AEC HE Mass Flow Series Drying hoppers User Manual

HE • CHE • BCHE

Mass Flow Series

Drying Hoppers

AEC, Inc.

801 AEC Drive

Wood Dale, IL 60191-1198

Tel [phone]

Fax [phone]

Part No. A0548656 Revision A Bulletin No. WH1-630B

Performance figures stated in this manual are based on a standard atmosphere of 59°F
(15°C) at 29.92” Hg (1,014 millibars) at sea level, using 60 hz power. Altitude is an
important consideration when specifying dryer components. AEC/Whitlock can advise
you on proper selection and sizing of systems for your operating environment.

AEC/Whitlock is committed to a continuing program of product improvement.

Specifications, appearance, and dimensions described in this manual

are subject to change without notice.

© Copyright AEC/Whitlock and AEC, Inc. 2011
All rights reserved. Effective 4/13/2011
Part No. A0548656 Revision A Bulletin No. WH1-630B.1

Page 2 HE • CHE • BCHE Mass Flow Series Drying Hoppers

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

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

Parts and Service Department

The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering
design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone
or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list
is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to
providing excellent customer service.

For immediate assistance, please contact:

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

North America email: [e-mail]

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

• Europe, Middle East & Africa [phone]

Email: [e-mail]

• India [phone]

Email: [e-mail]

• Asia/Australia [phone]

Email: [e-mail]

Sales and Contracting Department

Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the
name of the sales representative nearest you.

Let us install your system. The Contract Department offers any or all of these services: project planning; system packages
including drawings; equipment, labor, and construction materials; and union or non-union installations.

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

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

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

Facilities:

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

United States:

ACS Schaumburg – Corporate Offices

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

ACS New Berlin – Manufacturing Facility

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

Asia/Australia:

ACS Suzhou

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

Europe/Middle East/Africa:

ACS Warsaw

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

India

ACS India

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

Safety Considerations

AEC/Whitlock HE, CHE, and BCHE Mass Flow Series drying hoppers are designed to provide
safe and reliable operation when installed and operated within design specifications, following
national and local safety codes.

To avoid possible personnel injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:

; Follow all SAFETY CODES.
; Wear SAFETY GLASSES and WORK GLOVES.
; Disconnect and/or lock out power before servicing or maintaining the dryer.
; 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 this equipment. You

should remove the fuses and carry them with you.

; Make sure the dryer and components are properly GROUNDED before you switch on

power.

; Do not jump or bypass any electrical safety control.
; Do not restore power until you remove all tools, test equipment, etc., and the dryer and

related equipment are fully reassembled.

; Only PROPERLY TRAINED personnel familiar with the information in this manual should

work on this equipment.

HE • CHE • BCHE Mass Flow Series Drying Hoppers Page 3

Table of Contents

1 General Information ................................................. 7

1-1 Introduction
1-2 Equipment Function
1-3 The HE Heater Drying Hopper Package
1-4 The CHE Control and Heater Drying Hopper Package
1-5 The BCHE Blower Controls Heater Drying Hopper Package

2 Shipping Information ............................................. 11

2-1 Unpacking and Inspection
2-2 In the Event of Shipping Damages
2-3 If the Shipment is Not Complete
2-4 If the Shipment is Not Correct
2-5 Returns

3 Installation ............................................................... 13

3-1 Work Rules
3-2 Necessary Documents
3-3 Installing Machine-Mount Drying Hoppers
3-4 Installing Floor-Mount Drying Hoppers
3-5 Making Hose Connections
3-6 Making Electrical Connections
3-7 Checking for Proper Blower Rotation

4 Startup, Shutdown, and Operation ....................... 21

4-1 Pre-Startup Checklist
4-2 Starting the Process
4-3 Shutting Down the Process

Page 4 HE • CHE • BCHE Mass Flow Series Drying Hoppers

Table of Contents

5 1/4 DIN Controllers ................................................. 25

5-1 Graphic Panel for 1/4 DIN Controller
5-2 Using the 1/4 DIN Temperature Controller
5-3 Using Temperature Controller Internal Switches
5-4 Using the Temperature Controller Anti-Tamper Lockout Switch
5-5 Changing the Display from Fahrenheit to Celsius
5-6 Setting the Process Air Temperature
5-7 Setting the High Temperature Alarm
5-8 Activating the Auto-Tune Function
5-9 Restoring the Controller to Factory Setup

6 1/16 DIN Controllers ............................................... 35

6-1 Graphic Panel for 1/16 DIN Controller
6-2 Using the 1/16 DIN Temperature Controller
6-3 Setting the Process Air Temperature on the 1/16 DIN Controller
6-4 Setting the High Temperature Alarm on the 1/16 DIN Controller
6-5 Restoring the 1/16 DIN Temperature Controller to Factory Setup

7 Maintenance ............................................................ 47

7-1 Work Rules
7-2 Cleaning Out the Drying Hopper
7-3 Replacing the Process Heater
7-4 Servicing Process Air Filters

8 Troubleshooting ..................................................... 53

HE • CHE • BCHE Mass Flow Series Drying Hoppers Page 5

Charts and Figures

1

Typical HE Drying Hopper Package 8

2

Typical CHE Drying Hopper Package 9

3

Typical BCHE Drying Hopper Package 10

4

Machine Mounting Flange Dimensions 15

5

Drying Hopper Cover Bolt Patterns 16

6

Typical Single Hopper Drying Hose Installation 18

7

Typical Multiple Hopper Drying Hose Installation 19

8

Component Identification Exploded View 23

9
10
11
12
13
14
15
16
17
18

Graphic Panel for 1/4 DIN Controller 25

1/4 DIN Controller 26

1/4 DIN Temperature Controller Preset Parameters 32

Self-Diagnostic Error Messages 34

Graphic Panel for 1/16 DIN Controller 35

1/16 DIN Controller 37

Display Readout for Mode Settings 42
Default Setting List for 1/16 DIN Process Temperature Controller:

Protect / Level / Setup / Expansion
Available Board Options 46

Recommended Spare Parts List 51

43-45

Page 6 HE • CHE • BCHE Mass Flow Series Drying Hoppers

1 General Information

1-1 Introduction

AEC/Whitlock HE (Heaters), CHE (Controls and Heaters), and BCHE (Blower, Controls and
Heaters) Mass Flow Series drying hopper packages offer a high efficiency alternative for drying
multiple materials when used with a single or multiple dryer(s).

1-2 Equipment Function

AEC/Whitlock HE, CHE, and BCHE Mass Flow Series drying hoppers are used in conjunction
with a dehumidifying dryer unit. This dryer/drying hopper system generates heated,
dehumidified air to dry hygroscopic materials, such as plastic pellets. As in standard drying
systems, this operation removes moisture from the process air via molecular sieve desiccant beds
in the dehumidifying dryer unit. The system then sends this dry air to the HE, CHE, or BCHE
drying hopper, where heating elements are located. Heating the air at the drying hopper cuts
energy waste otherwise caused by heated air flowing through the dryer hose. After the system
heats air at the inlet of the drying hopper, it passes through the column of plastic resin in the
hopper and then returns to the dehumidifying dryer unit.

The drying hopper is designed to promote even drying and uniform material flow by using a
unique air/material diffuser cone. It is of modular construction, and can be configured and
oriented in numerous ways. You can easily change diameters on the process air inlet and outlet
with hand tools.

Material moves through the hopper in a first in, first out flow pattern. Located in the cover, the
removable air trap prevents introduction of moist ambient air into the drying system. Other
features on your system include lifting lugs plus a sight glass to let you see the material level.

Various types of material take-off compartments and/or drawer magnets can be installed at the
discharge point of the hopper. Contact your AEC/Whitlock sales representative for selecting
companion equipment.

Drying hopper systems are sized to meet specific customer requirements. Sections on the
following few pages list the differences between HE, CHE, and BCHE drying hopper systems.

HE • CHE • BCHE Mass Flow Series Drying Hoppers Page 7

1-3 The HE Heater Drying Hopper Package

The AEC/Whitlock HE drying hopper package offers a process air heater removed from the
dryer and mounted at the hopper with the temperature controller at the dryer. The HE drying
hopper package is designed for application where one dryer is delivering dehumidified air to one
drying hopper.

Figure 1

Typical HE Drying Hopper Package

Heater

Outlet transition

Sight
glass

Cover and air trap/diffuser

Return air outlet

Process air connection

Heater

Page 8 HE • CHE • BCHE Mass Flow Series Drying Hoppers

1-4 The CHE Control and Heater Drying Hopper

Package

The AEC/Whitlock CHE drying hopper package offers a process air heater removed from the
dryer and mounted at the hopper. The temperature controller is mounted at or on the drying
hopper. The design of the CHE package allows the dryer to deliver dehumidified air to multiple
drying hoppers to promote drying of different resins at different temperatures in different
hoppers.

Note: The CHE hopper package uses separate power drops to each hopper and avoids feeding

high voltage power through the dryer. An interlock prevents operation of heaters on the
hopper when the dryer is not running.

Figure 2

Typical CHE Drying Hopper Package

Heater

Sight
glass

Cover and air trap/diffuser

Outlet transition

Return air outlet

Process air connection

Disconnect

Heater

Control
panel

Temperature
controller

HE • CHE • BCHE Mass Flow Series Drying Hoppers Page 9

1-5 The BCHE Blower Controls Heater Drying

Hopper Package

The AEC/Whitlock BCHE drying hopper package features a process air blower, heater and
controls for each hopper in your system. BCHE also offers a process air heater removed from the
dryer and mounted at the hopper. The temperature controller is mounted at or on the drying
hopper.

Important!

The main dryer may or may not have a process blower.

Check your drying system for specific options.

The BCHE drying hopper package design allows one dryer to generate dehumidified air for
multiple hoppers. Materials can be dried by a single dryer at different temperatures. BCHE can
also serve as a stand alone hot air dryer for non-hygroscopic materials when an optional ambient
air filter is installed to filter air entering the system.

Note: The BCHE package utilizes individual power drops to each hopper.

Figure 3

Typical BCHE Drying Hopper Package

Sight

glass

Cover and air trap/diffuser

Outlet transition

Return air outlet

Process air connection

Heater

Heater

Control
panel

Temperature
controller

Filter assembly/
process air inlet

Blower

2" high-temp
flex hose

Page 10 HE • CHE • BCHE Mass Flow Series Drying Hoppers

2 Shipping Information

2-1 Unpacking and Inspection

You should inspect your AEC/Whitlock drying hopper unit for possible shipping damage. If the
container and packing materials are in re-usable condition, save them for reshipment, if
necessary.

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 case of
breakage, damage, shortage, or incorrect shipment, refer to the following sections.

2-2 In the Event of Shipping Damages

Important!

According to the contract terms and conditions of the Carrier,

the responsibility of the Shipper ends at the time and place of shipment.

The Carrier then assumes full responsibility of the 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 to AEC, Inc. before the transportation company inspection and
authorization.

; File a claim against 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 AEC, Inc. regarding your wish for replacement and to obtain an RMA (return

material authorization) number.

Parcel Post Shipment

; Notify AEC, Inc. at once in writing, giving details of the loss or damage. This information is

required for filing a claim with our insurance company.

; Hold the damaged goods with the container and packing materials for possible inspection by

postal authorities.

HE • CHE • BCHE Mass Flow Series Drying Hoppers Page 11

United Parcel Service

; Contact your local UPS office regarding damage and insurance claims.
; Retain the container and packing.
; Notify AEC, Inc. at once.

2-3 If the Shipment is Not Complete

Check the packing list. The apparent shortage may be intentional. Back-ordered items are noted
on the packing list. You should have:

; AEC/Whitlock HE/CHE/BCHE Mass Flow Series drying hopper
; 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. Determine that the item was not inadvertently taken from the area before you
checked in the shipment. Notify AEC, Inc. immediately of the shortage.

2-4 If the Shipment is Not Correct

If the shipment is not what you ordered, contact AEC, Inc. immediately. Include the order
number and item. Hold the items until you receive shipping instructions.

2-5 Returns

Important!

Do not return any damaged or incorrect items

until you receive shipping instructions from AEC, Inc.

Page 12 HE • CHE • BCHE Mass Flow Series Drying Hoppers

3 Work Rules

3-1 Work Rules

The installation, operation, and maintenance of this equipment must be conducted in accordance
with all applicable work and safety codes for the installation location. This may include, but is
not limited to, OSHA, NEC, CSA, and any other local, national and international regulations.

; Read and follow these operating instructions when installing, operating and maintaining this

equipment. If the instructions become damaged or unreadable, you can obtain additional
copies from AEC/Whitlock.

; Only qualified personnel familiar with this equipment should work on or with this

equipment.

; Work with approved tools and devices.
; Disconnect the electricity before maintenance or service.
; Always work from a stable, debris-free work platform.
; Remove any debris from the blower suction area.

3-2 Necessary Documents

The documents listed below are necessary for the operation, installation, and maintenance of
AEC/Whitlock drying hopper systems. Additional copies are available from AEC, Inc.

Familiarize the appropriate personnel with these documents:

• This manual.

• The electrical schematic included in the customer information packet.

• The Customer Spare Parts List included in the information packet.

• Operation and installation manuals for the dryer, optional controls or auxiliary equipment

in the drying system.

HE • CHE • BCHE Mass Flow Series Drying Hoppers Page 13

3-3 Installing Machine-Mount Drying Hoppers

Note: Figure 5 on Page 16 shows typical mounting bolt patterns.

Important!

Do not mount the drying hopper where excessive vibration is present.

AEC, Inc. is not responsible for any damages caused by excessive vibration.

1. Determine which position the process air inlet, outlet, access door, drawer magnet (if so

equipped) and slide gate/dump spout should be oriented.
You can rotate the assembly 90º to fit your installation and provide a neat and efficient

installation.

2. Loosen the band clamps fastening the cylindrical section to the cover.

3. Orient the outlet in the direction of the return air line, and re-tighten band clamps.

Important!

Using a degreaser, remove rust inhibitor before using your drying hopper.

4. While the drying hopper is still bolted to the shipping pallet, install any needed vacuum

hoppers, hopper loaders, etc. on the cover. The bolt patterns are shown in Figure 3.

Note: AEC/Whitlock VH, PVH, and 99XX Series units with vacuum hoppers and hopper

loaders use covers with the keyhole cutout. AL, VF and TF series vacuum hoppers and
hopper loaders use the circular cutout covers.

Important!

Provide external support for all material conveying piping.

5. Check the flange bolt pattern on the machine the drying hopper is to be mounted on. If

the flange bolt patterns do not match, drill out the drying hopper mounting flange so they
match.

Note: A special flange adapter may be required if the bolt pattern does not mate properly.

Contact your AEC sales representative for more information.

6. Position the included slide gate flange on the processing machine mounting flange and

position the spacers on the slide gate flange so the spacers are parallel to the desired
direction of the slide gate. The slide gate itself can be installed after you secure the drying
hopper to the processing machine.

Note: Some drying hoppers may be equipped with an optional standard slidegate/premium

slidegate or drawer magnet.

Page 14 HE • CHE • BCHE Mass Flow Series Drying Hoppers

Figure 4

Machine Mounting Flange Dimensions

Mounting Flange Supplied With DH-1.5, DH-3.0, DH-4.0 & DH-6.0

Mounting Flange Supplied With DH-12.0, DH-17.0 & DH-23.0

HE • CHE • BCHE Mass Flow Series Drying Hoppers Page 15

Figure 5

Drying Hopper Cover Bolt Patterns

Cover Cutout for AL, VF and TF Hopper Loaders and Vacuum Hoppers

Cover Cutout VH, PVH and 99XX Hopper Loaders and Vacuum Hoppers

Caution!

Make sure the band clamps are seated and tight and all other components

are secure before lifting the drying hopper from the shipping pallet.

Page 16 HE • CHE • BCHE Mass Flow Series Drying Hoppers

7. Rig the empty drying hopper by the lifting lugs and install it on the processing machine.

8. Insert properly-sized bolts through the drying hopper flange, the slide gate spacers and

the processing machine flange. Fasten securely.

9. Insert the slide gate through the slot made by the slide gate spacers. The slide lip may be

installed up or down.

10. Screw the two retaining bolts provided into the portion of the slide gate exposed when the

slide is fully inserted.

3-4 Installing Floor Mount Drying Hoppers

AEC/Whitlock HE, CHE, and BCHE Mass Flow Series drying hoppers are available in many
floor mount configurations. The size and quantity of the drying hoppers determine the style of
floor stands.

1. Select an installation location with sufficient access for the dump spout, slide gate and

access door.
You can rotate the assembly 90º to fit your installation and provide a neat and efficient

installation.

2. Secure the drying hopper stand to the floor or platform using the appropriate hardware.

3-5 Making Hose Connections

Hose and/or conduit connections must be made to deliver the process air from the dehumidifying
dryer to each drying hopper and back again. The exact connections will vary depending on the
size of the system and the number of drying hoppers involved.

HE • CHE • BCHE Mass Flow Series Drying Hoppers Page 17