AEC WD 350 through WD3000 Dehumidifying Dryers User Manual

$30.00

Operation and Installation Manual

WDMR and WDFR Series

Dehumidifying Dryers

Important! Read Carefully Before Attempting to Install or Operate Equipment

WD Series

Dehumidifying Dryer

Process

HI-Process

Heater on
Process Delivery

Process Delivery

Air Temp

Temperature

Temperature

ON

Left Bed

Righp Bed

Heater

Heater

888

Left Bed

Right Bed

OFF

In Regen

In Regen

Process Dew Point

-

­20

15

­10

25-

-

-

30

5

3540-

0

-

High Dew Point

DEW POINT (F)

WD Series

Dehumidifying Dryer

Process

HI-Process

Heater on
Process Delivery

Process Delivery

Temperature

Temperature

888

3540-

-

Part No. A0547682 Bulletin No. WH1-615

Air Temp

ON

Righp Bed

Left Bed

Heater

Heater

Left Bed

Right Bed

OFF

In Regen

In Regen

Process Dew Point

-

­20

15

­10

25-

-

-

30

5

0

High Dew Point

DEW POINT (F)

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 dehumidifying dryers. 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. 2004
All rights reserved. Effective 7/23/2004
Part No. A0547682 Bulletin No. WH1-615.2

Page 2 WDMR and WDFR Series Dehumidifying Dryers

Safety Considerations

AEC/Whitlock WDMR and WDFR Series dehumidifying dryers 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. It is a

good idea to remove the fuses and carry them with you

 Make sure the dryer and components are properly GROUNDED before switching on power.

 Do not jump or bypass any electrical safety control.

 Do not restore power until all tools, test equipment, etc. have been removed and the dryer

and allied equipment are fully reassembled.

 Only PROPERLY TRAINED personnel familiar with the information within this manual

should work on this equipment.

WDMR and WDFR Series Dehumidifying Dryers Page 3

Table of Contents

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

1-1 Models Covered
1-2 Equipment Function
1-3 Necessary Documents
1-4 Standard Features
1-5 Options
1-6 The Closed Loop Drying System
1-7 What is Desiccant?
1-8 The Process/Regeneration Cycle
1-9 Specifying a Drying System

2 Shipping Information..............................................13

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............................................................... 15

3-1 Work Rules
3-2 Rigging and Placing the Dryer
3-3 Making Electrical Connections
3-4 Checking for Proper Blower Rotation
3-5 Making Dryer/Drying Hopper Process Air Connections
3-6 Drying Hopper Air Trap Considerations
3-7 Installing the Optional Aftercooler

4 Level 1 Controllers .................................................25

4-1 Level 1 Control Panel Indicator Lights
4-2 Level 1 Switches and Meters
4-3 Level 1 PLC Controller
4-4 Level 1 Process Air Temperature Controller
4-5 Level 1 PLC LED Indicators
4-6 Level 1 Temperature Controller LED Indicators
4-7 Level 1 Temperature Controller Keys

Page 4 WDMR and WDFR Series Dehumidifying Dryers

Table of Contents

5 Additional Level 2 Controller Features................. 33

5-1 Level 2 Control Panel
5-2 Level 2 Control Panel Indicator Lights
5-3 Level 2 Switches and Meters
5-4 Level 2 PLC Controller
5-5 Level 2 Process Air Temperature Controller
5-6 Level 2 Temperature Controller LED Indicators
5-7 Level 2 PLC LED Indicators
5-8 Level 2 Temperature Controller Keys
5-9 Level 2 Optional Communications Protocols

6 Startup, Shutdown, and Operation .......................41

6-1 Pre-Startup Checks
6-2 Startup
6-3 Shutdown
6-4 Setting the Process Air Temperature
6-5 Setting the High Temperature Alarm
6-6 Temperature Controller Internal Switches
6-7 Enabling the Temperature Controller Anti-Tamper Lockout Switch
6-8 Changing the Display from Fahrenheit to Celsius

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

7-1 Work Rules
7-2 Servicing Process Air Filters
7-3 Servicing the Dew Point Monitor
7-4 Symptoms of Worn Desiccant
7-5 Replacing Worn Desiccant
7-6 Replacing the Process Heater
7-7 Replacing the Regeneration Heater
7-8 Restoring the Temperature Controller to Factory Setup
7-9 Error Display and Output
7-10 Maintaining the Aftercooler
7-11 Entering Level 2 Controller Parameters/Advanced Topics

8 Troubleshooting ..................................................... 71

WDMR and WDFR Series Dehumidifying Dryers Page 5

Charts and Figures

1

Typical Air Flow Schematic 9

2

WD10MR to WD50MR Dryer Specifications 10

3

WDMR Series Machine-Mount Dimensions 10

4

WDFR Series Floor-Mount Dimensions 11

5

Suggested Lift Rigging for WDMR and WDFR Dryers 16

6

Typical WD10MR/FR Electrical Schematic, Drawings 1 and 2 18, 19

7

Typical WD25MR/FR, WD50 MR/FR Electrical Schematic, Drawings 1 and 2 20, 21

8

Typical Control Subpanel Layout 22

9

Aftercooler Design Specifications 24

10
11
12
13
14
15
16
17
18
19
20
21
22

Typical Enclosure with Level 1 Control Panel, Optional Dew Point System, Disconnect 26

Level 1 Process Air Temperature Control Graphic Layout 27

Level 1 PLC Controller Details 30

Optional Level 2 Controller 34

Level 2 PLC Controller Details 37

Required Desiccant Amounts per Bed 52

Level 1 Controller Factory Preset Parameters 56

Level 2 Controller Factory Preset Parameters 59

Level 1 Controller Error Messages 60

Level 2 Process Temperature Controller Error Messages 66

Optional 7-Day Timer 66

Optional WD50MR/FR Aftercooler Spare Parts List 74

WD10MR and WD10FR Spare Parts List 75

23
24

Page 6 WDMR and WDFR Series Dehumidifying Dryers

WD25MR and WD25FR Spare Parts List 76

WD50MR and WD50FR Spare Parts List 77

1 General Information

1-1 Models Covered

This manual provides instructions for installing and operating AEC/Whitlock WD10MR,
WD25MR, and WD50MR dehumidifying dryers. Models designated with
configurations and models designated with
represents air flow capacity. WD10 models have a 10 cfm (17 cmh) air flow capacity, WD25
models have a 25 cfm (42 cmh) air flow capacity, and WD50 models have a 50 cfm (85 cmh)
capacity.

F are floor-mount models. The number designation

1-2 Equipment Function

Whitlock dehumidifying dryers are designed to generate heated, dehumidified air at carefully
controlled temperatures for use in closed-loop plastic drying systems. Drying systems are sized
to meet the specific requirements stated by the purchaser at the time of purchase.

Moisture removal from hygroscopic (moisture attracting) plastic pellets is an essential step in the
manufacture of high-quality plastic products.

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

M are machine-mount

1-3 Necessary Documents

The documents listed below are necessary for the operation, installation, and maintenance of
AEC/Whitlock WD10MR/FR through WD50MR/FR dryers. Additional copies are available
from AEC, Inc. Familiarize the appropriate personnel with these documents:

 This manual.

 The schematic and assembly drawings included in the customer information packet.

 The Customer Parts List included in the information packet.

 Operation and installation manuals for any optional controls or auxiliary equipment in the

drying system.

WDMR and WDFR Series Dehumidifying Dryers Page 7

1-4 Standard Features

 Dual desiccant beds

 Electric air control valve

 13X desiccant

 Up to 400ºF (204ºC) drying temperature range

1-5 Options

Options can tailor your AEC/Whitlock dehumidifying dryer to meet the exact requirements of
the drying task being performed.

 Dew point monitor indicates dryer efficiency.

 Electrical disconnect.

 Seven day timer to allow programmable dryer startup.

 Communications to meet customer needs.

 Drying hoppers come in many sizes and mounting configurations.

 Conveying equipment to transport material to and from the drying system.

1-6 The Closed Loop Drying System

AEC/Whitlock 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, a desiccant bed strips moisture from the air. 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. AEC/Whitlock uses the closed loop system 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.

Page 8 WDMR and WDFR Series Dehumidifying Dryers

P

Drying

hopper

Figure 1

Typical Air Flow Schematic

rocess

filter

Regeneration &
process
blower

Bed

shift

valve

Desiccant

bed

Left

regeneration

heater

Arrows represent air flow

Bed

shift

valve

Desiccant
bed

Right
regeneration

heater

Process

heater

WDMR and WDFR Series Dehumidifying Dryers Page 9

Figure 2

A

WD10MR through WD50MR Dryer Specifications

Hopper Process Full

Model size air flow Standard load

number cu. ft. liters lbs. Kg cfm cmh voltage amps 

WD10MR 0.7 20 25 11.3 10 17 115/1/60 20.8
WD10MR 1.5 40 50 22.7 10 17 115/1/60 20.8
WD25MR 1.5 40 50 22.7 25 42 460/3/60 10.8
WD25MR 3.0 80 100 45.4 25 42 460/3/60 10.8
WD50MR 4.0 120 150 68.1 50 85 460/3/60 19.0
WD50MR 6.0 160 200 90.8 50 85 460/3/60 19.0

 At high temperature operation.

Figure 3

WDMR Series Machine-Mount Dimensions

E

B

Process

HI-Process

Heater on
Process Delivery

Process Delivery

Air Temp
Temperature

Temperature

ON

Left Bed

Righp Bed

Heater

Heater

888

Left Bed

Right Bed

OFF

In Regen

In Regen

Process Dew Point

-

­15

20

­10

25-

-

-

30

5

3540-

0

-

High Dew Point

DEW POINT (F)

C

F

G

D

H

Mounting flange

J

J

Diameter hole:

K

Hopper mounting flanges on 0.75 and

Notes:

and 1.5 cu. ft. (20 & 40 liter) hoppers
are supplied blank so the customer
can drill to match existing machine throat.

3.0 cu. ft. (80 liter) hoppers and larger

are not supplied with a cast flange

(as shown).

Front Side

WD10MR, WD25MR, WD50MR machine-mount dimensions in inches/cm
WD10MR WD25MR WD50MR
.7 ft.3/20 liters 1.5 ft.3/40 liters 1.5 ft.3/40 liters 3.0 ft.3/80 liters 4.0 ft.3/120 liters 6.0 ft.3/160 liters

Dimension in. cm in. cm in. cm in. cm in. cm in. cm

A 24´´ 61.0 cm 27´´ 68.6 cm 29´´ 73.7 cm 385/8´´ 98.1 cm 38´´ 96.6 cm 38´´ 96.6 cm

B 101/8´´ 25.7 cm 141/8´´ 35.9 cm 141/8´´ 35.9 cm 20´´ 50.8 cm 20´´ 50.8 cm 20´´ 50.8 cm
C 31´´ 78.7 cm 351/2´´ 90.2 cm 351/2´´ 90.2 cm 38´´ 96.6 cm 45´´ 114.3 cm 56´´ 142.3 cm
D 18´´ 45.7 cm 163/4´´ 42.6 cm 21´´ 53.3 cm 251/2´´ 64.8 cm 26´´ 66.1 cm 26´´ 66.1 cm

E 301/2´´ 77.5 cm 301/2´´ 77.5 cm 34´´ 86.3 cm 34´´ 86.3 cm 40´´ 101.6 cm 40´´ 101.6 cm

F 343/4´´ 88.3 cm 361/2´´ 92.7 cm 393/4´´ 101.0 cm 447/8´´ 114.0 cm 51´´ 129.6 cm 51´´ 129.6 cm
G 101/2´´ 26.7 cm 143/4´´ 37.5 cm 15´´ 38.1 cm 17´´ 43.2 cm 17´´ 43.2 cm 17´´ 43.2 cm
H 14´´ 35.6 cm 121/2´´ 31.8 cm 15´´ 38.1 cm 15´´ 38.1 cm 18´´ 45.7 cm 18´´ 45.7 cm

J 4´´ 10.2 cm 4´´ 10.2 cm 4´´ 10.2 cm 7´´ 17.8 cm 7´´ 17.8 cm 7´´ 17.8 cm

K 11/2´´ 3.8 cm 11/2´´ 3.8 cm 11/2´´ 3.8 cm 2´´ 5.1 cm 2´´ 5.1 cm 2´´ 5.1 cm

Page 10 WDMR and WDFR Series Dehumidifying Dryers

Figure 4

r

WDFR Series Floor-Mount Dimensions

B

Process

HI-Process

Heater on

Air Temp

Process Delivery

Process Delivery
Temperature

Temperature

ON

Left Bed

Righp Bed

Heater

Heater

888

Left Bed

Right Bed

OFF

In Regen

In Regen

Process Dew Point

-

­20

15

­10

25-

-

-

30

5

3540-

0

-

High Dew Point

C

D

DEW POINT (F)

2" OD (about 51 mm)

FMASSY

6"

15.2 cm

2" OD (about 51 mm)
return from hoppe

delivery to hopper

WD10FR, WD25FR, WD50FR floor-mount dimensions in inches/cm

WD10FR WD25FR WD50FR

Dimension in. cm in. cm in. cm

A 121/2 31.8 121/2 31.8 14 35.6
B 321/2 82.6 33 83.8 41 104.2
C 241/2 62.2 27 68.6 34 86.3
D 23 58.4 25 63.5 32 81.3
E 16 40.6 18 45.7 18 45.7

A

1-7 What is Desiccant?

Desiccant is a material that attracts and holds (absorbs) water from the air. The desiccant
AEC/Whitlock dryers use is a synthetic crystalline metal aluminosilicate blended with a clay
binder and formed into beads.

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

1-8 The Process/Regeneration Cycle

AEC/Whitlock WDMR and WDFR dryers have two desiccant beds. While one bed is on-line in
the process air loop, the other is off-line, being regenerated.

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

WDMR and WDFR Series Dehumidifying Dryers Page 11

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

If you measure the temperature of the air bled to the atmosphere (bleed temperature), you should
observe a rise after a period of time. This condition, called bed breakthrough, indicates that the
bed is dry. At bed breakthrough, the bleed air temperature peaks at approximately 400°F
(204ºC).

1-9 Specifying a Drying System

Many variables were 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, AEC/Whitlock can advise you on necessary equipment and
process time and temperature modifications required for your system.

Page 12 WDMR and WDFR Series Dehumidifying Dryers

2 Shipping Information

2-1 Unpacking and Inspection

You should inspect your Whitlock dehumidifying dryer 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.

WDMR and WDFR Series Dehumidifying Dryers Page 13

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:

 WDMR or WDFR Series 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. 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 14 WDMR and WDFR Series Dehumidifying Dryers

3 Installation

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 dryer.

• Work with approved tools and devices.

• Disconnect the electricity before maintenance or service. If the dryer is installed with a

power cord that can be unplugged, unplug it. If the dryer is permanently wired to a power
main, you must install a fused power disconnect to allow the disconnect to be locked in the

OFF position. Open and lock out the disconnect installed in the control enclosure.

3-2 Rigging and Placing the Dryer

Take care when rigging and placing the dryer. Figure 5 on the following page shows a suggested
safe rigging diagram. It lets you lift the dryer/hopper unit vertically for installation on the
machine throat. Adjust chain lengths at the center sling bracket before you lift the unit. Your
dryer has built-in lifting lugs.

Caution!

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

Note: Due to the large physical size of WD50MR dryer units, extra customer-provided support

is required to stabilize these units and to protect personnel when installing on machine
throats.

WDMR and WDFR Series Dehumidifying Dryers Page 15

Figure 5

Suggested Lift Rigging for WDMR and WDFR Dryers

1

2

3

4

A0552486

Item Quantity Description Vendor Vendor part no.

1 1 Adjustable alloy chain sling McMaster-Carr 33665T32
2 2 Existing hopper lifting bracket — —
3 1 Drop forged steel eye nut McMaster-Carr 3019T15
4 1 Chain connector McMaster-Carr 3712T23

Page 16 WDMR and WDFR Series Dehumidifying Dryers

3-3 Making 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%).

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

 A qualified electrician should make all electrical connections.

 Make sure all electrical connections are tight.

 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.

3-4 Checking for Proper Blower Rotation

Three-Phase Models

The blower rotates properly when air flows from the delivery outlet.

Caution!

In three-phase models, incorrect phasing of power leads

can cause backward rotation of blower motors

and CONTAMINATION OF THE DESICCANT!

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

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

WDMR and WDFR Series Dehumidifying Dryers Page 17

L1

L2

OPTIONAL

DISCONNECT

1DISC

115/60/1

Figure 6

Typical WD10MR/FR Electrical Schematic, Drawing 1

115/1/60

1DBLK

1L1

1L1

TB1

1L3

1L1

1L2

1M

1M

1T1

1MTR

1T2

BLOWER

CONTROL POWER

4

4

4

4

OFF ON

G

18GA RED (TYP)

SUBPANEL

GROUND

GROUND

1RS

3

OX

1LT

1L1

1L2

1L1

1L2

1L1

1L2

2FU

1L1

1L2 1L2

1C

1C

2C

2C

3C

3C

18GA WHT (TYP)

1H1

PROCESS

1HTR

2HTR

3HTR

1L2

1L2

HEATER

LEFT
REGENERATION
HEATER

RIGHT
REGENERATION
HEATER

POWER ON

BLOWER CONTACTOR

1H2

2H1

2H2

3H1

3H2

1M

4

4

4

4

2CR

2CR

LEGEND:

5 10

5

4

3

PROCESS

2

TEMPERATURE

CONTROLLER

[-]RED

TYPE "K"

5 5

[+]YEL

1TC

1L2

4

9

8

7

61

1CR

6

4

A054616

OPTIONAL COMPONENTS
COMPONENTS LOCATED EXTERNALLY

OF CONTROL ENCLOSURE

7

518

5

5

8

18

1C

OPTIONAL AUDIBLE ALARM

3CR

2RS

3CR

19

1AH

1CR

R

1SOL

2SOL

1L2

1L2

1L2

1LTG1LT

3CR SILENCE BUTTON

1AH

1L2

1L2

2LT

1L2

1L2

PROCESS HEATER CONTACTOR

"PROCESS HEATER ON"

AUDIBLE ALARM

PROCESS HIGH TEMP. RELAY

"HI-PROCESS AIR TEMP"

RIGHT VALVE SHIFT SOLENOID

LEFT VALVE SHIFT SOLENOID

1L2

Page 18 WDMR and WDFR Series Dehumidifying Dryers

Figure 6

Typical WD10MR/FR Electrical Schematic, Drawing 2

L2

1L2

115/1/60

1L2

4 1L2

10

1PLC

L1

44

COM

99

11

12

-

1DMTR

000

001

002

003

004

005

+

1M

10

1CR

10

18GA BLUE 24VDC

INPUT WIRING

4

DEW POINT

METER

4

+24V

-24V
10

COM

4

0

13

1

14

COM

4

2

15

3

16

OPTIONAL DEW POINT CONTROL

RED BLK

1DPB

4

17 4

3LT

1L2

G

2CR

14

15

16

1DPT

7654321

1L2

4LT

G

2C

5LT

G

3C

6LT

G

"LEFT BED IN REGEN"

1L2

BED SHIFT RELAY

1L2

"RIGHT BED IN REGEN"

1L2

LEFT BED CONTACTOR

1L2

"LEFT BED HEATER" ON

1L2

RIGHT BED CONTACTOR

1L2

"RIGHT BED HEATER" ON

DEW POINT CONTROL BOARD

1L2

4

17

4

A054616

7LT

G "HIGH DEW POINT"

1L2

LEGEND:

OPTIONAL COMPONENTS
COMPONENTS LOCATED EXTERNALLY

OF CONTROL ENCLOSURE

Refer to your Customer Information Packet on actual drawings for your specific dryer.

WDMR and WDFR Series Dehumidifying Dryers Page 19

Figure 7

Typical WD25MR/FR, WD50MR/FR Electrical Schematic, Drawing 1

1M 1OL

1M 1OL

1T1

1T1

1T2

1T2

1T3

1T3

1MTR

BLOWER

L1

L2

L3

OPTIONAL

DISCONNECT

1DISC

1DBLK

TB1

1L1

TB1

1L2

TB1

1L3

1L1

1L2

1L3

CONTROL POWER

4

4

4

4

OFF ON

G

18GA RED (TYP)

SUB-PANEL

GROUND

GROUND

1RS

OX

1LT

2FU

3

1L2

1L1

1L2

1L1

1L2

1L1 1L3

115V

1

1L3

1T

1T

GND

2 2

1C

1C

2C

2C

3C

3C

18GA WHT (TYP)

1H1

PROCESS

1HTR

2HTR

3HTR

2

2

HEATER

LEFT
REGENERATION
HEATER

RIGHT
REGENERATION
HEATER

POWER ON

1H2

2H1

2H2

3H1

3H2

1OL

20

1M BLOWER CONTACTOR

4

TYPE "K"

TC

5 5

2CR

4

2CR

4

4

LEGEND:

[-]RED

[+]YEL

4

5

5

4

3

PROCESS

TEMPERATURE

CONTROLLER

2

1

2

10

4

9

8

7

6

1CR

6

4

A0547615

OPTIONAL COMPONENTS
COMPONENTS LOCATED EXTERNALLY
OF CONTROL ENCLOSURE

2

7 1LTG1LT

518

5

5

8

18

1C PROCESS HEATER CONTACTOR

OPTIONAL AUDIBLE ALARM

3CR

2RS

3CR

19

1AH

1AH

1CR

2LT

R

1SOL1SOL

1SOL1SOL

2

2

"PROCESS HEATER ON"

2

3CR SILENCE BUTTON

2

AUDIBLE ALARM

2

PROCESS HIGH TEMP. RELAY

2

"HI-PROCESS AIR TEMP"

2

RIGHT VALVE SHIFT SOLENOID

2

LEFT VALVE SHIFT SOLENOID

2

Page 20 WDMR and WDFR Series Dehumidifying Dryers

Figure 7

Typical WD25MR/FR, WD50MR/FR Electrical Schematic, Drawing 2

4 2

10

1PLC

L1

44

L2

2

2

COM

99

11

12

-

1DMTR

000

001

002

003

004

005

+

1M

10

1CR

10

18GA BLUE 24VDC

INPUT WIRING

4

DEW POINT

METER

4

+24V

-24V
10

COM

4

0

13

1

14

COM

4

2

15

3

16

OPTIONAL DEW POINT CONTROL

RED BLK

1DPB

4417

3LT

2

G

2CR

14

15

16

1DPT

7654321

2

4LT

G

2C

5LT

G

3C RIGHT BED CONTACTOR

6LT

G

"LEFT BED IN REGEN"

2

BED SHIFT RELAY

2

"RIGHT BED IN REGEN"

2

LEFT BED CONTACTOR

2

"LEFT BED HEATER" ON

2

2

"RIGHT BED HEATER" ON

DEW POINT CONTROL BOARD

2

4

17

4

A0547615

2

7LT

G

"HIGH DEW POINT"

LEGEND:

OPTIONAL COMPONENTS
COMPONENTS LOCATED EXTERNALLY
OF CONTROL ENCLOSURE

Refer to your Customer Information Packet on actual drawings for your specific dryer.

WDMR and WDFR Series Dehumidifying Dryers Page 21

Figure 8

Typical Control Subpanel Layout

1DPT

1DBLK

omron

SYSMAC mini

PLC

1T

1DPB

2CR1CR

3C2C1M

1FU

GRD

1C

10L

A0547616

Refer to your Customer Information Packet on actual drawings for your specific dryer.

Page 22 WDMR and WDFR Series Dehumidifying Dryers

3-5 Making Dryer/Drying Hopper Process Air

Connections

Floor Mount Models (FR)

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

hopper.

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

strongly recommend insulated hose for maximum energy savings.

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

 Do not shorten the return hose. The return air to the blower must be 150°F (66ºC) or

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

 Make sure that hoses are not kinked or collapsed.

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

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

3-6 Drying Hopper Air Trap Considerations

AEC/Whitlock’s exclusive air trap assembly on the top of the drying hopper prevents ambient air
from contaminating the material being dried.

 Keep the material level at the mid point of the air trap for maximum efficiency.

 Use a hopper loader or vacuum conveying system to maintain the proper material level.

3-7 Installing the Optional Aftercooler

Air-cooled WD10MR/FR and WD25MR/FR models use an air-to-air heat exchanger as an
aftercooler. No cooling water is required for this design. Return air from the hopper passes
through the air filter to trap fines and dust before entering the heat exchanger.

WDMR and WDFR Series Dehumidifying Dryers Page 23

Installing Air Hose

Water-Cooled Aftercooler for WD50MR Dryers

Air is routed from the bottom of the aftercooler up through the top.

• Connect the hot incoming air hose from the drying hopper to the bottom 2” (about 51 mm)

tube stub with a hose clamp.

• Connect the cooled outgoing air hose to the 2” (about 51 mm) tube at the top of the cooler.

Run this hose to the inlet of the process air filter on top of the dryer.

Figure 9

Aftercooler Design Specifications

Entering air temp. Leaving air temp. Entering water temp. Leaving water temp. Initial flow rate

ºF ºC ºF ºC ºF ºC ºF ºC gpm lpm

250ºF 121ºC 130ºF 54ºC 80ºF 27ºC 85ºF 29ºC 3 gpm 11 lpm

Installing Water Lines

WD50MR/FR Models

• Use the ½” (about 13 mm) brass pipe nipples for water line connections. Connect the

entering water line to the pipe nipple, located in the center of the cover.

• Make sure you grip the nipple tightly when attaching a fitting. Doing so prevents damage

to the soft copper coils. You should make connections with flexible hose to allow removing
the coil assembly for cleaning.

• The aftercooler is designed to utilize either tower or city water as warm as 85ºF (29ºC).

Recommended flow rate is one to three (1 to 3) gallons per minute (4 to 11 liters per
minute).

Important!

You must use an aftercooler on WD50MR/FR models to operate

at process supply temperatures of 180ºF (82ºC) or below.

You are required to use a chilled water supply of 50ºF (10ºC) to

pre-condition the dryer return air so the dryer can properly

achieve low dew points and process temperatures.

If an aftercooler is used with a drying system, AEC highly recommends that a

high temperature return air filter element is substituted for the standard

element. Order Part No. A0538636 from the AEC/Whitlock Parts Department.

Page 24 WDMR and WDFR Series Dehumidifying Dryers

4 Level 1 Controllers

Your dryer comes with the standard Level 1 control panel or the optional Level 2 control panel.
This chapter discusses the features of each, starting with Level 1 features. Level 2 features
begin in Chapter 5 on Page 33, with a graphic of the Level 2 control panel in Figure 13 on Page

34.

4-1 Level 1 Control Panel Indicator Lights

Control Power On

Control Power On indicator lights when the dryer control circuit energizes.

The

Process Heater On

The

Process Heater On indicator lights when the process air heater energizes.

High Process Air Temperature Alarm

The

High Process Air Temperature alarm indicator lights when the temperature at the process

air thermocouple is above the set high alarm value. When the indicator lights, the alarm relay
energizes and all the heaters turn off while the blower remains on to cool the dryer.

• The alarm mode and value are factory-set to track 25° above the process set point. The

alarm value is a deviation above the process set point, and the user can adjust it.

• When the temperature at the process thermocouple returns to within the acceptable range,

the alarm output de-energizes and all the heaters turn on again automatically.

• You can alter the alarm range. See Section 6-5 on Page 43 for more information.

Regen Heater On

The Regen Heater On indicator lights when the left or right bed regeneration heater is on.

Left Bed Regenerating and Right Bed Regenerating

The lit
being regenerated (off-line).

High Dew Point Alarm (optional)

The
dew point alarm point, factory set at -10°F (-23ºC).

Left Bed Regenerating or Right Bed Regenerating LED indicates the bed currently

High Dew Point alarm indicator lights when the process air delivery dew point exceeds the

WDMR and WDFR Series Dehumidifying Dryers Page 25