DRI-AIR INDUSTRIES, INC.
ARID-X & HP4-X 150-300
FLOOR MOUNT DRYERS
OPERATING MANUAL
OPERA TING MANUAL - ARID-X, HP4-X 150-300 FM DR YERS
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 06088-1020
Tel. (860) 627-5110
FAX (860) 623-4477
Internet http://www.dri-air.com
e-mail: sales@dri-air.com
OPERA TING MANUAL - ARID-X , HP4-X 150-300 FM DR YERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
CONTENTS
DRYER OPERA TION/FEATURES---------------------------4
AIR FLOW SCHEMA TIC FOR ARID-X DRYERS--------6
AIR FLOW SCHEMA TIC FOR HP4-X 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 ----------------------------------- 11
Standard Electrics----------------------------------------- 1 1
To Set Temperature: -------------------------------------- 11
Microprocessor Control ---------------------------------- 12
DRYER OPERATION-TROUBLE SHOOTING --------- 13
DRYER OPERA TION-DETAILED DIAGNOSIS -------- 14
DRI-AIR PNEUMA TIC ZONE VALVE --------------------- 15
PARTS LISTS
ARID-X & HP4-X 150 - 300 ----------------------------- 17
OPERA TING MANUAL - ARID-X, HP4-X 150-300 FM DR YERS
Revision 10/8/02
Page 3
DRI-AIR INDUSTRIES, INC.
DRYER OPERATION/
FEATURES
The ARID-X and HP4-X 150, 200, and 300 model dryers are
designed for use in high volume injection or extrusion molding
applications with usage rates up to 300 lbs. per hour.
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.
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.
Page 4
OPERA TING MANUAL - ARID-X , HP4-X 150-300 FM DR YERS
Revision 10/8/02
DRYER OPERATION/
FEATURES (Cont.)
DRI-AIR INDUSTRIES, INC.
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 - ARID-X, HP4-X 150-300 FM DR YERS
Revision 10/8/02
Page 5
AIR FLOW SCHEMATIC
FOR ARID-X DRYERS
DRI-AIR INDUSTRIES, INC.
CONTROL
THERMOCOUPLE
H1
VORTEX BLOW ER
4-WAY ZO N E
VENT
REGENERATION
AND PR OC ESS
HEATER
SAFETY THER M AL
VA LVE
XX
FILTER
CONTROL
THERMOCOUPLE
H2
CONTROL
THERMOCOUPLE
L1
Page 6
CONTROL
THERMOCOUPLE
L2
SAFETY THER M AL
TO HO PPER
PROCESS HEATER
(APD 5-9)
OPERA TING MANUAL - ARID-X , HP4-X 150-300 FM DR YERS
Revision 10/8/02
AIR FLOW SCHEMATIC
FOR HP4-X DRYERS
DRI-AIR INDUSTRIES, INC.
CONTROL
THERMOCOUPLE
H1
CONTROL
THERMOCOUPLE *
M1
CONTROL
THERMOCOUPLE
L1
VORTEX BLOW ER
VENT
SAFETY THERMAL
SECONDARY
REGENERATION
HEATER
4-WAY ZON E
VA LV E
XX
FILTER
CONTROL
THERMOCOUPLE
H2
CONTROL
THERMOCOUPLE *
M2
CONTROL
THERMOCOUPLE
L2
REGENERATION
AND PROC ESS
HEATER
* - CONTROL THERMOCOUPLE
FOR PLC CONTROL ONLY
OPERA TING MANUAL - ARID-X, HP4-X 150-300 FM DR YERS
Revision 10/8/02
SAFETY THERMAL
REGENERATION
AND PROC ESS
HEATER
SAFETY THERMAL
TO HOPPER
PROCESS H EATER
(H P D 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
Valve Shif t s
Dryer Cycle
Diagram
D esicant Beds
XX
Zo ne 2 H e a ti ng
Zo ne 2 C o o ling
Page 8
OPERA TING MANUAL - ARID-X , HP4-X 150-300 FM DR YERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
PLC ST ANDARD
ELECTRICS
U2A
R11
R12
R13
R14
DISPLAY B O 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 BOTTOM HEATER
Z2 TOP HEATER
Z1 TOP HEATER
+-
SS3
1
OSC3
U9
Jp7
OSC1
S2
PORT
+
U5
D16
J12
DRI-AIR INDUSTRIES
EXPANDER BD REV C
PROCESS HEATER
+
+-
SS4
SS5
-
J11
J11A
1
Rn7
+
C15C13
U2
OSC1
S1
R36
J5
Z1 BOTTOM HEATER
+
+
SS1
SS2
-
-
D8D11
J118
D9D13
J2
D10D14
D12
OSC2
D15
C14
+
D20
++
C20
U7
C11
P/N 84100
MOTHER BOARD
Tb2
C14
8 UNUSED
8A UNUSED
9 UNUSED
9A UNUSED
10 ALARM (OPTIONAL)
11 HIGHTEMP. ALARM (OPTIONAL)
12 UNUSED
AL1
T1
AL2
110 VAC
13 MAIN CONTACTOR/TEMPCONTROL
14 ZONE VALVE
FROM XFORMER
CR1
M2
50
14
J1
ANALOG
TC
JP2
1
2
3
C7
C21
C19
Rgain
C20
C13C14C15C16C17
C12
TC rev B
-+-+-+-+-+-+-
THERMOCOUPLE BOARD
H2H1M2M1L2
C8
3
C18
OSC1
C5
C6
JP1
1
2
C11
C10
Ch5 Ch4 Ch 3 C h2PWR Ch1 Ch0
+
L1
UNUSED
OPERA TING MANUAL - ARID-X, HP4-X 150-300 FM DR YERS
Revision 10/8/02
C19 J5
C18
D8
D9
D11
D10
D12
D13
D14
XX
J2
DegC
X10
JP3
1
2
C9
C4
U10
C3
U1
C2
C1
NON H.P.
50-300
#9TEMP. CONTSIGNAL
SAFETY
TC1
UNUSED
OL1
C101234567
UNUSED
7DAYTIMER
7DAYTIMER
UNUSED
HI TEMP. ALARM SIGNAL
TC1
UNUSED
UNUSED
L1
JUMP
GROUND
8
9
10
J2
U8
L2
QT9
QT8QT7QT6QT5
11
U5
U18
C0
C1
H.PONLY 50-100 PROCESSTUBE
U9
Tb1
C2
Jp7
Rn3
Rn4
U1
R1R2R3R4R5
012
R38
C1
Rn7
R2
OSC2
C15
U6
C13
OSC1
U4
U3
C8
U11
OSC3
C2
C3
C4C5C6
C7
Rn5
D16
R37
C11
C16
Jp6
Jp5
C12
U2
R6
Jp1
3
567
4
C17
R8
R7
C23
Jp2
Jp3
C22
OUTPUTS
POW ER
D15
C9
INPUTS
+C18
Br1+
L1
Jp4
UNUSED
UNUSED
HI TEMP
REV E
MAIN
SAFETY
TEMP
50-300
Rn6
NON H.P.
D0 D1 D2 D3 D4 D5 D6 D7
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 electric panel
enclosure box by turning the disconnect off , loosening the
clamping screws and sliding the clamps off the door tabs.
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 panel enclosure box.
« 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.
3 PHASE DRYER INST ALLATION
CHECK FOR CORRECT MOTOR ROTATION
BEFORE RUNNING DRYER
To check motor rotation.......
Remove front panel to Blower Cabinet (below elec. panel box)
so the blower can be observed. Turn on the power to the dryer
and press the ON/START 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 required for ARID-X and HP4-X 150/200/
300 Floor Mount models to operate the dryer’s Zone V alve.
CONNECT COMPRESSED AIR TO INLET ON DRYER SIDE
P ANEL. Maximum incoming pressure not to exceed 145 psi
(1.0 mpa). The pressure gauge on the dryer is factory set to
60 psi.
The unit is now ready for operation.
Page 10
OPERA TING MANUAL - ARID-X , HP4-X 150-300 FM DR YERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
START-UP PROCEDURE
Standard Electrics
Turn Power on to Dryer:
1. Power light indicates power to the unit is on.
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 lights indicate 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 unit has
failed. Further diagnostics are required
XX
OPERA TING MANUAL - ARID-X, HP4-X 150-300 FM DR YERS
Revision 10/8/02
To Set Temperature:
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
OPERA TING MANUAL - ARID-X , HP4-X 150-300 FM DR YERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
DRYER OPERATION
TROUBLE SHOOTING
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:
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 noting the valve’s zone position as
detailed in the section discussing troubleshooting the
Pneumatic Zone valve on page 15 of this manual.
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.
OPERA TING MANUAL - ARID-X, HP4-X 150-300 FM DR YERS
Revision 10/8/02
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.
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.
Page 13
DRI-AIR INDUSTRIES, INC.
DRYER OPERATION
DETAILED DIAGNOSIS
(PLC Controlled Dryer)
For Micro Controlled dryers please
see the Microprocessor Control
Instruction Manual
Machine will not start: Power light is not on.
1. Check 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
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.
OL1 located in the panel. If it
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 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.
B.Check solid state relays.
C.Check that the air flow is correct.
D.Check blower rotation.
E.Check heater for continuity .
Page 14
OPERA TING MANUAL - ARID-X , HP4-X 150-300 FM DR YERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
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.
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 solid state relays 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 Zone V alve position.
DRI-AIR
PNEUMATIC ZONE
VALVE
TROUBLESHOOTING
The Dri-Air Pneumatic Zone V alve is designed to provide very
little flow restriction and no leakage. It incorporates an AirFlow Diversion Valve controlled by a single solenoid valve.
The solenoid valve simultaneously actuates air cylinders on
each side of the Air-Flow V alve, altering air flow through the
dryer. When a new regeneration cycle begins, the valve
diverts air to the newly regenerated tower and exhausts wet
regeneration air from the desiccant bed being regenerated.
This allows for a constant supply of dry air to flow to the
material hopper. Air pressure should be kept at 60 psi to
ensure reliable operation.
Trouble shooting is easy. To access the Air-Flow Diversion
V alve, remove either side panel on the dryer cabinet. The
valve is located in the “Blower Section”, positioned on the
upright separating the blower section from the tower section of
the cabinet. To determine which zone the valve is set to,
locate the two ports on the top of the valve (one on each end)
for exhausting wet regeneration air and place your hand over
an exhaust port to feel for air flow. Air will be flowing from the
port that is set to regeneration. (Note, as you face the dryer’s
electrical panel enclosure, the exhaust port on the right side of
the valve is for ZONE 1 and the port on the left side is for
OPERA TING MANUAL - ARID-X, HP4-X 150-300 FM DR YERS
Revision 10/8/02
Page 15
DRI-AIR INDUSTRIES, INC.
ZONE 2.) Compare your findings to the lighted ZONE
Position LED on the control panel display to ensure that they
correspond with each other. If they do not correspond or if air
is exhausting from both ports, the valve is not working
properly . Check the following:
1. Check all air line connections to make sure they are
tight.
2. Check air lines to ensure they are not cracked or
broken.
3. Check incoming air pressure (60 psi min.).
4. Check operation of solenoid valve (See below).
To check operation of solenoid valve, remove front
panel to blower compartment. The valve is located
on the right-hand wall, directly connected to the air
pressure regulator. Located on the top of the valve
is a button, that when depressed will actuate the
valve. With air pressure supplied to the dryer, use
a small screw driver to depress the actuator
button. Observe the action of the Air Diversion
V alve. If the Diversion Valve operates, the
solenoid valve is operating correctly .
Page 16
OPERA TING MANUAL - ARID-X , HP4-X 150-300 FM DR YERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
ARID-X & HP4-X 150 - 300
DESCRIPTION AX HP
GENERAL
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 83786 83786
Thermocouple (Process) 82174 82174
Thermocouple (Tower) 82175 82175
Desiccant 80082 (Lbs/Machine) 74 lbs. 136 lbs.
Tower Clamp 82197 82197
Tower Gasket 83815 83815
Pressure Switch 82813 82813
Regulator 82995 82995
SMC V alve 84220 84220
Caster (Swivel) 8231 1 82311
Caster (Fixed) 82312 82312
STD MICRO
Disconnect (230v) 82714 82714
Disconnect (460v) 82308 82308
Temperature Control (RKC CB-100) 84016 NR
Main Board 84100 82071
Display Board 83401 82072
Thermocouple Board 84049 NR
Current Transformer 83437 84131
Signal Transformer (230v) NR 83817
Signal Transformer (460v) NR 82246
Main Contactor (230v) 82904 82904
Main Contactor (460v) 82270 82270
Solid State Heater Relay 82302 82302
IEC Contactor 80576 80576
IEC Contactor* 84860 84860
Single Pole Relay(Option) 82496 82496
Double Pole Relay 80587 80587
Four Pole Relay 81050 NR
Dual Solid State Board NR 82870
T oggle Switch 80466 80466
Safety Thermal Switch 80221 80221
Dewpoint Sensor 81908 81908
HEATERS
OPERA TING MANUAL - ARID-X, HP4-X 150-300 FM DR YERS
Revision 10/8/02
230V 400V 480V 575V
Regeneration (Cone Style) 81091 81923 81367 81494
HP Center (Flat Style) 82722 82506 82517 84046
Process 82672 82047 82047 82696
Page 17
DRI-AIR INDUSTRIES, INC.
NOTES:
Page 18
OPERA TING MANUAL - ARID-X , HP4-X 150-300 FM DR YERS
Revision 10/8/02
DRI-AIR INDUSTRIES, INC.
NOTES:
OPERA TING MANUAL - ARID-X, HP4-X 150-300 FM DR YERS
Revision 10/8/02
Page 19
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