DRI-AIR INDUSTRIES, INC.
APD 1-9 HPD 1-9
OPERATING MANUAL
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
Page 1
DRI-AIR INDUSTRIES, INC.
Page 2
DRI-AIR INDUSTRIES, INC.
16 THOMPSON ROAD
P.O. BOX 1020
EAST WINDSOR, CT 060881020
Tel. (860) 627-5110
FAX (860) 623-4477
Internet http://www.dri-air.com
e-mail: sales@dri-air.com
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
CONTENTS
DRYER OPERA TION/FEATURES---------------------------4
AIR FLOW SCHEMA TIC FOR APD 1-9 DRYERS-------6
AIR FLOW SCHEMA TIC FOR HPD 1-9 DRYERS ------ 7
(HIGH PERFORMANCE MODEL SHOW)
DRYER CYCLE DIAGRAM------------------------------------8
PLC ST ANDARD ELECTRICS -------------------------------9
INST ALLATION PROCEDURE ----------------------------- 10
Electrical Connection ------------------------------------- 10
Check for correct motor rotation ----------------------- 10
Compressed Air Connection---------------------------- 10
START-UP PROCEDURE ----------------------------------- 1 1
Standard Electrics----------------------------------------- 11
To Set Temperature: -------------------------------------- 11
Microprocessor Control ---------------------------------- 12
CLOSED LOOP LOADING SYSTEM --------------------- 13
Receiver Installation -------------------------------------- 13
Vacuum Check --------------------------------------------- 14
Adjustment of Sensors ----------------------------------- 14
Material Flow Adjustment-------------------------------- 15
BASIC TROUBLE SHOOTING for
CLOSED LOOP LOADING SYSTEM --------------------- 16
Material will not feed. ------------------------------------- 16
CLL MAINTENANCE------------------------------------------ 16
Daily Maintenance:---------------------------------------- 16
Monthly Maintenance: ------------------------------------ 16
DRYER OPERATION-TROUBLE SHOOTING --------- 17
DRYER OPERA TION-DETAILED DIAGNOSIS -------- 18
DRI-AIR ROT AR Y ZONE VALVE--------------------------- 19
PARTS LISTS
ARID-X 18 - 35 APD 1-4 and HPD 1-4--------------- 20
ARID-X 50 - 100 APD 5-9 and HPD 5-9 ------------- 21
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
Page 3
DRI-AIR INDUSTRIES, INC.
DRYER OPERATION/
FEATURES
The ARID-X dryer series is a dual bed design that provides a
constant supply of dry air to the material hopper. While one
bed is removing moisture from the process air the other is
regenerating by heating the desiccant to a high temperature.
Once the regenerated bed cools down, the Zone V alve
switches the airflow, and the newly regenerated bed is used to
desiccate the process air stream. The saturated bed is now
regenerated in the same manner, completing the regeneration
cycle. The cycle is depicted Page 8.
The airflow design of the ARID-X 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.
HP4-X Design
Our patented HP4-X design incorporates 4 desiccant beds
where two are stacked, one over the other. 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 ARID-X 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. Please
see the Air FLow Diagram on Page 7.
Page 4
Hopper Design
Dri-Air’s ”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 dried 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.
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
DRYER OPERATION/
FEATURES (Cont.)
Closed Loop Loading System
Dri-Air’s closed loop loading system utilizes a dedicated
blower, small receiver, filtration system and desiccated air to
move the material from the dryer hopper to the molding
machine. This eliminates the possibility that your material will
be contaminated with moisture as with some other material
transfer systems, helping to eliminate defects resulting from
moisture contamination. Please refer to the Closed Loop
Loader System section of this manual for the proper
installation and maintenance.
Dryer Controls
The ARID-X series can be supplied with the standard PLC
Control Module or the advanced Microprocessor Control
Module, while the HP4-X series is only available with the
Microprocessor Control Module.
The PLC Control module includes a PLC control board,
display board, temperature controller and touch pad that is
programmed for the drying cycle described above. The
controller, display board and touch pad indicate the machine
status, alarms, set points and allow you to enter operational
settings for the dryer. These are explained in more detail later
in this manual.
The Microprocessor Control Module is one of the most
sophisticated yet operator friendly controls on the market. It
has many more features than the PLC control module that
provide 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.
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
Page 5
AIR FLOW SCHEMATIC
FOR APD 1-9 DRYERS
DRI-AIR INDUSTRIES, INC.
CONTROL
THERMO COUPLE
H1
VORTEX BLOW ER
4-W AY ZON E
VENT
REGENERATION
AND PRO CESS
HEATER
SAFETY THERMAL
VA LVE
XX
FILTER
CONTROL
THERMO COUPLE
H2
CONTROL
THERMO COUPLE
L1
Page 6
CONTROL
THERMO COUPLE
L2
SAFETY THERMAL
TO HOPPER
PROCESS H EATER
(APD 5-9)
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
AIR FLOW SCHEMATIC
FOR HPD 1-9 DRYERS
DRI-AIR INDUSTRIES, INC.
CONTROL
THERM OCOU PLE
H1
CONTROL
THERM O CO UPLE *
M1
CONTROL
THERM OCOU PLE
L1
VORTEX BLOW ER
VENT
SAFETY THERMAL
SECOND ARY
REGENERATION
HEATER
4-WAY ZO N E
VA LVE
XX
FILTER
CONTROL
THERM OCOU PLE
H2
CONTROL
THERM O CO UPLE *
M2
CONTROL
THERM OCOU PLE
L2
REGENERATION
AND PRO CESS
HEATER
* - CONTROL THERMOCOUPLE
FOR PLC CONTROL ONLY
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
SAFETY THERMAL
REGENERATION
AND PRO CESS
HEATER
SAFETY THERMAL
TO HOPPER
PROCESS HEATER
(HPD 5-9)
Page 7
DRYER CYCLE
DIAGRAM
DRI-AIR INDUSTRIES, INC.
Zo ne 1 C o o ling
Va lv e Shif t s
Zo ne 1 H e a ti ng
Va lve Shif t s
Dryer Cycle
Diagram
D esicant Bed s
XX
Zo ne 2 H e a ti ng
Zo ne 2 C o o ling
Page 8
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
PLC ST ANDARD
ELECTRICS
DISPLAY BO ARD - P/N 83401
The control package includes a PLC controller which is
programmed for the drying cycle previously discussed. The
display board indicates the machine status, heater operation
and alarms. See section on start up for details.
Below are descriptions of the inputs and outputs of the PLC
which are used for trouble shooting. A lit LED indicates the
input or output is actuated. All inputs are 12 volts AC and all
outputs are 1 10 volts AC and 15 v DC to the heater relays.
Refer to the electrical schematic for more detail.
ARID-X50-100
Z2 TOP HEATER
Z1 TOP HEATER
+-
+-
SS4
SS3
J11A
U2A
Jp7
R11
R12
R13
R14
OSC1
S2
PORT
11
Rn7
OSC3
U9
+
U5
U2
OSC1
D16
J12
DRI-AIR INDUSTRIES
EXPAND ER BD REV C
R36
J5
Z2 BOTTOM HEATER
PROCESS HEATER
+
SS5
-
J11
+
C15C13
S1
Z1 BO TTOM HEATER
+
+
SS1
SS2
-
-
D8D11
J118
D9D13
J2
D10D14
D12
OSC2
D15
C14
+
D20
++
C20
U7
C11
P/N 84100
MO THER BO ARD
Tb2
C14
8 UNUSED
8A UN USED
9 UNUSED
9A UNUSED
10 ALARM (OPTIONAL)
11 HIGH TEMP. ALARM (OPTIONAL)
AL1
AL2
110 VAC
13 MAIN CON TACTOR/TEMP CONTROL
14 ZON E VALVE
12 UNUSED
T1
FROM XFORMER
CR1
M2
50
14
J1
ANALOG
TC
JP2
1
2
3
C7
C21
C19
Rgain
C20
C13C14C15C16C17
C12
TC rev B
-+-+-+-+-+-+-
THERM OCOUPLE BOARD
C8
C18
OSC1
C5
C6
JP1
1
2
3
Ch5 Ch4 Ch3 Ch2PWR Ch1 Ch0
H2H1M2M1L2L1UNUSED
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
C19 J5
C18
D8
D9
D11
D10
D12
D13
D14
XX
J2
DegC
X10
JP3
1
2
C9
C4
U10
C11
C3
U1
C10
C2
C1
NON H.P.
50-300
#9TEMP.CONTSIGNAL
TC1
UNUSED
OL1
C101234567
UNUSED
SAFETY
7DAYTIMER
HI TEMP. ALARM SIGNAL
TC1
7DAYTIMER
UNUSED
L1
UNUSED
JUMP
GROUND
UNUSED
8
9
10
J2
U8
L2
U5
QT9
QT8QT7QT6QT5
U18
C0
C1
H.P ONLY 50-100 PROCESS TUBE
11
C2
Jp7
Rn3
Rn4
U9
U1
R1R2R3R4R5
012
R38
C1
Tb1
Rn7
R2
OSC2
C15
U6
C13
OSC1
U4
U3
C8
U11
OSC3
C2
C4C5C6
C7
Rn5
C3
D16
R37
C11
C16
Jp6
Jp5
R7
Jp2
567
C17
R8
C23
Jp3
C22
C12
U2
R6
Jp1
3
4
OUTPUTS
POW ER
D15
C9
+C18
Br1+
L1
Jp4
UNUSED
UNUSED
HI TEMP
INPUTS
REV E
MAIN
SAFETY
TEMP
50-300
Rn6
D0 D1 D2 D3 D4 D5 D6 D7
NON H.P.
PLC03
mal l
S
C2
Z1
L2
+
Page 9
DRI-AIR INDUSTRIES, INC.
INSTALLATION
PROCEDURE
For all Dri-Air models except ARID-X 10, AHM-1, & PDII
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.
NOTE:
When 3 wire supplies are used in place of 4 wire supplies,
a control transformer is required.
XX
3 PHASE DRYER INST ALLATION
CHECK FOR CORRECT MOTOR ROTATION
BEFORE RUNNING DRYER
To check motor rotation.......
Leave the electrical cabinet door open so the blower can be
observed. Turn on the power to the dryer and press the ON/
ST ART touch pad and then immediately press the OFF/STOP
touch pad. Observe the cooling fan on the top of the blower
motor and verify the fan is turning clockwise. If the motor is
not turning clockwise, switch any two adjacent supply wires.
Compressed Air Connection:
Compressed air is only required for dryers which have the
closed loop loader as part of the system. For those units:
CONNECT COMPRESSED AIR TO INLET ON FRAME
UNDER DRYER. The closed loop system includes a
regulator that is set to the proper pressure and an automatic
drain water separator. Maximum incoming pressure not to
exceed 145 psi (1.0 mpa).
The unit is now ready for operation.
Page 10
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
START-UP PROCEDURE
Standard Electrics
Operating this unit is very simple. Once the dryer is
connected to the facility power supply, the unit can be started
by turning the disconnect located on the electrical panel
enclosure to the ON position and pressing the ON button on
the Control Panel Key Pad. To shut the dryer off, simply push
the OFF button on the Control Panel Key Pad and turn the
disconnect to the OFF position.
Setting the process air temperature is done using the Digital
Controller.
For a more detailed explanation, see the following sections.
Control Panel - Operating Display
Turn power on at dryer using disconnect.
1. POWER light indicates power to the unit is on.
Press ON button on key pad
2. Illuminated BLOWER Light indicates Blower is on.
3. Flashing ZONE light indicates bed is in
Regeneration cycle.
4. Steady ZONE light means bed is in cooling cycle.
5. Illuminated HEATER light indicates heater is on.
Alarm Conditions:
6. Flashing HIGH TEMP . ALARM indicates an over or
under temp alarm. Unit shuts down.
7. Steady HIGH TEMP. ALARM light indicates thermocouple has failed. Further diagnostics are required.
8. Flashing ALARM light indicates a safety override
condition has occured. Dryer shuts down.
XX
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
Digital Controller - Setting Process Air T emperature:
Press SET button - temperature set display will flash.
Press up arrow to increase temperature and down arrow to
decrease temperature.
Press SET again to enter the new temperature.
If the display flashes, the temperature is out of the control
range.
If the display shows 0000 the thermocouple is not connected
or is faulty .
Page 11
DRI-AIR INDUSTRIES, INC.
Microprocessor Control
1. Power light indicates there is power on.
2. After initializing, dri Air will be displayed.
3. Press
4. To set the temperature:
5. Left display indicates actual temperature
6. Right display shows dewpoint or set temp
7. To set high temp alarm: (degrees over setting)
8. Status block indicates heater on or fault
9. See manual for setting 7-day timer .
10. Configuration of the dryer parameters is done
START to start the dryer.
press SET - right display shows set temp
change setting using arrow keys
press ENTER to input new setting
press TEMP D.POINT button to change
press ALARM - right display shows setting
change setting using arrow keys
press ENTER to input new setting
using the setup button. see manual.
Page 12
For a more detailed explanation of the features and operation
of our Microprocessor Controller, please consult the
Microprocessor Operating manual enclosed with this unit.
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
CLOSED LOOP
LOADING SYSTEM
DRI-AIR INDUSTRIES, INC.
The closed loop loading system uses a separate vortex blower
to provide the vacuum and “pressure assist” necessary to
move the dried resin from the hopper take-off box to the
receiver mounted on the feed throat of the molding machine.
At the start of the loading sequence, the lower proximity switch
on the receiver senses there is no material. The blower starts,
and the loader valve on the inlet line to the blower is opened.
Because the receiver is sealed to the feed throat, a vacuum is
created within the take off box, pulling material from the
hopper.
The outlet of the blower ( pressure side) blows air into the take
off box to help move the material to the receiver and close the
air loop. When the upper proximity switch on the receiver
senses material, the blower is stopped and the loader valve is
closed to prevent anymore material from being conveyed and
left in the hose to possibly be contaminated with moisture.
To operate the system, complete the installation steps detailed
below and turn on the system by actuating the toggle switch
labeled LOADER on the front of the electrical panel enclosure.
If the Dual Closed Loop Loading option has been installed,
please consult the
enclosed with your dryer.
Dual Closed Loop Loader Operating Manual
RECEIVER
INSTALLATION
Prior to installing the receiver, you must inspect the surface of
the molding press feed throat that the receiver is being installed
upon to ensure that it is clean and flush. Surface irregularities
must be removed, or a gasket installed, so that there will be no
vacuum leaks between the receiver and feed throat after
installation.
IMPORTANT
If the molding machine is equipped with a slide gate, swing
arm, starve feeder, additive feeder, or feed throat vent, you
must ensure these are sealed, as the system may not work
properly . If it is impractical, or impossible to seal of f the
aforementioned equipment, Dri Air Industries has a Flap V alve,
available for purchase, that will enable the loading system to
function properly .
To install the receiver, simply drill holes in the bottom flange of
the receiver to match the hole pattern on the molding press
feed throat and affix the receiver with bolts sufficient to
accommodate the operating stresses. A silicone gasket is
provided with the receiver to ensure a tight seal between the
receiver bottom and the feed throat. Connect the plug for the
upper proximity switch into the line labeled H and connect the
lower proximity switch plug into the line labeled L. Connect the
material feed hose and vacuum hose as shown in drawing
82222 in the appendix to this manual.
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
Page 13
VACUUM CHECK
DRI-AIR INDUSTRIES, INC.
Prior to production operation of the loading system, we strongly
recommend that you ensure the loading system is properly
sealed. To test the seal, follow the steps detailed below.
While the loader is running, close the hopper slide gate
and remove the material wand and attached hose from
the takeoff box. Check the vacuum level by placing
your hand over the wand. Return the wand to the takeoff box.
Remove the hose from the bottom port of the blowback
filter canister. Place your hand over the filter canister
port. Compare this vacuum level to the level observed
at the material wand. The two vacuum levels should be
the same.
Any difference between the vacuum levels is caused from
leaks in the loading system. Check for loose hoses, missing
gasket on the cyclone, or other possible sources of leaks
described below.
PROXIMITY SENSOR
ADJUSTMENT
Page 14
The most likely source is the seal between the feed throat and
receiver, or the configuration of the feed throat and material
feeder associated with the molding press. The presence of
vacuum leaks at these locations may exhibit the following
characteristics:
n Material in the receiver may be seen to bubble or
move when loading, as a leak at the feed throat causes
air to be drawn in at the bottom of the receiver rather
than from the take off box.
n Poor transfer of material from the take-off box to
the receiver.
n Large amounts of material or dust being pulled
into the blowback filter cannister.
If any of these occurrences are observed, the steps to improve
the vacuum seal detailed in the previous section on Receiver
Installation will be required.
The proximity sensors supplied with the receiver may require
adjustment to operate properly . When positioning the sensors,
ensure that they are placed as close as possible to the outer
surface of the receiver as they operate by sensing the density
of the material in the receiver. Vertically position the lower
sensor to set the material level at which the load cycle will
initiate and the upper sensor to set the material level at which
the load cycle will stop. CAUTION: Do not overfill the
reciever as material may be drawn back into the blowback
filter canister.
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
To adjust the sensor’s sensitivity, turn the adjustment screw on
the back of the sensor. The adjustment screw turns a 20 turn
potentiometer with a clutch to prevent over adjustment. If you
are unsure as to the current setting of the sensor, turn the
screw 20 turns counterclockwise. The LED should light with
no material in front of the sensor. Turn the screw 4-6 turns
clockwise and proceed as directed below .
With no material in front of the sensor , the LED on the back of
the sensor should be lit. If not, turn the adjustment screw
located on the end of the sensor counterclockwise until the
LED turns on.
With material in front of the sensor, the LED on the back of the
sensor should be off. If not, turn the adjustment screw
clockwise, until it turns off.
MATERIAL FLOW
ADJUSTMENT
Material flow to the receiver should be continuous and smooth.
Irregularities in flow rate and volume can be affected by the
position of the material wand inserted into the take-off box or
the density of the resin. To adjust the flow, take the steps
detailed below.
Upon initial operation of the loading system, push the wand in
until it stops. Then pull it out 1 to 2 inches and tighten the set
screw on the take-off box material outlet. Operate the loading
system and observe how the material flows into the receiver. If
the flow rate is not as desired, the wand can be adjusted out to
reduce the flow of material conveyed, or in, to increase the
amount. Typically, loading times are 5-6 seconds for a 2”
receiver and 15-20 seconds for the 4” receiver.
If the material flow is irregular, with “slugs” of resin being
delivered to the receiver, the wand is most likely pushed too far
into the take-off box. This “chokes” off the air flow required to
convey the material, causing the irregular flow. To remedy this
condition, pull the wand out slightly and the material will flow
more evenly and quickly .
If little or no material is conveyed and there are no blockages in
the take-off box or material hose the wand may be pulled too
far out of the take-off box. Push the wand in until you get the
desired flow rate.
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
Page 15
DRI-AIR INDUSTRIES, INC.
Material will not feed.
BASIC TROUBLE
SHOOTING for
CLOSED LOOP
LOADING SYSTEM
1. Ensure the proximity sensors are adjusted and working
properly . Both sensors LED’s should be lit when the
receiver is empty . Check that the sensors are tightened
on the bracket and the cable connectors are tight and
correct.
2. Check system for leaks. Tighten hose clamps. Check
seal at receiver/feed throat interface by comparing
vacuum levels as directed in previous section on
Receiver Installation.
3. Ensure the blower operates. Check the electrical
system to see if the relay is working and that the blower
overload is not tripped. Trip window will be orange/yellow
if tripped. Check to see that the blower rotation is
correct (clockwise).
4. Ensure that the compressed air is connected to the
system and the pressure regulator is set to 60 psi. Does
the air valve open when the system calls for material?
The air line to the valve can be easily disconnected by
pushing in on the plastic sleeve and removing the hose.
The air line should be pressurized when the system is
loading.
CLOSED LOOP LOADER
MAINTENANCE
5. Ensure the drain valve at the bottom of the filter is
closed properly .
Daily Maintenance:
Clean filter when loader is not working.
The filter is cleaned automatically with an air blast at the start
of each loading cycle. The canister needs to be drained
periodically by opening the valve at the bottom of the canister.
Gently bang on the side of the cannister with your hand to
loosen any fines and
Monthly Maintenance:
Clean filter sock by removing the quick clamp on the filter and
removing the top cover. Remove the bag assembly and blow
off with an air gun. Install bag assembly, top cover and quick
clamp checking that the seal is proper. This maintenance may
need to be performed more frequently if your material is dusty ,
or less frequent if your material is clean. We strongly
recommend it be performed every 6 months regardless of
material conditions
Tighten all hoses and hose clamps and check for leaks.
close the valve.
Page 16
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
DRYER OPERATION
TROUBLE SHOOTING
DRI-AIR INDUSTRIES, INC.
The new Dri-Air Standard PLC and MICROPROCESSOR
Electrics were designed for quick diagnosis of problems.
The following steps should be done before proceeding with
other diagnostic steps.
1. Check the Power Circuit:
a. Incoming fuses or circuit breaker
b. All dryer fuses:
Each fuse, with the exception of the main fuses, has
a blown fuse indicator light that illuminates when the
fuse is blown.
c. Is power supplied to the unit?
d. Check heater continuity using a volt ohmmeter.
2. Compressed Air:
For those models that require compressed air.
a. Is compressed air connected with at least 60 PSI
b. Check water separator and drain if necessary
c. Pressure gage should read 60 PSI
3. Air Flow Circuit:
a. Ensure Zone V alve position corresponds to the
regeneration cycle by comparing the Zone position lights
on the Zone V alve to the ZONE position lights on the
dryer panel.
b. Make sure that all hoses are connected, not crushed,
and free from obstructions.
c. Inspect filter and make sure cover is tight and the filter is
clean.
4. Control Circuit:
a. Using the PLC/MICRO Display Panel ZONE indicator
lights as a guide for the dryer regeneration cycle, check
that all inputs/outputs are proper for the part of the
regeneration cycle that the machine is in.
b. Monitor the PLC output lights to ensure the
corresponding LED on the power board is illuminated
and there is an output voltage to the heater.
5. Operating Conditions:
a. Check the process temperature. It should not be set
below 140° F (60° C) because the unit will go into high
temp alarm.
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
Page 17
DRYER OPERATION
DETAILED DIAGNOSIS
(PLC Controlled Dryer)
For MicroControlled dryers please see the
Microprocessor Control Instruction Manual
DRI-AIR INDUSTRIES, INC.
Machine will not start: Power light is not on.
1. Check circuit breakers (CB1) or incoming fuses inside
control box to see if they are tripped or blown. Reset
circuit breakers by turning them off and then on.
2. Check small fuses (FU1 & FU2) next to contactor. The
LED will be lit if they are blown. Replace if necessary by
opening the fuse holder and put new fuse into holder.
3. Check that incoming power to the unit is proper.
4. Check safety snap discs.
Alarm light is flashing: Unit will not run.
Main contactor is not pulling in.
1. Check the motor overload OL1 located in the panel. If it
is tripped, the window will show as orange/yellow. Reset
overload by pushing in the reset button.
Machine will not run: High T emp Alarm Light flashing.
This indicates that the temperature has exceeded the high
limit programmed into the temperature control or the set
temperature can not be reached.
Press stop and restart machine holding in the start button.
Monitor the actual temperature to see if it exceeds the set
point or can not reach the set point. If it can not reach set
point, see section below.
Machine will not run: High T emperature Alarm Light on, not
flashing:
1. This indicates an “open” thermocouple or the
temperature in the desiccant tower exceeded 900° F.
Machine will not reach temperature:
1. If the process heater light is not lit.
A.Check output from temperature controller and input to
PLC.
B.Check the thermocouple. The tip should be in the
middle of the hose.
2. If the process heater light is lit.
A.Check fuses on power board
B.Check solid state relays on power board.
C.Check that the air flow is not obstructed.
D.Check blower rotation
E.Check heater for continuity.
Page 18
Check the limit first by pressing the SET button on the
temperature control and holding until AL is displayed. The
setting shown indicated the amount over set point that the
alarm will be actuated. It is factory set to 50°F (30°C) and
should not be set below 30°F (16°C) or it will actuate too soon.
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
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 the power boards to see if one of the solid state
relays has failed on. Using an ammeter or voltmeter on
the output to the heater, see if there is power when the
LED is not lit which will indicate a failed relay .
4. Check the valve position.
DRI-AIR
ROTARY ZONE VALVE
The Dri-Air rotary valve is designed to provide very little flow
restriction and no leakage. It incorporates high temperature,
self adjusting seals for years of trouble free service. The
electrical controls are built into the end of the valve and
include position lights.
Trouble shooting is easy. If the lights indicating position do not
match the zone displayed on the control panel, or there are no
lights, the valve is not working properly. See if the cam is
actuating a switch.
DO NOT PUT FINGERS INTO VALVE WITH POWER ON
Check all electrical connections to make sure they are tight.
Contact factory with the serial number of the dryer for a
replacement valve.
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
Page 19
DRI-AIR INDUSTRIES, INC.
APD 1-4 and , HPD-1-4
PARTS LISTS
GENERAL
CLOSED LOOP LOADER
ELECTRICAL
NOTE:
TO ORDER BLOWERS OR
OVERLOAD REFER TO
P AR T NUMBER ON ITEM.
*:
IEC CONTACTOR USED IN ALL
FM, PD & HM DRYERS AND CLL
POWER PACKS WITH SERIAL
NUMBERS GREA TER THAN
D14650
DESCRIPTION APD HPD
Dryer Filter Element 81055 81055
Zone V alve 83705 83705
Thermocouple (Process) 82174 82174
Desiccant 80082 (Lbs/Machine) 8 lbs. 14 lbs.
Tower Clamp 81017 81017
Tower Gasket 81028 81028
Regeneration V alve NR NR
Pressure Switch NR NR
Regulator NR NR
MAC V alve NR NR
Caster (Swivel) 81799 81799
Caster (Fixed) 81798 81798
Filter Element 82389 82389
Blowback V alve 82695 82695
Proximity Switch (K10203 Std. El.) 81 18 0 8118 0
Proximity Switch (K15208 Micro) 82298 82298
Regulator 82995 82995
Air V alve (SMC) 84220 84220
Load V alve 84229 84229
STD MICRO
Disconnect 82308 82308
Temperature Control (RKC CB-100) 84016 NR
Main Board 84100 82071
Display Board 83401 82072
Thermocouple Board 84049 NR
Transformer 83437 84131
Current Transformer NR 82246
Main Contactor 82270 82270
Solid State Relay 82302 82302
IEC Contactor 80576 80576
IEC Contactor * 84860 84860
Power Board 83493 83493
Power Board (208 & 230 v Dryers) 84080 84080
Single Pole Relay 82496 82496
Double Pole Relay 80587 80587
Dual Solid State Board NR 82870
Toggle Switch 80466 80466
Safety Thermal Switch (Tower) 80221 80221
Thermocouple (Tower) 82174 82174
TRI-Solid State Board NR 83468
Dewpoint Sensor 81908 81908
Solid State Timer (Blowback) 83318 83318
Solid State Timer (Cleanout) 83527 83527
Solid State Timer (Auger Delay) 83442 83442
HEATERS
Page 20
208V 230V 400V 480V 575V
Regeneration (Cone Style) 83342 83373 83982 83374 84235
HP Center (Flat Style) 82373 82373 83958 82505 84260
Process NR NR NR NR NR
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
APD 5-9 and , HPD-5-9
DESCRIPTION APD HPD
GENERAL
CLOSED LOOP LOADER
ELECTRICAL
NOTE:
TO ORDER BLOWERS OR
OVERLOAD REFER TO
P AR T NUMBER ON ITEM.
*:
IEC CONT ACT OR USED IN ALL
FM, PD & HM DRYERS AND CLL
POWER P ACKS WITH SERIAL
NUMBERS GREA TER THAN
D14650
Dryer Filter Element 81331 81331
Zone V alve 83705 83705
Thermocouple (Process) 82174 82174
Desiccant 80082 (Lbs/Machine) 30 lbs. 50 lbs.
Tower Clamp 81172 81172
Tower Gasket 82795 82795
Regeneration V alve NR NR
Pressure Switch NR NR
Regulator NR NR
MAC V alve NR NR
Caster (Swivel) 81799 81799
Caster (Fixed) 81798 81798
Filter Element 82389 82389
Blowback Valve 82695 82695
Proximity Switch (K10203 Std. El.) 81 180 81 180
Proximity Switch (K15208 Micro) 82298 82298
Regulator 82995 82995
Air V alve (SMC) 84220 84220
STD MICRO
Disconnect 82308 82308
Temperature Control (RKC CB-100) 84016 NR
Main Board 84100 82071
Display Board 83401 82072
Thermocouple Board 84049 NR
Transformer 83437 84131
Current Transformer NR 82246
Main Contactor 82270 82270
Solid State Relay 82302 82302
IEC Contactor 80576 80576
IEC Contactor * 84860 84860
Power Board 83493 83493
Power Board (208 & 230 v Dryers) 84080 84080
Single Pole Relay 82496 82496
Double Pole Relay 80587 80587
Dual Solid State Board NR 82870
T oggle Switch 80466 80466
Safety Thermal Switch (Tower) 80221 80221
Safety Thermal Switch (Process) 80551 80551
Thermocouple (Tower) 82175 82175
Transformer .050 82245 82245
TRI-Solid State Board NR 83468
Dewpoint Sensor 81908 81908
Solid State Timer (Blowback) 83318 83318
Solid State Timer (Cleanout) 83527 83527
Solid State Timer (Auger Delay) 83442 83442
HEATERS
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
230V 400V 480V 575V
Regeneration (Cone Style) 81351 81766 81366 81432
HP Center (Flat Style) 82364 83934 82493 83372
Process 82343 84204 82319 84065
Page 21
DRI-AIR INDUSTRIES, INC.
NOTES:
Page 22
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
NOTES:
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
Page 23
DRI-AIR INDUSTRIES, INC.
NOTES:
Page 24
OPERA TING MANUAL - APD 1-9, HPD 1-9 POR TABLE DRYERS
Revision 10/8/02
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