AEC TD4-400-500 Floor Mount Dryer User Manual

TD4-400 - 500

FLOOR MOUNT DRYER

OPERATING MANUAL

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

Page 1

801 AEC Drive
Wood Dale, IL 60191-1198

Tel. [phone]
FAX [phone]

Internet http://www.aecinternet.com

Page 2

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

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

CONTENTS

DRYER OPERATION/FEATURES ---------------------------- 4
AIR FLOW SCHEMATIC FOR TD4-X DRYER------------ 6
DRYER CYCLE DIAGRAM-------------------------------------- 7
INSTALLATION PROCEDURE -------------------------------- 8

Electrical Connection ----------------------------------------- 8
Check for correct motor rotation -------------------------- 8
Compressed Air Connection ------------------------------- 8

START-UP PROCEDURE --------------------------------------- 9

Set Temperature: ---------------------------------------------- 9
DRYER OPERATION-TROUBLE SHOOTING-----------10
DRYER OPERATION-DETAILED DIAGNOSIS ----------11
PNEUMATIC ZONE VALVE ------------------------------------12
PARTS LIST---------------------------------------------------------13

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

Page 3

DRYER OPERATION/

FEATURES

The TD4-400/500 dryer series is a four bed dryer design that
is ideal for use on large molding press or extrusion
applications. This large capacity dryer combines our patented
desiccant tower design and state of the art microprocessor
controls to provide a constant supply of dry air to the material
hopper. Material drying is controlled by utilizing one zone for
removing moisture from the process air, while regenerating
the other by heating the desiccant to a high temperature.
Once the regenerated beds cool down, the Zone Valve
switches the airflow, and the newly regenerated beds are used
to desiccate the process air stream. The saturated beds are
now regenerated in the same manner, completing the
regeneration cycle. The cycle is depicted Page 7.

The airflow design of the TD4 dryers makes the regeneration
cycle more efficient because we utilize a small amount of the
desiccated process air rather than ambient air to regenerate
the desiccant bed. This reduces the impact of the high
moisture content of the ambient air, which would contaminate
the desiccant bed, and allows the dryer to attain a lower dew
point. Please see the Air Flow Schematic on Page 6.

TD4 Design
Our patented TD4 design incorporates 4 double-stacked

desiccant beds . This nearly doubles the amount of desiccant
available for drying the process air stream, and because of the
tower design, the dryer is able to regenerate the desiccant in
the same time as our TD2 series. This allows the dryer to
operate in very high humidity conditions without affecting the
process air dew point. In fact, this design produces dew point
levels of – 40’ to -80’ C for faster more complete drying of your
material.

Page 4

Unique to the TD4-400/500 disiccant bed design is the use of
two sets of desiccant towers per zone. The first tower in each
Zone Set is the regeneration cycle “control tower”, while the
second tower of the Zone Set is “slaved” off the first. Please
see the Air Flow Diagram on Page 7.

Hopper Design
These dryers are designed to be used with our large capacity

1000, 1500, and 2000 lb. hoppers. Our ”all stainless” hopper
design utilizes a stainless steel inner shell surrounded by a
stainless steel jacketed insulation layer. The easily removable
stainless steel spreader cone promotes proper material flow to
ensure that the material is dried efficiently and no undried

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

DRYER OPERATION/

FEATURES (Cont.)

material is left at the hopper bottom that needs to be fed out
prior to operating. You must ensure that your hopper is
adequately sized for your usage rate and is kept filled, to
ensure that you have sufficient time to dry the material.

Dryer Controls
The TD4 series is supplied with the advanced Microprocessor

Control Module. The module includes a mother board, display
board and key pad that allow the operator to easily monitor
dryer performance and input operational settings.

The Microprocessor Control Module is one of the most
sophisticated yet operator friendly controls on the market. It
has many more features than other PLC and Microprocessor
controls currently available. This module provides the
operator with more control and operational flexibility with the
dryer. These features and the operating instructions are
covered in detail in the Microprocessor Control Instruction
Manual included with your dryer.

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

Page 5

AIR FLOW SCHEMATIC TD4-400/500

ZONE 2
TOWERS

ELECTRICAL BOX

ZONE 1

TOWERS

PLAN VIEW

CONTROL
THERMOCOUPLE

SECONDARY
HEATER

CONTROL
THERMOCOUPLE

REGENERATION
AND PROCESS
HEATER

BLOWER

ZONE VALVE ZONE VALVE

VENT

VENT

FILTER

FROM
MATERIAL
HOPPER

CONTROL
THERMOCOUPLE

SECONDARY
HEATER

CONTROL
THERMOCOUPLE

REGENERATION
AND PROCESS
HEATER

Page 6

SAFETY
THERMAL THERMAL

PROCESS HEATER

SAFETY

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

SAFETY THERMAL

TO MATERIAL HOPPER

DRYER CYCLE

DIAGRAM

Zone 1 Co oling

Valve Shifts

Zone 1 Heating

Va lve Shifts

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

Dryer Cyc le

Diagram

XXXX

Des icant Beds

Zone 2 Heating

Zone 2 C ooling

Page 7

INSTALLATION

PROCEDURE

Electrical Connection:

Open electrical access door on the front of the machine by
turning the disconnect off and turning the lower clamping
screw 1/2 turn counterclockwise. Locate the disconnect by
following the operating handle down to the electrical panel.

Insert the incoming power cable or conduit through the hole
provided on the side of the machine.

« use approved wire and fastening means «

Wire incoming power to the top of the disconnect as shown in
the diagrams below.

208/230 1PH 50/60 HZ 380/415 3PH 4W 50HZ *

L1 L2 L3

GND MP R S T

NOTE:
When 3 wire supplies are used in place of 4 wire supplies,
a control transformer is required.

3 PHASE DRYER INSTALLATION

CHECK FOR CORRECT MOTOR ROTATION

XXXX

BEFORE RUNNING DRYER

To check blower motor rotation.......

Remove the front panel of the blower compartment so the
blower can be observed. Turn on the power to the dryer and
press the START touch pad on the dryer’s control panel and
quickly press the STOP touch pad. Observe the cooling fan on
the motor. The motor should rotate in a “clockwise” direction.
If the motor is rotating counterclockwise, switch any two
adjacent supply wires.

Compressed Air Connection:

Compressed air is required for the TD4-400/500 Floor Mount
models to operate the dryer’s Zone Valve. For those units:

Page 8

CONNECT COMPRESSED AIR TO INLET ON DRYER SIDE
PANEL. Maximum incoming pressure not to exceed 100 psi
(.69 MPa). The pressure gauge on the dryer is factory set to
70 psi.

The unit is now ready for operation.

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

START-UP PROCEDURE

Turn disconnect on electrical panel to ON position and follow
the instructions below:

Microprocessor Control Panel

1. Power light indicates there is power on.

2. After initializing, AEC rdY will be displayed.

3. Press START to start the dryer.

4. To set the process air temperature:
Press SET - right display shows set temp.
Change setting using arrow keys.
Press ENTER to input new setting.

5. Left display indicates actual temperature

6. Right display shows dewpoint or set temp
Press TEMP to display process air set temp.
Press D.POINT to display dew point.

7. To set high temp alarm: (degrees over setting)
Press ALARM - right display shows setting.
Change setting using arrow keys.
Press ENTER to input new setting.

8. Status block indicates heater on or fault

9. See Microprocessor manual for setting 7-day timer .

10. Configuration of the dryer parameters is done
using the setup button. See Microprocessor Control
manual.

These instructions are covered in detail in Microprocessor
Control Instruction Manual. Please read this manual before
proceeding further.

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

Page 9

DRYER OPERATION &

BASIC

TROUBLESHOOTING

Operating the Dryer

Our dryers are capable of operating in heavy industrial to
clean room environments with no significant loss in
performance. In order to maintain this high level of
performance, the operator should take the following steps:

Hopper Maintenance/Material Control

1. In order to ensure that material is sufficiently dried;
a. The material hopper should be kept filled to a constant,

predetermined level to allow sufficient dwell time in the
hopper to dry the material

b. To ensure proper air flow through the hopper, always

keep the level of material above the spreader cone on
the diffuser basket, ensuring that it is completely
covered.

c. Routinely clean the hopper and diffuser basket by

removing the spreader cone assembly and blowing the
basket and hopper out with compressed air.

d. Do not overfill the hopper, blocking the exhaust port at the

top.

Filter Maintenance

1. Routinely remove and clean the filter element by blowing it
out with compressed air. DO NOT OPERATE DRYER
WITHOUT FILTER ELEMENT INSTALLED.

Page 10

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

Basic Trouble-Shooting

Our new MICROPROCESSOR Electrics are designed for
quick diagnosis of problems. The microprocessor is designed
to display error codes and faults that indicate the nature of the
failure that has occurred. The most common errors and faults
are discussed in the Microprocessor Control Instruction
Manual and should be consulted in the event of a failure.

The following steps should be taken before proceeding with
other diagnostic steps.

1. Check the Power Circuit:

a. Incoming power fuses or circuit breaker
b. Check all dryer fuses with multimeter.
c. Is power supplied to the unit?
d. Check heater continuity using a volt/ohmmeter.

2. Compressed Air:

a. Is compressed air connected with at least 70 PSI
b. Check water separator and drain if necessary
c. Pressure gauge should read 70 PSI

3. Air Flow Circuit:

a. Ensure Zone Valve position corresponds to the

regeneration cycle by comparing the position of the Zone
Valve to the ZONE position lights on the dryer control
panel (See pg. 12 for details).

b. Make sure that all process air hoses are connected, not

crushed, and free from obstructions.

c. Inspect filter and make sure cover is tight and the filter

element is clean.

4. Control Circuit:

a. Using the MICRO Display panel ZONE indicator

5. Operating Conditions:

a. Check the process temperature. It should not be set

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

lights as a guide for the dryer regeneration cycle, check
that all outputs to heaters are proper for the part of the
regeneration cycle that the machine is in. (Output
voltage to heater relays is approx 4.5v)

below 140° F (60° C) because the unit will go into high
temp alarm.

Page 11

DETAILED DIAGNOSIS &

TROUBLESHOOTING

Diagnosing problems with the dryer is very easy, as the
Microprocessor Control Module performs numerous internal
diagnostic checks upon start-up and continually monitors
critical parameters during operation. When a fault or failure is
detected, the dryer shuts down and an Error Code is displayed
on the dryer’s control panel.

Error codes are displayed on the control panel by Err
appearing in the left display and a three digit number
appearing in the right display. Each code corresponds to a
specific type of failure. These codes are discussed in detail in
the Microprocessor Control Instruction Manual.

If the temp will not reach set point, check the following:

1. Check heater fuses with multimeter.

2. Check blower rotation by utilizing procedure detailed on
page 8 of Installation Procedures.

3. Check location of process air thermocouple. Ensure
that is positioned so that the tip is centered in the inlet
port to the hopper.

4. Check dryer’s internal air flow by the following:

a. Ensure that Zone Valve Air Diversion Valve is
positioned correctly.
b. Ensure filter element is not blocked or choked
with dust/material.
c. Ensure air flow to hopper is sufficient by
removing process air hose from dryer and
checking flow from dryer.

Page 12

If the temp exceeds the set point, check the following:

1. Remove the hose from the top of the hopper to check air

flow. There should be air flow out of the hopper with a
suction on the hose. If there is little or no flow, check the
inlet hose.

2. Inspect the filter to make sure that it is clean and not

affecting the air flow.

3. Check to see if heater relay has failed on. Using an

ammeter or voltmeter, check the output lead from the
relay to the heater for power to the heater when the

Micro Display LED for that heater is off.

4. Check the Zone Valve position.

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

PNEUMATIC

ZONE VALVE

TROUBLESHOOTING

The Pneumatic Zone Valve assembly is designed to provide
very little flow restriction and no leakage. To direct the air flow
for the regeneration cycle and process air, the assembly
incorporates pneumatic Air-Flow Diversion Valves and
Regeneration Air Exhaust Valves controlled by a single
solenoid valve.

TROUBLESHOOTING is easy. The Air-Flow Diversion Valve
assembly located on the top of the dryer cabinet is equipped
with viewing ports to observe the assembly’s operation. To
check the valve, note which zone is in regeneration by
observing the REGEN indicator LED on Microprocessor
Control Panel and then checking that the corresponding Air
Diversion Cylinder has actuated, closing the port to the
towers. The Regeneration Air Exhaust Valves located in the
dryer blower compartment, work in tandem with the Air-Flow
Diversion Valves, by opening when the Diversion Valve is
closed, to allow the wet regeneration air to exhaust. To check
these valves, simply check to see if air is exhausting out the
bottom of the dryer. If the valves are not working properly
check the following:

1. Check all air line connections to make sure they are
tight.

2. Check air lines to ensure they are not cracked or
broken.

3. Check incoming air pressure (70 psi min.).

4. Check operation of solenoid valve (See below).

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

To check operation of solenoid valve, remove front
panel to blower compartment. The valve is located
on the right-hand wall, directly connected to the air
pressure regulator. Located on the top of the valve
is a button, that when depressed will actuate the
valve. With air pressure supplied to the dryer, use
a small screw driver to depress the actuator
button. Observe the action of the Air Diversion
Valves on the top of the dryer. If the Diversion
Valves operate, the solenoid valve is operating
correctly.

Page 13

TD4-400 - 500

DESCRIPTION 400 500

GENERAL

ELECTRICAL

Dryer Filter Element T83011 T83011
Zone Valve Air Cylinder T83897 T83897
Thermocouple (Process) T82174 T82174
Thermocouple (Tower) T82175 T82175
Desiccant T80082 (Lbs./Machine) 262 lbs 262 lbs.
Tower Clamp T82197 T82197
Tower Gasket T83815 T83815
Pressure Switch T82813 T82813
Regulator T82995 T82995
MAC Valve T83783 T83783
Caster (Swivel) T82311 T82311
Caster (Fixed) T82312 T82312

MICRO

Disconnect T82714
Main Board T82071
Display Board T82072
Transformer T82245
Current Transformer T82246
Main Contactor T82904
Solid State Relay T82302
IEC Contactor T80576
Solid State Heater Relay T82302
Dual Solid State Board T82870
Safety Thermal Switch(Tower) T80221
Safety Thermal Switch (Process) T80551
Transformer .050 T84131
Dewpoint Sensor T81908

NOTE:

TO ORDER BLOWERS OR
OVERLOAD REFER TO
PART NUMBER ON ITEM.

Page 14

HEATERS

400V 480V 575V

Regeneration (Cone Style) T81923 T81367T81494
HP Center (Flat Style) T82506 T82517T84046
Process T82047 T83845T82696

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

NOTES:

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

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NOTES:

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OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

NOTES:

OPERATING MANUAL - TD4-400-500 DRYERS
Revision 10/3/01

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