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
Process Delivery		Heater on	Air Temp
Temperature
888	ON	Left Bed	Righp Bed
		Heater	Heater
	OFF	Bed	Right Bed
		InLeftRegen	In Regen
	Process Dew Point
			High Dew Point
					WD	Series
					Dehumidifying Dryer
					Process	HI-Process
			Process Delivery		Heater on	Air Temp
			Temperature
			888	ON	Left Bed	Righp Bed
					Heater	Heater
				OFF	Left Bed	Right Bed
					In Regen	In Regen
				Process Dew Point
					High Dew Point
Part No. A0547682						Bulletin No. WH1-615

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

4

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

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

8

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

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	Typical Enclosure with Level 1 Control Panel, Optional Dew Point System, Disconnect	26
	11	Level 1 Process Air Temperature Control Graphic Layout	27
	12	Level 1 PLC Controller Details	30
	13	Optional Level 2 Controller	34
	14	Level 2 PLC Controller Details	37
	15	Required Desiccant Amounts per Bed	52
	16	Level 1 Controller Factory Preset Parameters	56
	17	Level 2 Controller Factory Preset Parameters	59
	18	Level 1 Controller Error Messages	60
	19	Level 2 Process Temperature Controller Error Messages	66
	20	Optional 7-Day Timer	66
	21	Optional WD50MR/FR Aftercooler Spare Parts List	74
	22	WD10MR and WD10FR Spare Parts List	75
	23	WD25MR and WD25FR Spare Parts List	76
	24	WD50MR and WD50FR Spare Parts List	77

Page 6

WDMR and WDFR Series Dehumidifying Dryers

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 M are machine-mount configurations and models designated with F are floor-mount models. The number designation 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.

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.

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

Figure 1

Typical Air Flow Schematic

Process

filter

Regeneration &

process blower

Drying hopper

Bed	Bed
shift	shift
valve	valve
Desiccant	Desiccant
bed	bed
Left	Right
regeneration	regeneration
heater	heater

Process

heater

Arrows represent air flow

WDMR and WDFR Series Dehumidifying Dryers

Page 9

Figure 2

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

B

A

E

Mounting flange

J

888

J

C

F

Diameter hole:

K

Notes: Hopper mounting flanges on 0.75 and

and 1.5 cu. ft. (20 & 40 liter) hoppers

G

are supplied blank so the customer

can drill to match existing machine throat.

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

D

H

are not supplied with a cast flange

Front

Side

(as shown).

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

WDFR Series Floor-Mount Dimensions

B

888

C D

	6"
FMASSY	15.2 cm

A

2" OD (about 51 mm) delivery to hopper

2" OD (about 51 mm) return from hopper

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

Dimension		WD10FR		WD25FR				WD50FR
	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

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

Figure 6

Typical WD10MR/FR Electrical Schematic, Drawing 1

115/1/60

L1

L2

4

4

4

OPTIONAL
DISCONNECT
1DISC		1DBLK
1L1		1L1		1L1	1M	1T1
		TB1			1M		1MTR	BLOWER
1L3				1L2		1T2
115/60/1
		SUBPANEL		1L1	1C	1H1
		GROUND
							1HTR	PROCESS
				1L2	1C	1H2		HEATER
				1L1	2C	2H1
							2HTR	LEFT
								REGENERATION
				1L2	2C	2H2		HEATER
				1L1	3C	3H1
							3HTR	RIGHT
								REGENERATION
				1L2	3C	3H2		HEATER
CONTROL POWER
OFF ON						18GA WHT (TYP)
		2FU
1RS	3		1L1	1L2			1L2
OX							1L2
G 1LT								POWER ON
						1M	1L2	BLOWER CONTACTOR

18GA RED (TYP)

4

4

5

10

1L2

1L2

5

4

9

4

1CR

3

8

6

1C

1L2

PROCESS HEATER CONTACTOR

PROCESS

[-]RED

TEMPERATURE

4

7

1LT

1L2

2

CONTROLLER

7

G

"PROCESS HEATER ON"

TYPE "K"

1TC

[+]YEL

1

6

OPTIONAL AUDIBLE ALARM

5

3CR

18

2RS

3CR

SILENCE BUTTON

3CR 19

5

1AH

AUDIBLE ALARM

1AH

5

5

1CR

1L2

PROCESS HIGH TEMP. RELAY

5

R

2LT

1L2

"HI-PROCESS AIR TEMP"

A054616

2CR

1SOL

4

8

1L2

RIGHT VALVE SHIFT SOLENOID

4

2CR

18

2SOL

1L2

LEFT VALVE SHIFT SOLENOID

OPTIONAL COMPONENTS

LEGEND:

COMPONENTS LOCATED EXTERNALLY

4

OF CONTROL ENCLOSURE

1L2

Page 18

WDMR and WDFR Series Dehumidifying Dryers

Figure 6

Typical WD10MR/FR Electrical Schematic, Drawing 2

115/1/60

4

1L2

10
				1PLC
4		4	L1	L2	1L2
		9	COM	+24V	9
10	1M	11	000	-24V	10
10	1CR	12	001	COM	4
	18GA BLUE 24VDC		002	0	13
	INPUT WIRING

1L2

G	3LT	1L2	"LEFT BED IN REGEN"

		003	1	14						2CR		1L2	BED SHIFT RELAY
									14	G	4LT	1L2	"RIGHT BED IN REGEN"
		004	COM
				4
		005	2	15						2C		1L2	LEFT BED CONTACTOR
									15	G	5LT	1L2	"LEFT BED HEATER" ON
			3
				16						3C		1L2	RIGHT BED CONTACTOR
									16	G	6LT	1L2	"RIGHT BED HEATER" ON
4
		OPTIONAL DEW POINT CONTROL
									1DPT
		RED		BLK
DEW POINT	-	+				1DPB
METER													DEW POINT CONTROL BOARD
		1	2	3	4	5	6		7
		1DMTR
				17		4	1L2		4
4												1L2
4								4	A054616
				17						G	7LT	1L2	"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 19

Figure 7

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

OPTIONAL
DISCONNECT
1DISC		1DBLK
L1	1L1	TB1	1L1	1M	1OL	1T1
L2	1L2	TB1	1L2			1T2	1MTR	BLOWER
		TB1
L3	1L3		1L3			1T3
		SUB-PANEL	1L2	1C		1H1
		GROUND
							1HTR	PROCESS
			1L3	1C		1H2		HEATER
			1L1	2C		2H1
							2HTR	LEFT
								REGENERATION
			1L2	2C		2H2		HEATER
			1L1	3C		3H1
							3HTR	RIGHT
								REGENERATION
			1L2	3C		3H2		HEATER
		1L1	1L3

4

4

4

4

4

4

4

4

			1T
CONTROL POWER			115V
OFF ON			GND				18GA WHT (TYP)
1RS 3 2FU 1
			2									2
OX												2
G 1LT													POWER ON
								1OL	20			2
										1M			BLOWER CONTACTOR
18GA RED (TYP)
	4	5		10	2							2
	5	4		9	4	1CR
		3		8	6					1C		2	PROCESS HEATER CONTACTOR
			PROCESS
	[-]RED		TEMPERATURE		4		7				1LT	2
		2	CONTROLLER	7						G			"PROCESS HEATER ON"
TYPE "K"	[+]YEL	1		6
TC
								OPTIONAL AUDIBLE ALARM
							5			3CR	18
										2RS	3CR	2	SILENCE BUTTON
									3CR 19
							5				1AH	2	AUDIBLE ALARM
										1AH
5							5			1CR		2	PROCESS HIGH TEMP. RELAY
							5			R	2LT	2	"HI-PROCESS AIR TEMP"
2CR						A0547615				1SOL
							8					2	RIGHT VALVE SHIFT SOLENOID
2CR							18			1SOL		2	LEFT VALVE SHIFT SOLENOID
			OPTIONAL COMPONENTS
LEGEND:
			COMPONENTS LOCATED EXTERNALLY
			OF CONTROL ENCLOSURE										2

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WDMR and WDFR Series Dehumidifying Dryers

Figure 7

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

4

2

10
				1PLC
4		4	L1	L2	2
		9	COM	+24V	9
10	1M	11	000	-24V	10
10	1CR	12	001	COM	4
	18GA BLUE 24VDC		002	0	13
	INPUT WIRING

2

G	3LT	2

		003	1	14						2CR		2
									14	G	4LT	2
		004	COM
				4
		005	2	15						2C		2
									15	G	5LT	2
			3
				16						3C		2
									16	G	6LT	2
4
		OPTIONAL DEW POINT CONTROL
									1DPT
		RED		BLK
DEW POINT	-	+				1DPB
METER
		1	2	3	4	5	6		7
		1DMTR
				17		4	2		4
4												2
4								4	A0547615
				17							7LT	2
										G

LEGEND:

OPTIONAL COMPONENTS

COMPONENTS LOCATED EXTERNALLY

OF CONTROL ENCLOSURE

"LEFT BED IN REGEN"

BED SHIFT RELAY

"RIGHT BED IN REGEN"

LEFT BED CONTACTOR

"LEFT BED HEATER" ON

RIGHT BED CONTACTOR

"RIGHT BED HEATER" ON

DEW POINT CONTROL BOARD

"HIGH DEW POINT"

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

WDMR and WDFR Series Dehumidifying Dryers

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Figure 8

Typical Control Subpanel Layout

1DBLK

GRD

omron

SYSMAC mini

PLC

1T

1DPT

1DPB

1CR 2CR

1M	2C	3C	1FU

1C

A0547616

10L

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

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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

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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.

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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

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

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 Left Bed Regenerating or Right Bed Regenerating LED indicates the bed currently being regenerated (off-line).

High Dew Point Alarm (optional)

The High Dew Point alarm indicator lights when the process air delivery dew point exceeds the dew point alarm point, factory set at -10°F (-23ºC).

WDMR and WDFR Series Dehumidifying Dryers

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