 day programmable timer that can be used to start and stop the dryer on a repeating schedule.

1. Press “ON TIME” or “OFF TIME” to enter the time of day in 24 hour format for

each start and stop event. Midnight, 00:00, is treated as a skip event in order to allow event durations that span multiple days.

2. Press the “Auto Start Option” button to allow dryer start and stop events to occur as

scheduled “Option ON” or to temporarily disable all automatic start and stop events “Option OFF”.

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Main Menu

3. Press the “Clear All Days” button to reset all the start and stop times to 00:00 and

turn off the auto-start option.

4. Press “System Menu” to return to the system menu display.

5. Press “Help” to access the help menu display.

1. Press “System Overview” to access the first system overview display.

2. Press “Hopper Status” to access the first drying hopper status display.

3. Press “Alarm History” to access the alarm history display.

4. Press “Dryer Menu” to access the dryer menu display.

5. Press “System Menu” to access the system menu display.

6. Press “Help Menu” to access the help menu display.

7. Press “Equipment Runtimes” to access the equipment runtime display.

8. Press “Press to Log Off” to log off all active security levels.

System Menu

1. Press “System Setup” to access the system setup display.

2. Press “Set Clock” to access the clock setting display.

3. Press “Main Menu” to return to the main menu display.

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4. Press “I/O” status to access the system inputs and outputs status display.

5. Press “DeviceNet” status to access the DeviceNet network status display.

6. Press “Auto-Start Timer” to access the auto-start timer display.

7. Press “Save and Restore” to access the system settings save and restore display.

8. Press “Help Menu” to access the help menu display.

System Setup

1. Press “Strobe Suppress” to change the amount of time the alarm light remains off

following a push to silence event.

2. Press “Horn Silence” to change the amount of time the horn is silenced following a

push to silence event.

3. Press “Operator Password” to change the operator level password value.

4. Press “Operator Duration” to change the amount of time before the operator level is

automatically logged off.

5. Press “Setup Password” to change the setup level password value.

6. Press “Setup Duration” to change the amount of time before the setup level is

automatically logged off.

7. Press “Main Menu” to access the main menu display.

8. Press “System Menu” to return to the system menu display.

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Set Clock

1. Press the time value to change the system time.

2. Press the date value to change the system date.

3. Press “Overview” to access the overview display.

4. Press “Main Menu” to access the main menu display.

5. Press “System Menu” to return to the system menu display.

6. Press “Help” to access the help menu display.

7. The system time needs to be entered as ‘hh.mm.ss’

8. The system date needs to be entered as ‘yyyy.mm.dd’

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I/O Status

• Use the I/O status displays to see what inputs and outputs are active.

• A point that is ON is displayed as a green box.

• A point that is OFF is displayed as a black box.

DeviceNet Status

The AP1+ control system uses a high speed DeviceNet network to communicate to the drying hopper control box(es) on central drying system of more than 2 drying hoppers.

The DeviceNet network is self healing once the source of the failure has been corrected. Manual intervention is normally not required.

A failure of this communications network will cause all drying hoppers on the effected node to shut down.

The failures detected are:

• No Network Power o The 24VDC network power is not present.

• Duplicate Address

o A node is misaddressed o The only node addresses allowed are

 0 DeviceNet Master

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 1 1st Drying Hopper Bank (1 – 8)  2 2  3 3

Drying Hopper Bank (9 - 16)

Drying Hopper Bank (17 – 24)

• Bus Off o Cable or termination failure

Save and Restore

The save and restore settings display is used to save or restore all of the system values and option status to the PLC’s compact flash memory card.

Settings can be saved and restored independent of the dryer status.

The “Autosave” feature is activated every time the dryer is powered up.

1. Press the “Save Settings” button to initiate a save to the memory card.

2. Press the “Restore Settings” button to read the settings back from the memory card.

Not valid if settings have not been saved.

3. Press the “Restore Autosave Settings” to read the automatically saved settings back

from the memory card.

The date and time of the last save is listed next to the restore buttons.

Multiple memory cards can be purchased and employed to save different dryer configurations allowing for a quick change of drying parameters to meet a customers specific needs.

The memory card is readable on a PC using a PCMCIA based compact flash memory card adapter. The format of the memory card is

\ AUTOEXEC.OBJ (PLC Program File) AUTOEXEC.STD (PLC Program File) COMMENTS.CMT (PLC Program File) DN00BKUP.DVF (DeviceNet File) PROGRAMS.IDX (PLC Program File) SYMBOLS.SYM (PLC Program File) SET\ (Settings Folder) DM1SAVED.CSV (Autosave Values) HR1SAVED.CSV (Autosave Options) DM2SAVED.CSV (User Saved Values) DM2SAVED.CSV (User Saved Options

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Important, never remove or insert the memory card while the PLC’s busy light is on. Damage to the card and data corruption can result.

Equipment Runtimes

The AP1+ tracks runtime on rotating equipment. Specifically the process and regeneration blowers.

Runtime is accumulated up to 99,999,999 hours or approximately eleven thousand four hundred and fifteen years. Please contact ACS if this time span is insufficient for your needs.

Both resettable and non-resettable runtime is accumulated.

Press the “Resettable” value to reset the resettable runtime to 0.

Note that restoring system settings will not change the equipment runtimes.

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4-7 Program Upgrade Procedures

The AP1+ PLC and touch screen both use compact flash memory cards for data and program storage. Occasionally, a program upgrade will become available from ACS for the AP1+ PLC, touch screen or both. The customer will receive the upgrade(s) by way of a new compact flash card. Follow the instructions in this document to upgrade the specific component.

PLC Program Upgrade

• Option – Save the dryers settings before executing this procedure.

• Power down the dryer and access the dry air source control enclosure.

• Remove and retain the existing memory card from the PLC.

• Turn on DIP switch 1-2 (Located under the CPU cover).

• Insert the upgrade memory card.

• Power up the dryer.

o When the PLC “Busy” LED stops flashing the PLC upgrade is complete.

• Power down the dryer.

• Remove the upgrade memory card.

• Re-insert the original memory card.

• Power up the dryer, inspect and verify the new version number(s)

• Start the dryer as required.

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Touch Screen Program Upgrade

• Remove and return the exiting memory card to ACS service.

• Insert the upgrade memory card.

• Turn ON DIP switch 1-1 (Located on the back of the touch screen).

• Press the RESET button.

o The RUN lamp will flash green when the upgrade is complete.

• Turn OFF DIP switch 1-1.

• Press the RESET button.

• Press the EXIT button that appears on the display after the touch screen resets.

• The upgrade is complete.

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4-8 Security

The AP1+ dryer control system implements a three tier security model.

The first tier is UNSECURED.

The seconds tier is SETUP protection.

• OPERATOR password = 0000.

• SETUP password = 0000.

• All objects can be changed.

• All customer displays can be accessed.

• This is the default configuration of the AP1+

• OPERATOR password = 0000.

• SETUP password ≠ 0000 (default = 1234).

• Anyone can change OPERATOR protected objects.

• Anyone can access OPERATOR level displays.

• Only SETUP can change SETUP protected objects.

• Only SETUP can access SETUP protected displays.

The final tier is SECURED.

• OPERATOR password ≠ 0000.

• SETUP password ≠ 0000 (default = 1234).

• OPERATOR and SETUP can change OPERATOR protected objects.

• OPERATOR and SETUP can access OPERATOR protected displays.

• Only SETUP can change SETUP protected objects.

• Only SETUP can access SETUP protected displays.

Certain displays and objects can only be accessed and changed by authorized ACS service personnel.

When a particular object is secured, access to the object or changing that objects value will require the entry of the assigned security tiers password if that tier is not already actively logged in. Once a tier is active, all objects secured by that tier are available and will not require another login to access or change.

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A security tier is activated by entry of the proper password. Once activated, that tier will remain active until:

• The customer manually logs off.

• The tiers active duration time expires.

• Power is cycled.

• The tiers password is changed to 0000.

4-9 Dryer & Drying Hopper Faults

AP1+ faults fall into two broad categories.

• Critical Faults – Shuts down equipment.

• Non-Critical Faults – Does not shut down equipment.

Critical faults are assigned to conditions that could cause damage to either the dryer components or the material in the drying hopper while non-critical faults are assigned to conditions that would allow an undesirable or inefficient Process condition to exist.

Because the Process and regeneration systems of the AP1+ dryer operate independently, is possible that a condition exists in the regeneration system that prevents it from operating while the Process system continues to operate without error.

When a fault condition occurs, the AP1+ displays an “Alarm Banner” showing the time, date and a brief description of the alarm. Optionally, the AP1+ will sound a klaxon and turn on an alarm lamp. The alarm banner, klaxon and lamp do not distinguish between critical and noncritical alarms. The klaxon can be silenced and the alarm lamp turned off by pressing the “Push to Silence” button on either the alarm banner or alarm history display. However, depending on the customer’s setup, the klaxon and lamp may repeat after a pre-set time if the alarm condition still exists.

If a dryer critical fault occurs then either a “Process Fault Push to Reset” or a “Regen Fault Push to Reset” button appears on the overview displays. Press the button to restart the failed system once the nature of the alarm is understood and corrected.

If a drying hopper critical fault occurs then disable and re-enable the drying hopper once the fault has been corrected.

Section [X] contains a list of all the alarms the AP1+ is capable of detecting and their effect on their associated system however some generalizations can be made.

• If something should be “ON” and it’s “OFF” or vice versa.

o Blower Motor Overloads should always be “ON”. o Heater isolation contactors should be “ON” when the heaters are in use and OFF

otherwise.

• If a value is less than a pre-set limit.

o Process supply air temperature low deviation alarm.

• If a value is greater than a pre-set limit.

o Dryer high dew point alarm.

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Alarm List

The following table lists all of the alarms the AP1+ can detect.

Alarm Text

PROC BLWR 1 CLS FAIL

PROC BLWR 2 CLS FAIL

PROC BLWR 3 CLS FAIL

PROC BLWR 4 CLS FAIL

PROC BLWR 1 OPN FAIL

PROC BLWR 2 OPN FAIL

PROC BLWR 3 OPN FAIL

PROC BLWR 4 OPN FAIL

PROC BLWR 1 AIR FAIL

PROC BLWR 2 AIR FAIL

PROC BLWR 3 AIR FAIL

PROC BLWR 4 AIR FAIL

PROC BLWR 1 AIR SHORT

PROC BLWR 2 AIR SHORT

PROC BLWR 3 AIR SHORT

PROC BLWR 4 AIR SHORT

PROC BLWR 1 OVERLOAD

PROC BLWR 2 OVERLOAD

PROC BLWR 3 OVERLOAD

PROC BLWR 4 OVERLOAD

PROC BLWR 1 FUSE FAIL

PROC BLWR 2 FUSE FAIL

PROC BLWR 3 FUSE FAIL

PROC BLWR 4 FUSE FAIL

MAIN VALVE LEFT FAIL

MAIN VALVE RIGHT FAIL

CLOSED LOOP FAIL

OPEN LOOP FAIL

AFTERCOOL SENSOR

PRECOOL SENSOR

AFTERCOOL HIGH TEMP

PRECOOL HIGH TEMP

DRYER EXIT SENSOR

DRYER EXIT HIGH TEMP

CLOSED LOOP SENSOR

CLOSED LOOP HIGH TEMP

PRESSURE SENSOR

PRESSURE LOW

DEW POINT SENSOR

DEW POINT HIGH

RETURN AIR FILTER

DUST CAN FILTER

DUST CAN FULL

DUST CAN OPEN

NO DESCRIPTION

MODULE 4 FAIL

System Severity

Process Critical

Dryer Critical

Regen Critical

Process

Regen

Regen Critical

Process

Process Critical

Process

Process Non

Process

Dryer Critical

NonCritical NonCritical

Critical Critical

NonCritical

Critical

NonCritical

NonCritical NonCritical NonCritical NonCritical NonCritical

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MODULE 5 FAIL

REGEN BLWR CLS FAIL

REGEN BLWR AIR FAIL

REGEN BLWR OVERLOAD

REGEN BLWR FUSE FAIL

REGEN BLWR OPN FAIL

REGEN AIR FILTER

LEFT 1 HIGH SURFACE

LEFT 1 HTR BURN ON

LEFT 1 ISO OPN FAIL

LEFT 1 IN SENSOR

LEFT 2 HIGH SURFACE

LEFT 2 HTR BURN ON

LEFT 2 ISO OPN FAIL

LEFT 2 IN SENSOR

RIGHT 1 HIGH SURFACE

RIGHT 1 HTR BURN ON

RIGHT 1 ISO OPN FAIL

RIGHT 1 IN SENSOR

RIGHT 2 HIGH SURFACE

RIGHT 2 HTR BURN ON

RIGHT 2 ISO OPN FAIL

RIGHT 2 IN SENSOR

LEFT 1 HTR BURN OUT

LEFT 1 FUSE

LEFT 1 ISO CLS FAIL

LEFT 2 HTR BURN OUT

LEFT 2 FUSE BLOWN

LEFT 2 ISO CLS FAIL

RIGHT 1 HTR BURN OUT

RIGHT 1 FUSE BLOWN

RIGHT 1 ISO CLS FAIL

RIGHT 2 HTR BURN OUT

RIGHT 2 FUSE BLOWN

RIGHT 2 ISO CLS FAIL

LEFT 1 OUT SENSOR

LEFT 1 HI TEMP

LEFT 1 LO TEMP

LEFT 1 LOOP BREAK

LEFT 1 LOW HEAT

LEFT 2 OUT SENSOR

LEFT 2 HI TEMP

LEFT 2 LO TEMP

LEFT 2 LOOP BREAK

LEFT 2 LOW HEAT

RIGHT 1 OUT SENSOR

RIGHT 1 HI TEMP

RIGHT 1 LO TEMP

RIGHT 1 LOOP BREAK

RIGHT 1 LOW HEAT

Regen Critical

Regen

Regen Critical

Regen

Regen Critical

Regen

Regen Critical

Regen

Regen Critical

Regen

Regen Critical

Regen

Regen Critical

Regen

Regen Critical

Regen

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

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RIGHT 2 OUT SENSOR

RIGHT 2 HI TEMP

RIGHT 2 LO TEMP

RIGHT 2 LOOP BREAK

RIGHT 2 LOW HEAT

DH 1 PH FUSE BLOWN

DH 2 PH FUSE BLOWN

DH 3 PH FUSE BLOWN

DH 4 PH FUSE BLOWN

DH 5 PH FUSE BLOWN

DH 6 PH FUSE BLOWN

DH 7 PH FUSE BLOWN

DH 8 PH FUSE BLOWN

DH 9 PH FUSE BLOWN

DH10 PH FUSE BLOWN

DH11 PH FUSE BLOWN

DH12 PH FUSE BLOWN

DH13 PH FUSE BLOWN

DH14 PH FUSE BLOWN

DH15 PH FUSE BLOWN

DH16 PH FUSE BLOWN

DH17 PH FUSE BLOWN

DH18 PH FUSE BLOWN

DH19 PH FUSE BLOWN

DH20 PH FUSE BLOWN

DH21 PH FUSE BLOWN

DH22 PH FUSE BLOWN

DH23 PH FUSE BLOWN

DH24 PH FUSE BLOWN

DH 1 PH ISO CLS FAIL

DH 2 PH ISO CLS FAIL

DH 3 PH ISO CLS FAIL

DH 4 PH ISO CLS FAIL

DH 5 PH ISO CLS FAIL

DH 6 PH ISO CLS FAIL

Regen Critical

Regen

Regen Critical

Regen

Process

NonCritical

NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical NonCritical

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DH 7 PH ISO CLS FAIL

DH 8 PH ISO CLS FAIL

DH 9 PH ISO CLS FAIL

DH10 PH ISO CLS FAIL

DH11 PH ISO CLS FAIL

DH12 PH ISO CLS FAIL

DH13 PH ISO CLS FAIL

DH14 PH ISO CLS FAIL

DH15 PH ISO CLS FAIL

DH16 PH ISO CLS FAIL

DH17 PH ISO CLS FAIL

DH18 PH ISO CLS FAIL

DH19 PH ISO CLS FAIL

DH20 PH ISO CLS FAIL

DH21 PH ISO CLS FAIL

DH22 PH ISO CLS FAIL

DH23 PH ISO CLS FAIL

DH24 PH ISO CLS FAIL

DH 1 PH ISO OPN FAIL

DH 2 PH ISO OPN FAIL

DH 3 PH ISO OPN FAIL

DH 4 PH ISO OPN FAIL

DH 5 PH ISO OPN FAIL

DH 6 PH ISO OPN FAIL

DH 7 PH ISO OPN FAIL

DH 8 PH ISO OPN FAIL

DH 9 PH ISO OPN FAIL

DH10 PH ISO OPN FAIL

DH11 PH ISO OPN FAIL

DH12 PH ISO OPN FAIL

DH13 PH ISO OPN FAIL

DH14 PH ISO OPN FAIL

DH15 PH ISO OPN FAIL

DH16 PH ISO OPN FAIL

DH17 PH ISO OPN FAIL

DH18 PH ISO OPN FAIL

DH19 PH ISO OPN FAIL

DH20 PH ISO OPN FAIL

DH21 PH ISO OPN FAIL

DH22 PH ISO OPN FAIL

DH23 PH ISO OPN FAIL

DH24 PH ISO OPN FAIL

DH 1 PH BURN ON

DH 2 PH BURN ON

DH 3 PH BURN ON

DH 4 PH BURN ON

Process

Process Critical

Large Dehumidifying Dryers Controls 69

DH 5 PH BURN ON

DH 6 PH BURN ON

DH 7 PH BURN ON

DH 8 PH BURN ON

DH 9 PH BURN ON

DH10 PH BURN ON

DH11 PH BURN ON

DH12 PH BURN ON

DH13 PH BURN ON

DH14 PH BURN ON

DH15 PH BURN ON

DH16 PH BURN ON

DH17 PH BURN ON

DH18 PH BURN ON

DH19 PH BURN ON

DH20 PH BURN ON

DH21 PH BURN ON

DH22 PH BURN ON

DH23 PH BURN ON

DH24 PH BURN ON

DH 1 PH BURN OUT

DH 2 PH BURN OUT

DH 3 PH BURN OUT

DH 4 PH BURN OUT

DH 5 PH BURN OUT

DH 6 PH BURN OUT

DH 7 PH BURN OUT

DH 8 PH BURN OUT

DH 9 PH BURN OUT

DH10 PH BURN OUT

DH11 PH BURN OUT

DH12 PH BURN OUT

DH13 PH BURN OUT

DH14 PH BURN OUT

DH15 PH BURN OUT

DH16 PH BURN OUT

DH17 PH BURN OUT

DH18 PH BURN OUT

DH19 PH BURN OUT

DH20 PH BURN OUT

DH21 PH BURN OUT

DH22 PH BURN OUT

Process Critical

Process

Large Dehumidifying Dryers Controls 70

DH23 PH BURN OUT

DH24 PH BURN OUT

E-STOP

DH 1 AIR FAIL

DH 1 HIGH SURFACE

DH 1 REDUN. SAFETY

DH 1 INLET SENSOR

DH 1 AIR SHORT

DH 1 OUTLET SENSOR

DH 1 HIGH TEMP

DH 1 LOW TEMP

DH 1 LOOP BREAK

DH 1 AIR DAMPER FAIL

DH 1 LOW LEVEL

DH 2 AIR FAIL

DH 2 HIGH SURFACE

DH 2 REDUN. SAFETY

DH 2 INLET SENSOR

DH 2 AIR SHORT

DH 2 OUTLET SENSOR

DH 2 HIGH TEMP

DH 2 LOW TEMP

DH 2 LOOP BREAK

DH 2 AIR DAMPER FAIL

DH 2 LOW LEVEL

DH 3 AIR FAIL

DH 3 HIGH SURFACE

DH 3 REDUN. SAFETY

DH 3 INLET SENSOR

DH 3 AIR SHORT

DH 3 OUTLET SENSOR

DH 3 HIGH TEMP

DH 3 LOW TEMP

DH 3 LOOP BREAK

DH 3 AIR DAMPER FAIL

DH 3 LOW LEVEL

DH 4 AIR FAIL

DH 4 HIGH SURFACE

DH 4 REDUN. SAFETY

DH 4 INLET SENSOR

DH 4 AIR SHORT

DH 4 OUTLET SENSOR

DH 4 HIGH TEMP

DH 4 LOW TEMP

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

Large Dehumidifying Dryers Controls 71

DH 4 LOOP BREAK

DH 4 AIR DAMPER FAIL

DH 4 LOW LEVEL

DH 5 AIR FAIL

DH 5 HIGH SURFACE

DH 5 REDUN. SAFETY

DH 5 INLET SENSOR

DH 5 AIR SHORT

DH 5 OUTLET SENSOR

DH 5 HIGH TEMP

DH 5 LOW TEMP

DH 5 LOOP BREAK

DH 5 AIR DAMPER FAIL

DH 5 LOW LEVEL

DH 6 AIR FAIL

DH 6 HIGH SURFACE

DH 6 REDUN. SAFETY

DH 6 INLET SENSOR

DH 6 AIR SHORT

DH 6 OUTLET SENSOR

DH 6 HIGH TEMP

DH 6 LOW TEMP

DH 6 LOOP BREAK

DH 6 AIR DAMPER FAIL

DH 6 LOW LEVEL

DH 7 AIR FAIL

DH 7 HIGH SURFACE

DH 7 REDUN. SAFETY

DH 7 INLET SENSOR

DH 7 AIR SHORT

DH 7 OUTLET SENSOR

DH 7 HIGH TEMP

DH 7 LOW TEMP

DH 7 LOOP BREAK

DH 7 AIR DAMPER FAIL

DH 7 LOW LEVEL

DH 8 AIR FAIL

DH 8 HIGH SURFACE

DH 8 REDUN. SAFETY

DH 8 INLET SENSOR

DH 8 AIR SHORT

DH 8 OUTLET SENSOR

DH 8 HIGH TEMP

DH 8 LOW TEMP

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

Large Dehumidifying Dryers Controls 72

DH 8 LOOP BREAK

DH 8 AIR DAMPER FAIL

DH 8 LOW LEVEL

DH 9 AIR FAIL

DH 9 HIGH SURFACE

DH 9 REDUN. SAFETY

DH 9 INLET SENSOR

DH 9 AIR SHORT

DH 9 OUTLET SENSOR

DH 9 HIGH TEMP

DH 9 LOW TEMP

DH 9 LOOP BREAK

DH 9 AIR DAMPER FAIL

DH 9 LOW LEVEL

DH10 AIR FAIL

DH10 HIGH SURFACE

DH10 REDUN. SAFETY

DH10 INLET SENSOR

DH10 AIR SHORT

DH10 OUTLET SENSOR

DH10 HIGH TEMP

DH10 LOW TEMP

DH10 LOOP BREAK

DH10 AIR DAMPER FAIL

DH10 LOW LEVEL

DH11 AIR FAIL

DH11 HIGH SURFACE

DH11 REDUN. SAFETY

DH11 INLET SENSOR

DH11 AIR SHORT

DH11 OUTLET SENSOR

DH11 HIGH TEMP

DH11 LOW TEMP

DH11 LOOP BREAK

DH11 AIR DAMPER FAIL

DH11 LOW LEVEL

DH12 AIR FAIL

DH12 HIGH SURFACE

DH12 REDUN. SAFETY

DH12 INLET SENSOR

DH12 AIR SHORT

DH12 OUTLET SENSOR

DH12 HIGH TEMP

DH12 LOW TEMP

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

Large Dehumidifying Dryers Controls 73

DH12 LOOP BREAK

DH12 AIR DAMPER FAIL

DH12 LOW LEVEL

DH13 AIR FAIL

DH13 HIGH SURFACE

DH13 REDUN. SAFETY

DH13 INLET SENSOR

DH13 AIR SHORT

DH13 OUTLET SENSOR

DH13 HIGH TEMP

DH13 LOW TEMP

DH13 LOOP BREAK

DH13 AIR DAMPER FAIL

DH13 LOW LEVEL

DH14 AIR FAIL

DH14 HIGH SURFACE

DH14 REDUN. SAFETY

DH14 INLET SENSOR

DH14 AIR SHORT

DH14 OUTLET SENSOR

DH14 HIGH TEMP

DH14 LOW TEMP

DH14 LOOP BREAK

DH14 AIR DAMPER FAIL

DH14 LOW LEVEL

DH15 AIR FAIL

DH15 HIGH SURFACE

DH15 REDUN. SAFETY

DH15 INLET SENSOR

DH15 AIR SHORT

DH15 OUTLET SENSOR

DH15 HIGH TEMP

DH15 LOW TEMP

DH15 LOOP BREAK

DH15 AIR DAMPER FAIL

DH15 LOW LEVEL

DH16 AIR FAIL

DH16 HIGH SURFACE

DH16 REDUN. SAFETY

DH16 INLET SENSOR

DH16 AIR SHORT

DH16 OUTLET SENSOR

DH16 HIGH TEMP

DH16 LOW TEMP

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

Large Dehumidifying Dryers Controls 74

DH16 LOOP BREAK

DH16 AIR DAMPER FAIL

DH16 LOW LEVEL

DH17 AIR FAIL

DH17 HIGH SURFACE

DH17 REDUN. SAFETY

DH17 INLET SENSOR

DH17 AIR SHORT

DH17 OUTLET SENSOR

DH17 HIGH TEMP

DH17 LOW TEMP

DH17 LOOP BREAK

DH17 AIR DAMPER FAIL

DH17 LOW LEVEL

DH18 AIR FAIL

DH18 HIGH SURFACE

DH18 REDUN. SAFETY

DH18 INLET SENSOR

DH18 AIR SHORT

DH18 OUTLET SENSOR

DH18 HIGH TEMP

DH18 LOW TEMP

DH18 LOOP BREAK

DH18 AIR DAMPER FAIL

DH18 LOW LEVEL

DH19 AIR FAIL

DH19 HIGH SURFACE

DH19 REDUN. SAFETY

DH19 INLET SENSOR

DH19 AIR SHORT

DH19 OUTLET SENSOR

DH19 HIGH TEMP

DH19 LOW TEMP

DH19 LOOP BREAK

DH19 AIR DAMPER FAIL

DH19 LOW LEVEL

DH20 AIR FAIL

DH20 HIGH SURFACE

DH20 REDUN. SAFETY

DH20 INLET SENSOR

DH20 AIR SHORT

DH20 OUTLET SENSOR

DH20 HIGH TEMP

DH20 LOW TEMP

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

Large Dehumidifying Dryers Controls 75

DH20 LOOP BREAK

DH20 AIR DAMPER FAIL

DH20 LOW LEVEL

DH21 AIR FAIL

DH21 HIGH SURFACE

DH21 REDUN. SAFETY

DH21 INLET SENSOR

DH21 AIR SHORT

DH21 OUTLET SENSOR

DH21 HIGH TEMP

DH21 LOW TEMP

DH21 LOOP BREAK

DH21 AIR DAMPER FAIL

DH21 LOW LEVEL

DH22 AIR FAIL

DH22 HIGH SURFACE

DH22 REDUN. SAFETY

DH22 INLET SENSOR

DH22 AIR SHORT

DH22 OUTLET SENSOR

DH22 HIGH TEMP

DH22 LOW TEMP

DH22 LOOP BREAK

DH22 AIR DAMPER FAIL

DH22 LOW LEVEL

DH23 AIR FAIL

DH23 HIGH SURFACE

DH23 REDUN. SAFETY

DH23 INLET SENSOR

DH23 AIR SHORT

DH23 OUTLET SENSOR

DH23 HIGH TEMP

DH23 LOW TEMP

DH23 LOOP BREAK

DH23 AIR DAMPER FAIL

DH23 LOW LEVEL

DH24 AIR FAIL

DH24 HIGH SURFACE

DH24 REDUN. SAFETY

DH24 INLET SENSOR

DH24 AIR SHORT

DH24 OUTLET SENSOR

DH24 HIGH TEMP

DH24 LOW TEMP

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

Process

Process Critical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

NonCritical NonCritical

NonCritical

Large Dehumidifying Dryers Controls 76

DH24 LOOP BREAK

DH24 AIR DAMPER FAIL

COMM FAULT 1ST BANK

COMM FAULT 2ND BANK

COMM FAULT 3RD BANK

COMM FAULT NO POWER

COMM FAULT BAD ADDRESS

COMM FAULT NO NODES

Process

Dryer Critical

NonCritical NonCritical

Large Dehumidifying Dryers Controls 77

Alarm Text Abbreviations

The 5.4” touch screen limits the amount of characters that are visible on the alarm banner and alarm history displays. The following list displays text that is commonly abbreviated and its expanded description.

CLS = CLOSE OPN = OPEN OVLD = OVERLOAD REDUN. = REDUNDANT PH = PROCESS HEATER ISO = ISOLATION CONTACTOR DH = DRYING HOPPER

Temperature Alarms

The AP1+ checks for high low and fail to change (loop break) alarm conditions on the regeneration inlet temperature and the drying hopper process supply air temperature. It also checks for high temperature on the dryer exit and the pre-cooler (or after-cooler) if the option is installed.

A high temperature alarm is generated when the actual temperature rises above a pre-set limit, or when the difference between the actual temperature and a controlling set point (if one exists) is greater than a calculated limit. High temperature alarms are always treated as critical alarms.

A low temperature alarm is generated when the actual temperature falls below a pre-set limit, or when the difference between the actual temperature and a controlling set point (if one exists) is less than a calculated limit. Low temperature alarms are always treated as noncritical alarms.

A loop break alarm is generated when a controlled temperature fails to rise by X degrees every Y seconds while its heaters are consuming power. The setting values associated with loop break alarms are automatically calculated following the completion of an auto-tune. Loop break alarms are always treated as critical alarms.

Large Dehumidifying Dryers Controls 78

Common Text Descriptions

CLS FAIL (Device Failure to Close)

OPN FAIL (Device Failure to Open)

AIR FAIL (No Air Flow or Pressure Detected)

AIR SHORT (Improper Air Flow Detected)

OVERLOAD Alarms

FUSE FAIL (Over current Protection Device Open)

LEFT/RIGHT Fail

CLOSED/OPEN LOOP FAIL

SENSOR

HIGH TEMP or HI TEMP

LOW TEMP or LO TEMP LOOP BREAK

LOW HEAT

HIGH SURFACE

BURN ON

BURN OUT

Generated when a valve or contactor is commanded to close and the position feedback does not indicate that it is closed after a brief delay.

Generated when a valve or contactor is commanded to open and the position feedback does not indicate that it is opened after a brief delay.

Generated when air flow is supposed to be detected and it is not.

Generated when air flow is detected when it is not supposed to be.

Generated when the motor overload opens, the alarm is commonly associated with a piece of rotating equipment that is consuming too much current. Generated when a monitored fuse opens.

Generated when the main air valve is commanded to a specific position and the position feed back does not indicated that the valve has achieved that position within an allotted time Generated when the regeneration heat exchange valve is commanded to a specific position and the feed back does not indicate that the valve has achieved that position within an allotted time.

Generated when a failure is detected in a process sensing element. The failure is commonly an open circuit condition.

Generated when a monitored temperature rises above a pre-set or calculated limit.

Generated when a monitored temperature falls below a pre-set or calculated limit.

Generated when a temperature is supposed to be rising due to the assumed application of heat but is not. Generated when a regeneration bed does not reach the regeneration temperature set point at any time during the heating portion of the regeneration cycle. Generated when a components surface temperature thermal safety switch opens.

Generated when a heating element is not supposed to be consuming power but is.

Generated when a heating element is supposed to be consuming power but is not.

Large Dehumidifying Dryers Controls 79

4-10 Troubleshooting

PLC Faults

If a fatal error occurs on the PLC the touch screen will display a special fault screen instructing you to call the ACS service department for assistance and the PLC’s ERR/ALM light will be red.

Please note the following information on the fault display for the service department.

• CODE ________________

• EXTRA ________________

• TASK # ________________

• FLAGS ________________

• ADDRESS ________________

Ref: Omron CS-CJ Operations Manual - M11W393E3041003 – Section 11

Large Dehumidifying Dryers Controls 80

PLC Module Faults

DeviceNet

The first module to the right of the PLC CPU is the DeviceNet master module. It controls all DeviceNet communication.

Normally the MS and NS lights will be green and the display will be 00 indicating that all is normal. Refer to the DeviceNet status display on the touch screen if there is any other indication.

None of the drying hoppers associated with a failed node will be visible on the overview displays. For reference, node 0 services drying hoppers 1 through 8, node 1 services drying hoppers 9 through 16 and node 3 services drying hoppers 17 through 24.

Analog Input

The analog input module, AD041-V1, is in the 8 dew point sensor signal. Only the green RUN light should be on. Call ACS service for a replacement module if there is any fault indication (red lamp) on this module.

Thermocouple Input

The thermocouple input modules, PTS51, occupy the 5 of the PLC CPU. Only the green RUN light should be on. Call ACS service for a placement module if there is any fault indication (red lamp) on this module.

position after the PLC CPU and it reads the

through the 7th position to the right

Ref: Omron CS-CJ DeviceNet Units Operations Manual - M26W380E1040104

Ref: Omron CS-CJ Analog IO Operation - M11W345E1061003

Ref: Omron CS-CJ Thermocouple Input Operations Manual - W368-E1-05

Large Dehumidifying Dryers Controls 81

DeviceNet I/O Faults

The drying hoppers DeviceNet inputs and outputs reside in the drying hopper control box located on the drying hopper stand. All the diagnostics lamps on the I/O assembly will normally be green. Any other indications signify a fault condition.

The assembly is divided into the communications slave unit at the left most position with the physical inputs and outputs following to the right.

The slave unit’s lamps reflect the status of DeviceNet communications (MD & NT), the operational state of the slave (RUN) and the condition of the power (UM & US).

The input and output devices ‘D’ lamps reflect the running status of the individual I/O slices. All other lamps on these units show the ON/OFF state of the input or output.

Call ACS service if there is a suspected failure of the drying hopper I/O. Note what diagnostics lamps are ON (GREEN)/OFF or RED.

Touch Screen Faults

Normally, very little can go wrong with the touch screen(s). The green RUN lamp should always be ON.

Virtually all significant errors can be traced to failed communications between the touch screen(s). In the event of an error, ensure that the communications cable is properly connected and that the PLC and touch screen are power on. The touch screen(s) will automatically resume functioning once the cause of the fault has been isolated and corrected.

Note that no pertinent system data is stored in the touch screen at any time.

Ref: Phoenix Inline DeviceNet Bus Coupler User Manual 1436c_e

Ref: Phoenix Inline 24VDC Digital Input 6842a_gb Ref: Phoenix Inline 24VDC Digital Output 6843b_gb Ref: Phoenix Inline Thermocouple 5722b_gb

Large Dehumidifying Dryers Controls 82

Chapter 5: Maintenance

5-1 Maintenance Schedule

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

Dryer Model #

Serial #

EVERY WEEK

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

Date/

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

Inspect desiccant. Replace if brown or broken

Next Scheduled

Inspection

Actual Inspection

Date/By

Next Scheduled

Inspection

Actual Inspection

Date/By

- Photocopy this page for your maintenance records -

Large Dehumidifying Dryers Maintenance 83

5-2 Preventative Maintenance

Cleaning or Replacing the Process Air Filters

Regular filter cleaning will keep your dryer operating at peak efficiency. The process air filters protect the centrifugal blowers from plastic fines being drawn in from the drying hopper. Filters should be cleaned when airflow restriction trips the dirty filter alarm. Filters should be replaced at least once a year.

Caution! Operating the dryer without the process air filters installed will void the

warranty.

On 600-1500 cfm dryers, there is a single high-temperature (up to 350ºF) filter mounted above the process blower on the rear of the dryer. On 2000-3000 cfm dryers, there are two high-temperature (up to 350ºF) filters located in the housing under the blower platform on the left rear corner of the dryer.

Vacuuming. Vacuum cleaning is the preferred method for cleaning the process air filters because compressed air or high-pressure washing can damage the filter. Vacuuming removes most large particles and surface contaminant. Use a commercial duty vacuum cleaner and vacuum the filter from the air intake (dirty) side only.

Compressed Air Cleaning. Blow clean, dry compressed air up and down the pleats, blowing out the filter from the clean side. Do not shoot the air in a criss-cross motion against the grain of the pleats—this won’t clean the filter, and it may damage it. Compressed air should be less than 100 psi—use a 1/8 diameter nozzle at least 2 inches away from the filter.

Temperature

Cartridge Filter

Stainless Steel

Filter Housing

Cover

High

Figure 13: Process Filter Housing

Stainless Steel

Filter Housing

High

Temeprature

Gasket

Filter Housing Cover Latches

High

Temeprature

Gasket

Stainless Steel

Filter Housing

Filter Housing Cover Latches

High

Temeprature

Gasket

Stainless Steel

Filter Housing

Cover

600-1500 cfm dryers 2000-3000 cfm dryers

High

Temperature

Cartridge Filter

Large Dehumidifying Dryers Maintenance 84

Use the following procedure to clean or replace the filter cartridges:

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

2. Remove the hand knobs or clamps securing the filter access cover and remove the

cover.

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

4. Vacuum, blow out, or wash the filter.

5. Inspect the filter - a damaged filter should not be reused. Check the following:

 Hold a light bulb behind the filter element to find holes,

tears, fatigued paper or residual dirt.

 Inspect the end plates—damage here could allow air to

bypass the filter.

 Look for rust on the end plates and metal core—rust

particles could flake off and contaminate the dryer and resin.

 Check the gasket for damage—a damaged gasket will allow

contaminants into the process. Replace if needed.

6. Return the filter cartridge to its original position and tighten the nut on the center

retaining rod to secure the filter cartridge.

7. Secure the filter access cover with the hand knobs or threaded fasteners.

Cleaning or Replacing the Regeneration Filter

Large dryers are equipped with a filter in the regeneration air loop located at the back of the dryer. Regular filter cleaning will keep your dryer operating at peak efficiency.

Caution! Operating the dryer without the regeneration air filters installed will void

the warranty.

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

2. Remove the knob securing the filter.

3. Remove the filter from the post..

4. Vacuum or carefully blow out the filter with compressed air. If the filter is worn or

can't be cleaned, replace it.

5. Slide the filter back onto its post and tighten knob back on the filter.

Calibrating the Dirty Filter Alarm

Your dryer may be equipped with a Dirty Filter alarm. When the alarm sounds, it is time to clean or change the filter. The Dirty Filter alarm is tested and calibrated at the factory, but it can be adjusted in the field. Be sure that your filter is clean, and use the following procedure to calibrate the alarm.

1. Remove the process air return filter element from its housing.

2. Block off approximately 50% of the filter’s surface area to simulate a dirty filter.

3. Reinstall the cartridge and secure the cover.

4. While the process blower is operating, adjust the trim screw on the differential

pressure switch until the alarm light just comes on.

Large Dehumidifying Dryers Maintenance 85

5. Remove the restricted filter cartridge from the housing again. The alarm light should

stay off when the process blower operates if the switch is adjusted correctly.

6. Re-install the obstructed cartridge filter. The alarm light should go on again if the

switch is adjusted correctly.

7. Fine tune the switch setting so it consistently warns of a blocked filter and does not

falsely indicate a blockage of a clean filter.

8. Remove the restriction from the filter element and re-install the clean filter. The

alarm light should remain off.

Checking the Dewpoint Control System

The Dewpoint Switch option on dryers depends on the proper operation of the dewpoint sensor and its control board. The dewpoint sensor is in the process air stream and is therefore susceptible to contamination.

Dewpoint sensor life is dependent on:

 Air temperature and flow passing over the sensor.

 The amount of fines [dust] in the process air.

 The amount of plasticizer vapor in the process air.

The dryer operator should monitor the initial dewpoint sensor readings and establish a periodic replacement schedule as needed.

Caution! Do not attempt to check the continuity or resistance of a dewpoint sensor. The

sensor will be destroyed.

If you suspect that the dewpoint readings on the dewpoint meter are incorrect, a dewpoint simulation calibrator is available from the manufacturer. This device simulates various dewpoint outputs. It can confirm proper operation of the dewpoint sensor and dewpoint system control board.

Use the following procedure to check the dewpoint sensor and dewpoint control board:

1. Remove the sensor cable from the sensor hex nut adapter.

2. Connect the cable to the plug on the rear of the simulator.

3. Turn the rotary knob on the simulator to each position and note the readings on the

dewpoint meter on the dryer's control panel. The readings should correspond within a degree or two across the entire range.

4. If the readings agree, the control board is OK. Dewpoint sensor replacement is

recommended. If the readings do not agree, replace the control board and run the test again to rule out the possibility of a bad sensor.

Note: Do not attempt to make any adjustments to the components on the dewpoint

control board.

5. When testing is finished, re-connect the control cable to the sensor adapter.

Large Dehumidifying Dryers Maintenance 86

5-3 Corrective Maintenance

Symptoms of Worn Out Desiccant

The moisture adsorption capacity of the desiccant used in Large Dehumidifying Dryers degrades after an indefinite period of time. Useful life depends on variables such as material moisture content, plasticizer vapors in the return air and number of regeneration cycles.

Your dryer may need new desiccant if it exhibits any of the following symptoms:

• The plastic material is not being dried sufficiently (high scrap/reject rate).

• The air temperature at the top of the regenerating desiccant bed rapidly climbs to

350°F or more shortly after the start of regeneration, even though a saturated bed has just started heating.

• The process air dewpoint, measured with a portable dewpoint monitor, is higher than

-10°F throughout the process drying cycle.

• Smoke or dust is being blown out of the process air outlet.

• Noticeable amounts of desiccant in the beds is a medium-brown color, or darker.

If any of these signs are noticed, the desiccant in the desiccant beds should be replaced. Desiccant replacement kits are available from the Parts Department. If you wish, the desiccant beds can be repacked at your site by a service technician.

WARNING! DESICCANT MATERIAL CAUSES EYE IRRITATION

BREATHING MAY BE HARMFUL/MAY CAUSE SKIN IRRITATION!

• Do not get in eyes.

• Avoid prolonged contact with skin.

• Use with adequate ventilation.

• Wash thoroughly after handling.

FIRST AID:

In case of eye contact, immediately flush eyes with plenty of water for at least 15 minutes. If irritation persists, see a physician.

Replacing the Desiccant

Follow the procedure below to change the desiccant. See Figure 14 below for desiccant tower components.

1. Disconnect electrical power to the dryer.

2. Remove the bolts and nuts securing the covers of each desiccant canister. Remove

the covers and set them aside.

3. With a shop vacuum that has a 4 micron HEPA filter, carefully remove all desiccant

from each tower.

4. Inspect all screens for tears or burn-through spots.

5. Fill each canister with 13X, 8 x 12 bead desiccant.

Large Dehumidifying Dryers Maintenance 87

6. Inspect the gaskets on each of the covers. Replace if necessary.

7. Re-install the covers.

Figure 14: Desiccant Tower Assembly

Figure 15: Desiccant Replacement Amounts

Regeneration

Heater Cover.

Heater Element Mounting Plate.

Viewing Glass, for

checking the status of

the desiccant inside.

High

Temperature

Gaskets.

Stainless Steel

Hollow Core

Desiccant Tank

Mounting

Platform

High

Temperature

Gaskets.

Regeneration

Heaters

Access cover can be

removed in order to

replace desiccant.

Dryer Desiccant Required per Tower

CFM “13 X”, 8 x 12 Bead Total 600 175 350 850 175 350 1000 300 600 1250 300 600 1500 300 600 2000 300 1200 2500 300 1200 3000 300 1200

Replacing the Process Heater (Electric Dryers)

Large Dryers have a number of single phase Calrod-type heater elements wired in a delta formation. They are mounted on top of the dryer or to the drying hopper. The number and wattage of the heaters varies with model, voltage, temperature range, etc., but the replacement procedure is the same.

DANGER! Disconnect and lock out power before heater replacement.

Large Dehumidifying Dryers Maintenance 88

1. Remove the bolts securing the process heater access cover.

2. Sketch the heater wiring configuration so the heaters may be re-wired properly.

Heaters are mounted on a common plate of three or six for easy maintenance.

3. Remove the jumper bars and wires for the heater plate assembly(ies) being removed

or replaced.

4. Remove the bolts securing the heater plate assembly and slide out the assembly.

Avoid damaging the gaskets.

5. Remove individual heaters for replacement by removing the large brass nuts and

washers.

6. Re-install the heaters and heater plate assemblies in reverse order, replacing gaskets

if necessary.

Caution! Heater loops should not touch each other. "Hot spots" will lead to

premature heater failure.

7. Re-install the jumper wires and bars according to the sketch made earlier.

8. Re-secure the process heater access cover.

Figure 16: Process Heater Box Assembly

High

Heater Elements

Heater Element

Mounting Plate

Temperature

Gasket

Double Wall

Stainless Steel

Heater Element Mounting Plate

Heater

Housing

High

Temperature

Gasket

Heater Elements

Stainless Steel

Heater Housing

Cover

Double Wall

Stainless Steel

Heater Housing

Heater Assembly

Cover

Hex Nut For

Securing the Heater

Wire

Washer

Gude Bars

Stainless Steel

High

Temperature

Gasket

Heater Element

Mounting Hex Nut

Heater

Housing

High Temperature

Washer / Gasket

Heater Element

Heater Assembly

Gude Bars

Heater Wire with

Crimped on Closed

Loop Connector

Heater Mounting

Plate

Heater Element Bulkhead Fitting

Heater Assembly

Guide Bar

Replacing the Regeneration Heater (Electric Dryers)

The regeneration heaters are wired in the delta formation, mounted in the core of the desiccant tanks.

DANGER! Disconnect and lock out power before heater replacement.

Large Dehumidifying Dryers Maintenance 89

1. Access the desiccant canisters by removing the panels on the dryer.

2. Remove the Regeneration Heater Cover.

3. Unscrew the six (6) screws on the Heater Element Mounting Plate.

4. Slide out the heater assembly, taking care to not damage the gaskets.

5. Unscrew the heater loops that need to be replaced.

6. Re-install the new heaters. Securely tighten all fasteners.

Caution! The heater loops should not touch each other. This will create "hot spots"

and lead to premature heater failure.

7. Insert the heater assembly back into the desiccant canister.

8. Fasten the six (6) screws on the Heater Element Mounting Plate.

9. Re-secure the Regeneration Heater Cover.

10. Re-install the dryer panels.

Figure 17: Regeneration Heater Box Assembly

Regeneration

Heater Cover.

Heater Element Mounting Plate.

Viewing Glass, for

checking the status of

the desiccant inside.

High

Temperature

Gaskets.

Stainless Steel

Hollow Core

Desiccant Tank

Mounting

Platform

High

Temperature

Gaskets.

Regeneration

Heaters

Access cover can be

removed in order to

replace desiccant.

Large Dehumidifying Dryers Maintenance 90

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.

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.

6-2 Basic Troubleshooting

Problem Possible Cause Corrective Action

Little or no air coming from process delivery tube.

Suction in delivery tube, pressure from the return tube.

Loss or reduction of process air temperature.

Dirty Filters Clean or replace filters.

Desiccant beds contaminated by material or plasticizer leaking into the system. See Sec. 6-6.

Blower fuse(s) blown. Fix problem and Replace fuse(s). Overload tripped. Fix problem and reset the

Wrong motor rotation. Turn off power. Reverse

Blower fins filled with dust or contaminants.

Phase is reversed on power drop coming into the dryer.

Process heaters are faulty.

Solid-state temperature controller faulty. Process temperature was adjusted in error by plant personnel.

Replace desiccant

overload.

incoming power. Remove blower side plate, clean baffles, replace. Stop the Dryer. If the dryer was connected to the drying hopper, check to see if the desiccant and process air heater has been contaminated with resin. If so, replace the desiccant and remove any resin carry-over. Otherwise, change the phase of two legs of the three-phase power drop. Never change the phase at the motor starters unless only one of the two blowers is rotating improperly. Check for open or shorted heaters. Replace if required. Check the fuses. Replace.

Make sure that plant personnel are aware of the proper temperature set point. A sign posted next to the control would be helpful.

Large Dehumidifying Dryers Troubleshooting 91

Problem Possible Cause Corrective Action

Loss or reduction in drying capacity.

Material in drying hopper cakes, or meltdown occurs.

Poor Dew Point Performance.

Process heaters are faulty. Replace. Desiccant beds are contaminated. Replace desiccant. Material being dried differs from material specified at the time of purchase.

Break in flex hose to/from drying hopper.

Blower fins filled with dust or contaminants.

Process temperature set too high due to operator error.

High temperature alarm not set properly. Process set point is out of acceptable range.

Burned out regeneration heater. Repair or replace. Contaminated or worn out desiccant. Leaking process air hoses. Repair or replace. Dryer is being operated beyond its capacity. Bad dew point sensor. Replace. Fouled dew point sensor manifold. Clear obstruction. Air should flow

Drying systems are designed for the material that was originally specified. Different materials may need a longer residence time or different drying temperature. Inspect for air leaks; replace if necessary.

Remove blower side plate, clean baffles, replace. Replace filter elements.

Check resin manufacturer's data sheet for proper drying temperature. Make sure plant personnel are aware of the correct process temperature Set Point. See Section “Temperature Screen Setup” on page 34. Restore temperature controller to factory pre-sets. Auto-Tune if necessary.

Replace.

Check dryer and drying hopper sizing.

freely through sensor.

Large Dehumidifying Dryers Troubleshooting 92

6-3 Determining Temperature Controller Errors or Sensor Errors

Using a Thermocouple

If the controller displays a temperature that is close to room temperature (70ºF/21ºC) when you short-circuit controller input terminals, the controller is normal and the sensor is probably broken, short-circuited, or incorrectly wired.

Using a Platinum Resistance Thermometer

If the controller displays a temperature of about 0.0°C (32ºF) when you insert a 100-ohm resistor between terminals A and –B of the controller, and you short-circuit controller terminals +B and –B, the controller is normal and the sensor is probably broken, shortcircuited, or incorrectly wired.

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

Large Dehumidifying Dryers Troubleshooting 93

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.

Large Dehumidifying Dryers Appendix 94

7-2 Technical Specifications

Annex B Information

The following design information is provided for your reference:

1. No modifications are allowed to this equipment that could alter the CE compliance

2. Ambient temperature: 0 degrees Celsius – Maximum (104 degrees Fahrenheit)

3. Humidity range: 50% relative humidity

4. Altitude: Sea level

5. Environment: Clean and non-explosive

6. Radiation: None

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

8. Allowable voltage fluctuation: +/- 10%

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

10. Nominal supply voltage: 460/3/60 (Verify on serial number tag)

11. Earth ground type: TN (system has one point directly earthed through a protective

conductor)

12. Power supply should include a ground connection.

13. Over-current protection is supplied in the dryer, but additional protection should be

supplied by the user.

14. The door-mounted disconnect serves as the electrical disconnect device.

15. Dryer is not equipped with local lighting.

16. Functional identification

17. Dryer is equipped with a CE mark

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

country.

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

20. No one is required to be in the interior of the electrical enclosure during the normal

operation of the unit. Only skilled electricians should be inside the enclosure for maintenance.

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

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

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

24. There are no frequent repetitive cycles that require manual controlrepetitive

functions are automatic while the dryer is operating.

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

26. The machine is not equipped with cableless controls.

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

Intermittent +/- 2%

Large Dehumidifying Dryers Appendix 95

7-3 Spare Parts List

LARGE DRYER SPARE PARTS LIST 600,850,1000, 1250,1500,2000,2500, AND 3000

600CFM

850CFM

1000CFM

1250CFM

1500CFM

2000CFM

2500CFM

3000CFM

LEVEL 1 ( Electrical Components )

PART # SIZE Description A0536474 50 Fuse, Process Heater Elements 3 A0536471 35 Fuse, Regen Heater Elements 3 A0534846 20 Fuse, Process Blower 3 A0545343 3.5 Fuse, Regen Blower 3 A0538001 3.2 Transformer, Control Primary 2 A0538017 6 Transformer, Control Secondary 1 A0538005 5 Transformer, Valve Motor Primary 2 A0534842 10 Transformer, Valve Motor Secondary 1 A0540997 1 Fuse, Control, PLC 1 A0540995 0.75 Fuse, Control, Output/Power Supply 2 A0542207 3 Fuse, Control, Power Supply Out 1

LEVEL 1 ( Mechanical Components )

PART # SIZE Description W00015435 Dew Point Sensor Insert A0548556 Dew Point Sensor A0568271 Dew Point Sensor Cable A0566467 Valve switch A0570595 Process Air Filter 600-850 CFM A0568062 Process Air Filter 1000-3000 CFM A0566531 Regeneration Air Filter 600-850 CFM A0572408 Regeneration Air Filter 1000-3000 CFM W00018051 13X molecular Sieve Desiccant ( 8 X 12 Beads ) W00013983 High Temperature Gasket (15 Ft Roll) A0566564 Desiccant Tank Sight Glass A0572479 Desiccant Tank Sight Glass Gasket A0566676 High Temperature Snap Switch.

LARGE DRYER SPARE PARTS LIST 600,850,1000,1250, 1500,2000,2500, AND 3000

LEVEL 2 ( Electrical Components )

PART # SIZE Description A0558000 9A Contactor, IEC 1 A0558002 16A Contactor, IEC 1 A0558004 32A Contactor, IEC 1 A0558040 Overload, IEC, 12-32A 1 A0558079 Overload, IEC, 1 - 2.9A 1 A0569887 Overload, IEC, 5 - 15A 1 A0569895 48A Relay, Solid State A0505417 Relay, 4PDT, Regeneration T'Couple A0567058 Relay, SPDT A0554555 * Circuit Board, Dew Point A0548556 * Sensor, Dew Point

LEVEL 2 ( Mechanical Components )

PART # SIZE Description A0566544 3500 Watts Heater Element 208/220 Volts 21 30 39 39 45 A0566547 3500 Watts Heater Element 230 Volts 21 30 39 39 45 A0566549 3500 Watts Heater Element 400 Volts 21 30 39 39 45 66 78 90 A0566549 3500 Watts Heater Element 460 Volts 21 30 39 39 45 66 78 90 A0566549 3500 Watts Heater Element 575 Volts 21 30 39 39 45 66 78 90 A0566415 Heater Element Gasket A0566682 1/4" OD Teflon Tube.

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

1 1 1 1 1

350 Lbs. 350 Lbs. 600 Lbs. 600 Lbs. 600 Lbs. 1200 Lbs. 1200 Lbs. 1200 Lbs.

2.25 Rolls 2.25 Rolls 2.75 Rolls 3.0 Rolls 3.0 Rolls 4.5 Rolls 4.5 Rolls 4.5 Rolls 2222244 22222444 3

600CFM

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

1 1 1 1

42 60 78 78 90 120 158 180

18 Feet 18 Feet 18 Feet 18 Feet 18 Feet 18 Feet 18 Feet 18 Feet

1111111 1 1 1111 1

1 1

1 11

1 1 1

111222

111111

3333555

600CFM

850CFM

1000CFM

1250CFM

1500CFM

2000CFM

2500CFM

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

1111111 1111111 1111111

1111111

11111 1

3000CFM

400V 50 HZ 3PH

1 1 1

3000CFM

460V 3PH

575V 60 HZ 3PH

3000CFM

575V 60 HZ 3PH

Large Dehumidifying Dryers Appendix 96

LARGE DRYER SPARE PARTS LIST 600,850,1000,1250, 1500,2000,2500, AND 3000

LEVEL 3 ( Electrical Components )

PART # SIZE Description A0567930 PLC, Controller A0567932 PLC, Temperature Control Module A0569896 PLC, Analog Input Module A0567933 PLC, Touch Screen A0563932 Power Supply, 24VDC A0568961 Redundant Temperature Safety Controller

LEVEL 3 ( Mechanical Components )

PART # SIZE Description A0542302 8" O.D. by 12 Ft Long Hi Temp Hose. A0571107 3" O.D. by 12 Ft Long Hi Temp Hose. A0570519 Return Air Cooling Coil 600-850 CFM A0566849 Return Air Cooling Coil 1000-1500 CFM A0568147 Return Air Cooling Coil 2000-3000 CFM A0568233 Closed Loop Cooling Coil A0546119 208-230/460 Volt Blower, 600 CFM 1111 A0562555 575 Volt Blower, 600 CFM 1 A0565900 208-230/460 Volt Blower, 850 CFM 1111 A0572510 380 Volt Blower, 1000 CFM 1 A0572509 230/460 Volt Blower, 1000 CFM 1 1 1 A0572511 575 Volt Blower, 1000 CFM 1 A0559792 380 Volt Blower, 1250 CFM 1 A0559903 230/460 Volt Blower, 1250 CFM 11 1 A0559998 575 Volt Blower, 1250 CFM 1 A0553766 230/460 Volt Blower, 1500 CFM 11 1 A0572513 380 Volt Blower, 2000 CFM 1 A0572512 230/460 Volt Blower, 2000 CFM 1 A0572514 575 Volt Blower, 2000 CFM 1 A0572516 380 Volt Blower, 2500 CFM 1 A0572515 230/460 Volt Blower, 2500 CFM 1 A0572517 575 Volt Blower, 2500 CFM 1 A0559815 380 Volt Blower, 3000 CFM 1 A0568211 230/460 Volt Blower, 3000 CFM 1 A0560003 575 Volt Blower, 3000 CFM 1 W00015335 Dew Point Sensor Manifold A0548558 Gasket for the Dew Point Sensor W00015436 Plastic Nut for the Dew Point Sensor A0572502 O-Ring for Main Valve A0566879 Main Valve Motor A0565249 Filter housing Latch A0565250 Filter Housing Strike A0566466 Closed Loop Cooling Valve Motor A0547006 Knob for the Regeneration Filter A0537908 Handle for Panels. A0568205 Latch for Panels A0542231 8" Hose Clamp A0571107 3" Hose Clamp

7-4

600CFM

850CFM

1000CFM

1250CFM

1500CFM

2000CFM

2500CFM

3000CFM

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH 1 1 1 1 1 1

1 1 11

11111111

1 1 1

3.2 Feet 3.2 Feet 3.2 Feet 3.2 Feet 3.2 Feet 3.2 Feet 3.2 Feet 3.2 Feet 1 4 4 1 1 8

24 16

1 1 1 1 1 1

1 1

1 1 1

1 4 4 1 1

8 24 16

1 1 1 1 1 1

1 1

111

1 1 1

1 4 4 1

1 12 36 16

1 1 1 1 1 1

1 1

1 1 1

1 4 4 1

1 12 36 16

1 1 1 1 1 1

1 1

1 1 1

1 4 4 1

1 12 36 16

11 111 11 111 11 111

1 1

111

1 1 1

1 4 4 1

1 16 48 32

1 1

1 1 11

1 4 4 1

1 16 48 32

460V 3PH

1 1

1 4 4 1

1 16 48 32

3000CFM

575V 60 HZ 3PH

Large Dehumidifying Dryers Appendix 97

8-4 Dryer Identification (Serial Number) Tag

(Located on back of Dryer)

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

Large Dehumidifying Dryers Appendix 98

7-5 Technical Assistance

Parts Department

Call toll-free 7am–5pm CST [800] 423-3183 or call [630] 595-1060, Fax [630] 475-7005 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service.

Service Department

Call toll-free 8am–5pm CST [800] 233-4819 or call [630] 595-1060 Emergencies after 5pm CST, call [847] 439-5655

We have a qualified service department ready to help. Service contracts are available for most products.

Sales Department

Call [630] 595-1060 Monday–Friday, 8am–5pm CST Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the name of the sales representative nearest you.

Contract Department

Call [630] 595-1060 Monday–Friday, 8am–5pm CST Let us install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or nonunion installations.

Large Dehumidifying Dryers Appendix 99

AEC AP Series Large Dehumidifying Dryer User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual