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FarragTech GmbH
Dammstrasse 61
A-6922 Wolfurt
+43.5574.83800
+43.5574.83800 11
info@farragtech.com
www.farragtech.com
OPERATING MANUAL
FIT 01.09
Version 6.15 ENGLISH
April 2010
Page 2
Page 3
CONTENT
1. CONTENT
1. CONTENT _____________________________________________________________ 1
2. GENERAL INFORMATION _____________________________________________ 3
2.1 T
2.2 A
2.3 L
2.4 M
2.5 C
2.6 M
2.7 A
3. GENERAL SAFETY INFORMATION ____________________________________ 6
4. TRANSPORTATION AND STORAGE ___________________________________ 7
HE IMPORTANCE OF THIS MANUAL _____________________________________________ 3
PPLICATION FIELD __________________________________________________________ 3
IABILITY AND WARRANTY _____________________________________________________ 3
ISUSE ____________________________________________________________________ 4
OPYRIGHT _________________________________________________________________ 4
ANUFACTURER _____________________________________________________________ 4
PPLIED SAFETY SIGNS _______________________________________________________ 5
5. NAME PLATE _________________________________________________________ 8
6. HOW IT WORKS _______________________________________________________ 9
7. TECHNICAL DATA __________________________________________________ 11
8. SET UP AND INSTALLATION _______________________________________ 13
8.1 C
OMPRESSED AIR HANDLING AND SUPPLY ______________________________________ 13
9. FIRST START-UP ____________________________________________________ 15
9.1 C
9.2 E
9.3 L
9.4 E
9.5 I
9.6 D
9.7 F
9.8 A
OMPRESSED AIR AND ELECTRICAL CONNECTIONS _______________________________ 15
XHAUST AIR FILTER ________________________________________________________ 16
OADING AND UNLOADING ___________________________________________________ 16
XTERNAL SLEEP-SIGNAL ____________________________________________________ 17
NSTALLATION OF EXTERNAL ALARM DEVICES ___________________________________ 17
ATA COMMUNICATION _____________________________________________________ 18
IRST START UP ____________________________________________________________ 18
DDITIONAL CHECK POINTS AT FIRST START UP __________________________________ 19
10.SWITCHING OFF ____________________________________________________ 22
11.OPERATION BASICS ________________________________________________ 23
12.MENU STRUCTURE _________________________________________________ 24
12.1 E
12.2 E
12.3 S
ASY MODE ________________________________________________________________ 25
XTENDED MODE ___________________________________________________________ 27
YSTEM PARAMETERS _______________________________________________________ 30
CARD G / FIT 1 V 6.15 E / April 2010
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CONTENT
13.DATA INPUT ________________________________________________________ 32
14.NAVIGATION ________________________________________________________ 35
15.START SCREEN AND LANGUAGE SELECTION ______________________ 37
16.EASY MODE _________________________________________________________ 39
17.EXTENDED MODE ___________________________________________________ 40
17.1 M
17.2 E
17.3 PROCESS DATA SCREEN _____________________________________________________ 48
17.4 D
17.5 C
17.6 R
17.7 WEEKLY TIMER ___________________________________________________________ 58
17.8 FAULTS SCREEN ____________________________________________________________ 63
17.9 S
17.10 S
AIN SCREEN AND OPERATION _______________________________________________ 40
NERGY AND DATA SCREENS _________________________________________________ 45
17.2.1 ENERGY SCREEN ________________________________________________________________________________ 45
17.2.2
INPUT STATUS SCREEN __________________________________________________________________________ 46
17.2.3 OUTPUT STATUS SCREEN _______________________________________________________________________ 47
RYING PARAMETERS _______________________________________________________ 50
ONVEYING PARAMETERS ____________________________________________________ 53
ECIPES __________________________________________________________________ 55
17.6.1 STANDARD RECIPES _____________________________________________________________________________ 55
17.6.2 CUSTOMER RECIPES _____________________________________________________________________________ 57
17.7.1 WEEKLY TIMER GENERAL ________________________________________________________________________ 58
17.7.2 WEEKLY TIMER LOADING ________________________________________________________________________ 61
17.7.3 DATE AND TIME _________________________________________________________________________________ 62
TATUS REPORT ___________________________________________________________ 65
YSTEM PARAMETERS _______________________________________________________ 66
17.10.1 DATA TRANSFER ________________________________________________________________________________ 68
17.10.2 LAN SETTINGS __________________________________________________________________________________ 71
17.10.3 UNIT SELECTION _________________________________________________________________________________ 72
18.FAULTS AND REMEDY ______________________________________________ 75
18.1 F
18.2 F
AULTS WITH DISPLAY TEXT __________________________________________________ 75
AULTS WITHOUT DISPLAY TEXT ______________________________________________ 82
19.MAINTENANCE ______________________________________________________ 83
20.SPARE PARTS LIST _________________________________________________ 84
CARD G / FIT 2 V 6.15 E / April 2010
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GENERAL INFORMATION
2. GENERAL INFORMATION
2.1 THE IMPORTANCE OF THIS MANUAL
This manual contains all the necessary
information for installation, operation, trouble shooting and maintenance of CARD G FIT series. It
is, therefore, very important that the user reads this manual before installing any CARD G FIT unit
and before setting the dryer in operation.
2.2 APPLICATION FIELD
The CARD G FIT series are
compressed air dryers designed only to dry hygroscopic plastic resins as described in this
manual. It is not permitted to use this dryer series in other fields, to dry other materials or to
operate this dryer series in a different way other than described in this manual without a written
agreement from .
and its sales representatives are not responsible for any damage or injury resulting
from installation, operation or maintenance works not performed according to the instructions in
this manual and any additional written instructions for special applications from .
2.3 LIABILITY AND WARRANTY
The warranty provided with the
CARD G FIT series is based on the TERMS AND CONDITIONS OF SALES of and/or
any additional written agreement between the owner/operator and or its
representative. The warranty is void if the CARD G FIT is not installed, operated or maintained
according to the instructions in this manual. No parts or components of the CARD G FIT series
are to be changed or replaced without a written instruction of or its representative.
is not responsible for any damage or injury resulting from altering, replacing or
changing any part or component of the CARD G FIT without written instructions from
. The user is requested not to allow anyone but qualified personnel to install, start up
or operate the CARD G FIT and only as instructed in this manual. Wear and tear parts and
components are not included in the standard warranty provided with the CARD G FIT series. In
case of discrepancies in the text of this manual, do not install, start up, operate or perform any
maintenance works on the CARD G FIT series without contacting or its
representative to clarify the correct text.
CARD G / FIT 3 V 6.15 E / April 2010
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GENERAL INFORMATION
is not liable for any damage or injury resulting from the misuse of CARD G FIT,
installation, start up, operation or maintenance not complying with the instructions in this
manual.
2.4 MISUSE
Installing, starting up, operating, repairing or performing maintenance on CARD G FIT without
reading and complying with the instructions in this manual or any written instructions from
regarding the use of CARD G FIT series is considered misuse. Altering, replacing or
changing any part or component of the CARD G FIT without written instruction from
is considered misuse. Using the CARD G FIT for other than its intended purpose is considered
misuse. is not responsible for any damages or injuries resulting from misuse.
2.5 COPYRIGHT
All copyrights of this manual are reserved for . This copy of the manual is provided
for the owner/operator of the CARD G FIT series and their personnel. The information included in
this manual and any part thereof must not be copied, distributed or made available to a third
party without the written permission of . Doing so may result in legal action against
the owner/operator.
2.6 MANUFACTURER
The name and the contact information of the manufacturer are printed on the front page of this
manual. The version and the release date of this manual are also printed on the front page of this
manual. The user may use the contact information of the manufacturer or the representative to
discuss any matters related to the CARD G FIT series of this manual.
CARD G / FIT 4 V 6.15 E / April 2010
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applied in this manual and their meaning is described below:
This denotes danger for man and equipment.
Damage to equipment may occur if not followed.
GENERAL INFORMATION
2.7 APPLIED SAFETY SIGNS
The following safety signs are often
This is useful information for operation of equipment.
CARD G / FIT 5 V 6.15 E / April 2010
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GENERAL SAFETY INFORMATION
3. GENERAL SAFETY INFORMATION
Only qualified and trained personnel are allowed to deal with equipment.
The owner/operator is responsible for following the instructions in this manual and fulfilling
the official safety requirements.
This manual does not contain the general safety instructions. The user is responsible for
obtaining and following the local safety information as required or requested by the local
authorities and insurance companies.
The CARD G FIT is to be installed and operated according to the data on the name plate of
the unit and according to the instructions in this manual. Any deviation requires the written
permission of .
This manual describes the standard CARD G FIT series. It does not contain constructional
details or modifications made by to meet the user’s expectations.
The user is to contact for any missing information or for any required
information.
Successful operation of CARD G FIT is achieved, when the unit is installed according to the
valid mechanical and electrical standards.
Wear and tear may lead to unsafe operation or unsatisfactory results. The owner/operator
is responsible for inspecting the equipment periodically and insuring that every component
is in good condition and safe to use. Defective parts must be replaced by new and approved
parts. Only qualified and trained personnel are allowed to remove or replace any
components.
Only qualified electricians are permitted to deal with wiring and wired components of the
equipment.
The electrical switch cabinet is to be kept closed at all times. Only qualified personnel are
permitted to open the cabinet.
The user is to use the proper cleaning material especially when using liquids and
detergents. No liquids are allowed on or near any electrical component of the equipment.
Damages and/or injuries may occur if the user does not follow the instructions in this
manual. is not responsible for any damages or injuries resulting from
installations or operations which are not in accordance with the instructions.
The user is responsible for forwarding this manual and any additional instructions from
to the owner/operator of the CARD G FIT in case of selling, renting or giving the
unit to a third party.
CARD G / FIT 6 V 6.15 E / April 2010
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TRANSPORTATION AND STORAGE
4. TRANSPORTATION AND STORAGE
All CARD G FIT units are completely assembled, tested and packed
in a cardboard box by the manufacturer before they are delivered to the user.
The box is not suitable for transportation by fork lifts, pallet jaks and cranes.
To transport the unit using any of the above, the box must first be placed on a
suitable pallet and may then be moved.
DO NOT SHAKE OR DROP THE UNIT EVEN WHEN PACKED IN THE BOX.
CARD G FIT includes sensitive electronic components which might get
damaged.
The standard delivery terms of the CARD G FIT series are ex-works unless
otherwise agreed upon in writing. The box including the CARD G FIT and any
accessories delivered with the main equipment are to be inspected upon arrival
at the owner’s/operator’s destination and prior to signing the delivery
documents provided by the shipping company. Any signs of damage must be
documented on the shipping documents before signing. The equipment must be
inspected and any signs of damage must be reported to the shipping company
and the insurance company within 72 hours from the delivery time. Failing to do
so may void all claims for shipping damages.
It is also necessary to inform and its representative about any
transportation damage to destination or when moving the equipment on the
owner’s/operator’s properties.
The CARD G FIT contains electronic and electrical components and therefore it
must be protected from rain and snow even when stored in the shipping box.
The
The unit must be stored in a good enviroment and ambient air temperature
between -20°C [-4°F] and +50°C [122°F]. Dew and moisture condensation must
be avoided in the storage area.
The CARD G FIT and accessories must be in operation environments (+20°C
[68°F] to +50°C [122°F] and relative humidity up to 80% without condensation)
for a period of 3 hours before it can be set in operation.
CARD G / FIT 7 V 6.15 E / April 2010
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NAME PLATE
5. NAME PLATE
The name plate of the CARD G FIT is mounted on the back side of the unit and it contains
important operation data. The example below shows the name plate of a CARD 3G FIT.
The name plate contains the following information:
Unit type
Serial number
Year of manufacture
Operating voltage and frequency
Maximum electrical power consumption
Manufacturer and manufacturer’s address
It is very important to read the electrical power data on the name plate and
insure it matches the connected power supply before operating the
CARD G FIT.
The owner/operator is to contact before operating the unit in case
of unreadable data on the name plate to obtain this important data.
will also send a replacement name plate to the owner/operator.
THE OWNER/OPERATOR IS RESPONSIBLE FOR MAINTAINING A READABLE
NAME PLATE ON THE UNIT AT ALL TIMES.
CARD G / FIT 8 V 6.15 E / April 2010
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HOW IT WORKS
6. HOW IT WORKS
CARD G / FIT 9 V 6.15 E / April 2010
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HOW IT WORKS
The compact midget dryers of the CARD G (Compressed Air Resin Drier Giant) series consist of
an insulated stainless steel drying hopper surrounded by a stainless steel housing. The
CARD G FIT unit is able to control a Venturi- or Vacuum loader for loading.
The main electrical power is to be connected to the CARD G FIT unit through the included power
cord which is to be plugged in to the customers own electrical supply (1N~230V/50Hz or
2~220V/60Hz). Compressed air is to be supplied through the hose connector (1.1) on the back of
the unit.
The CARD G FIT is switched on through the main switch on the back. The display of the FITcontroller (5.2) will illuminate when power is available.
As soon as the drying process is started, the solenoid valve (1.2) releases dry compressed air
(with a maximum pressure dew point of 5°C [41°F] at 7bars [102PSI] and maximum oil content of
3mg/m³ [3ppm]) to flow into the dryer. The pressure of the air is reduced by the pressure
regulator (1.4). The air passes at almost atmospheric pressure through the process heater (1.7)
and is warmed up to the required drying temperature. The temperature sensor (1.8) reports the
actual process air temperature to the FIT-Controller to maintain the desired temperature at high
accuracy. The hot dry air gets into the hopper through the air distributer (1.10), dehumidifies the
resin on its way to the top and exhausts through the air outlet filter (6.5) to the ambient.
A preset pressure switch (1.3) will send an alarm if compressed air is missed or the air pressure
is too low. A temperature limiter (1.9) alarms in case of excess temperature in the process
heater. In both cases, the FIT shuts down the process heater to protect of thermal overload.
The FIT-controller is also capable to control an optional material loader to load resin into the
dryer. A one- or two-components venturi type (4.7) or self contained vacuum loader can be used.
Electrical power for a vacuum loading unit must be supplied from an external source. Standard
provisions to connect control signals for a proximity switch or flap (3.2) as well as for a solenoid
valve or motor blower (3.3) and a compressed air coupling (1.13) are provided on the back of the
dryer housing.
The CARD G FIT series is equipped with a strobe light (5.3) and an optional dry contact (4.6) for
external alarm devices to alarm the operator in case of a malfunction.
A sight glass (6.7) in the upper part of the unit indicates the resin level in the drying hopper.
CARD G FIT units are equipped with a SUB-D-interface (3.10) to connect to the production
machine, thus allowing the production machine to control the dryer and to collect data and fault
messages of the drying process.
The CARD G FIT can be integrated to a local or public network through an optional Ethernet-jack
(4.6) on the back of the unit. This offers the possibility to monitor and record process data and to
control the drying process over the World Wide Web.
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TECHNICAL DATA
7. TECHNICAL DATA
CARD 1G FIT
HOPPER VOLUME [l / US gal]
1 / 0.3
MAX. POWER CONSUMPTION [W] 200
OPERATING VOLTAGE [V]
1N~230 / 2~220V
OPERATING FREQUENCY [Hz] 50 / 60
EXTERNAL FUSE [A]
ELECTRICAL CONNECTION CROSS SECTION [mm² / AWG]
COMPRESSED AIR CONNECTION [mm / inch]
COMPRESSED AIR CONSUMPTION [Nm³/h / cfm]
COMPRESSED AIR PRESSURE [bar / PSI]
MAX. DEWPOINT OF COMPRESSED AIR AT 7 BAR (102PSI) [°C / °F]
MAX. RESIDUAL OIL CONTENT [mg/m³ / ppm]
ADMISSIBLE AMBIENT TEMPERATURE [°C / °F]
10
1.0 / 18
8 / 0.315
1.0 / 0.6 1
6 ... 10 / 87 ... 145
5 / 41
+20 ... +70 / +68 ... +158
3 / 3
ADMISSIBLE AMBIENT HUMIDITY [%] 80 (no condensation!)
HEIGHT H [mm / inch]
WIDTH W [mm / inch]
DEPTH D [mm / inch]
WEIGHT [kg / lb]
1
Constant compressed air consumption
CARD 1G FIT E-Box
310 / 12.2 280 / 11.0
200 / 7.9 152 / 6.0
138 / 5.4 133 / 5.2
4 / 8.8 4 / 8.8
CARD G / FIT 11 V 6.15 E / April 2010
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TECHNICAL DATA
CARD 3G FIT CARD 6G FIT
HOPPER VOLUME [l / US gal]
MAX. POWER CONSUMPTION [W] 200W
OPERATING VOLTAGE [V]
OPERATING FREQUENCY [Hz]
EXTERNAL FUSE [A]
CONNECTION CROSS SECTION [mm² / AWG]
COMPRESSED AIR CONNECTION [mm / inch]
COMPRESSED AIR CONSUMPTION [Nm³/h / cfm]
COMPRESSED AIR PRESSURE [bar / PSI]
MAX. DEWPOINT OF COMPRESSED AIR AT 7 BAR (102PSI) [°C / °F]
MAX. RESIDUAL OIL CONTENT [mg/m³ / ppm]
ADMISSIBLE AMBIENT TEMPERATURE [°C / °F]
ADMISSIBLE AMBIENT HUMIDITY [%]
HEIGHT H [mm / inch]
WIDTH W [mm / inch]
DEPTH D [mm / inch]
WEIGHT [kg / lb]
1
Constant compressed air consumption
410 / 16.1 498 / 19.6
285 / 11.2 310 / 12.2
205 / 8.1 230 / 9.1
9 / 19.8 11 / 24.3
3 / 0.8 6 / 1.6
1N~230 / 2~220
50 / 60
10
1.0 / 18
8 / 0.315
2.0 / 1.2 1 3,0 / 1.8 1
6 ... 10 / 87 ... 145
5 / 41
3 / 3
+20 ... +70 / +68 ... +158
80 (no condensation!)
CARD G / FIT 12 V 6.15 E / April 2010
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SET UP AND INSTALLATION
8. SET UP AND INSTALLATION
CARD G FIT units are designed for direct installation on
the extruder of the production machine.
Make sure that the CARD G FIT unit is absolutly vertical to insure proper
material flow through the hopper.
Avoid direct heat radiation and hot air being blown towards the switch
cabinet of the CARD G FIT unit.
To install the CARD G FIT on an extruder, a flange needs to be mounted on the base plate of the
unit. This flange can then be slid on the steel base plate on the extruder. Locking the release
handle fastens the CARD G FIT on the extruder’s base plate. Opening the shut-off slide releases
the dried material to drop into the extruder.
8.1 COMPRESSED AIR HANDLING AND SUPPLY
Compressed air quality has a great influence on the drying
results. Proper industrial compressed air handling and installation is therefore requested to
guarantee proper function and good drying results. No special air quality is required. Standard
industrial compressed air quality is required:
Pressure dew point of 5°C [41°F] at 7bar [102PSI]
Residual oil content of 3mg/m³ [3ppm]
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SET UP AND INSTALLATION
Compressed air must be dried with a refrigeration dryer to the lowest possible dew point and
filtered at the highest possible pressure available right after the air compressor or the receiver
tank in the plant room.
The compressed air pressure at the compressed air inlet on the CARD G FIT
must not fall below 6bar [87PSI] at any time.
All compressed air supply lines to the CARD G FIT must be dimensioned to the
same size (or bigger) of the provided compressed air hose delivered with the
CARD G FIT unit to guarantee proper operation.
The main compressed air pipe is to be installed vertically and
upwards from the top of the receiver tank to the highest possible
level in the plant. The horizontal lines should be installed with a slight
slope downwards from the top of the main vertical pipe at 1-2° with a
condensate receiver at the lowest point of the horizontal line.
Branches should be attached on top of the horizontal line. The
compressed air temperature should never be lower at the end of the
line than it is at the receiver tank in the plant room or in between to
avoid condensation inside the compressed air pipe work.
It is strongly recommended to install a refrigeration dryer on the branch from the main
compressed air main pipe work to the CARD G FIT, if condensation is likely in the main lines or in
the branch to the dryer. The capacity of the dryer should match or exceed the maximum air flow
requirement of all units supplied from the line.
It is always recommended to install a liquid separator and an air filter on the
branch to the CARD G FIT.
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FIRST START-UP
9. FIRST START-UP
Hint:
Following numbers refer to the operating principle in chapter 6 on page 9.
9.1 COMPRESSED AIR AND ELECTRICAL CONNECTIONS
The power supply 1N~230V/50Hz or 2~220V/60Hz to the CARD G FIT is
to establish with the power cable delivered with the unit. The tables in chapter 7 / page 11 are
helpful to size the external fuses for the main power supply.
Compressed air is to be supplied by the customer and delivered to the hose connector (1.1) on
the CARD G FIT through the included compressed air hose.
ATTENTION!
A grounding wire (PE) is included in the power cable. A locally tested
grounding system is crucial for safe operation of the CARD G FIT.
The compressed air must be dehumidified and filtered. It must not
exceed a maximum pressure dew point of 5°C [41°C] at 7bar [102PSI]
and a residual oil content of 3mg/m³ [3ppm] to ensure a safe operation
and proper drying results!
The inner diameter of all compressed air lines leading to the CARD G
FIT must not be smaller than the inner diameter of the delivered
compressed air hose.
At all times, the air pressure at the compressed air inlet on the
CARD G FIT must be within minimum 6bar [87psi] and maximum 10bar
[145PSI].
Malfunctions during operation of venturi type loaders may occur if upper points are ignored. For
safe operation, it is important to ensure sufficient compressed air supply with minimum 6bar
[87PSI] according to the values for the compressed air consumption in chapter 7 on page 11 at
any time.
An external dry contact may be connected to pin 2 and 3 at the 4-poles plug (3.2) on the plug
panel to lower the drying temperature (SLEEP-Mode). The voltage to the external contact is
supplied by the CARD G FIT (24V DC – see wiring diagram in the annex).
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FIRST START-UP
A USB memory stick may be attached to the FIT-controller to record operating data. The operator
is allowed to select different kinds of process data which are to be saved.
In case of power failures, data on the USB storage device might get
corrupted. It is highly recommended to save the data regularly to an external
storage medium.
9.2 EXHAUST AIR FILTER
Due to transportation, the exhaust air filter (6.5) is mounted on the inside of the lid. At the first
start up, it must be changed to the outside of the lid.
9.3 LOADING AND UNLOADING
The FIT-controller of the CARD G FIT is programmed to control one loader to automatically load
material into the drying hopper. A venturi type loader (one- or two-components) may be bolted to
the lid of the dryer and connected to the provisions provided on the back of the CARD G FIT. The
electrical power (24V DC) for the solenoid valve of a venturi loader can be plugged to the
connection (3.3). The proximity switch of the venturi loader can be plugged to the connection
(3.2). Compressed air to operate the venturi loader may be taken from the outlet (1.13).
CARD G / FIT 16 V 6.15 E / April 2010
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FIRST START-UP
To use a vacuum loader to load the dryer is also possible. The flapper gate signal can be plugged
to the connection (3.2). The electrical power for the solenoid valve to clean the loader (24V DC)
and the electrical power for the motor contactor (24V DC) may be plugged to the connection (3.3).
The compressed air required for cleaning the filter of the vacuum loader may be supplied through
the outlet (1.13). The electrical power needed to operate the vacuum loader must be supplied
from an external source. An air outlet filter must necessarily be mounted on the vacuum loader.
ATTENTION!
The maximum allowable weight of the loading device must not exceed
9kg [20lb] (Danger of Tilting!).
The dried material inside the CARD G FIT is unloaded by gravity feed. Moving the drier on the
steel base plate of the extruder releases or stops the material flow (additionally to the slide).
Locking the release handle fastens the CARD G FIT in the appropriate position.
9.4 EXTERNAL SLEEP-SIGNAL
The SLEEP MODE is a very important
function programmed in the FIT-controller. The set drying temperature will be lowered to avoid
material degradation if material is not withdrawn from the drying hopper for a certain time.
Unless a loading unit is connected to the CARD G FIT, a dry contact (24V DC) can be provided
through pin 2 and 3 on the plug for the proximity switch or flap (3.2) on the back to allow an
external signal activating and deactivating the S
wiring diagram at the end of this manual for further information).
LEEP MODE (see chapter 17.4 on page 50 and the
9.5 INSTALLATION OF EXTERNAL ALARM DEVICES
Standard CARD G FIT units are equipped with a strobe light to
alarm the operator in case of malfunction. They can also be equipped with an optional dry
contact (4.6) at the plug panel. If the unit is powered on, the drying process is switched on and
there has not been an alarm for an adjustable time period, the contact will supply high signal.
This is useful in case that the dryer is not installed close to or in sight of the operator.
Dry two-way contact
Max. operating voltage: 24V DC
Max. operating current: 5A / AC1
CARD G / FIT 17 V 6.15 E / April 2010
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FIRST START-UP
9.6 DATA COMMUNICATION
The SUB-D plug (3.10) on the plug panel can be used for different kinds of communication with
external devices and with the production machine.
9.7 FIRST START UP
Only qualified personnel are permitted to deal with CARD G FIT units.
It is strongly recommended to read this manual before attempting to start up
the CARD G FIT unit.
It is strongly recommended to check proper set up and installation of the unit
and all components is completed before attempting to start up the CARD G FIT
unit.
It is important to double check that the electrical power supply matches the
data on the name plate of the unit and that the main compressed air supply to
the CARD G FIT unit matches the required specification.
Contact and/or its representative for any question regarding the
set up and the installation before start up.
The CARD G FIT unit may be started up by qualified personnel after insuring following points:
Make sure that the first set up and the installation are properly done.
Make sure that all mechanical accessories (flange, loading unit …) are mounted
properly and securely.
Make sure that the exhaust air filter is mounted on the outside of the lid of the unit
(or on the loading unit).
Make sure that all electrical connections to the loading device are established (if
controlled by the CARD G FIT).
Make sure that the compressed air connections to the loading device (if used) are
established.
Make sure that the power supply cord is attached to the unit and the electrical
power supply matches the data on the name plate.
Make sure that the main compressed air supply is connected and released.
CARD G / FIT 18 V 6.15 E / April 2010
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FIRST START-UP
9.8 ADDITIONAL CHECK POINTS AT FIRST START UP
The EXTENDED MODE must be activated on the FIT (see chapter 15 /
page 37). If alarms exist, the FAULT SCREEN will appear and the
strobe light will be activated.
Pressing at the same time deactivates the strobe
light. The MAIN SCREEN appears as soon as all faults are
eliminated.
Make sure that the desired unit (°F or °C) is displayed in the
upper part of the screen (SET, ACT). The temperature is
displayed with the letter C (for degrees Centigrade) or F (for
degrees Fahrenheit). The temperatures displayed should be around the ambient air
temperature or slightly lower. Refer to chapter 17.10.3 on page 72 to change the units
from metric to imperial or vice versa. OFF is shown for 8 seconds in turn with the set
value for 2 seconds in the green area and indicates that the dryer is not in operation.
Press to change to the menu with the
DRYING PARAMETERS. Input the drying
temperature by pressing once more.
Use the numeric keys to input the desired
temperature (80 to 120°C) [176 to 248°F].
ATTENTION: If the hopper has already been
filled with resin, the temperature must not be
set higher than to the maximum permitted
drying temperature of the resin.
Press to accept the new value. Press to return to the MAIN SCREEN. The
new set value is shown in the green area at the upper side (SET).
Now the drying process may be activated with .
The process air starts flowing and the actual process air temperature (ACT) starts
rising fast towards the set temperature. It slows down as it approaches the set
temperature and finally stays at the set temperature.
Switch the dryer off by simultaneously pressing .
CARD G / FIT 19 V 6.15 E / April 2010
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FIRST START-UP
The process air heater is now switched off but the process air continues flowing
until the actual process air temperature reaches 40°C [104°F].
After the heater has been cooled down (message disappears),
the dryer can be switched off through the main power switch.
To switch off the CARD G FIT always use the keys . Never use the
main power switch to switch off the CARD G FIT unless in emergency. The main
power switch will switch off the process air soon as it is turned into the OFF
position and the heater will not be safely cooled down.
The FIT-controller will alarm the operator in case of a faulty function through the strobe light.
Alarms will also be indicated through external alarm devices if connected to the optional dry
contact on the CARD G FIT. The actual screen will jump into the FAULTS SCREEN indicating the
faults one after the other as they have taken place.
See chapter 17.7.3 on page 62 to adjust date and time, if necessary.
Turn the main power switch to the OFF position if the dryer is not going to be used for a longer
period of time. You may, otherwise, continue the start up of accessories or start normal operation
if satisfied with the previous CARD G FIT start up procedures.
Contact and/or its representative for any question regarding the start up and the
normal operation if you feel unsure before you resume normal operation.
The function of the hopper loader may be adjusted and tested if it is installed and connected to
the CARD G FIT. It is strongly recommended to double check the installation of the hopper loader
before attempting to start up this device. Make sure that the proper electrical power and
compressed air are connected to the device before start up.
Make sure that the wand of the hopper loader is properly inserted in the material
supply container and that sufficient amount of the test material is available in the
container.
See chapter 17.5 on page 53 to set the desired loader parameters. Airjet (AJ) is the
commercial name of venturi type loaders. Parameters for vacuum loaders (HL) are
also included in this chapter.
To start the hopper loader press the keys .
CARD G / FIT 20 V 6.15 E / April 2010
Page 23
FIRST START-UP
To stop the hopper loader, press again.
Note: The FIT-controller contains a weekly timer to start loading material before the drying
process starts. The drying process has the same or its own weekly timer which automatically
starts the drying process.
Turn the main power switch to the OFF position if the dryer is not going to be used for a longer
period of time.
Contact and/or its representative for any question regarding the start up and the
normal operation if you feel unsure before you resume normal operation.
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Page 24
SWITCHING OFF
10. SWITCHING OFF
The following instructions are to be followed whenever the CARD G FIT unit is to be switched
off:
NEVER USE THE MAIN POWER SWITCH TO SWITCH OFF THE DRYER UNLESS
IN EMERGENCY.
To stop the hopper loader, press the keys (if connected to the
CARD G FIT).
To stop the drying process, press the keys simultaneously. The FIT-
controller will switch the heater off but it will continue the compressed air flow to
cool down the process air heater. The main power switch is to be kept in the ON
position until the cooling procedure is finished. Moving the main power switch to the
OFF position will also stop the hopper loader if connected to the CARD G FIT.
The main power switch is to be kept in ON position if the loader needs to be
kept in operation or if the dryer and/or loader are set up to automatically start
with the programmable weekly timer.
The following instructions are to be followed additionally whenever the CARD G FIT unit is to be
switched off for a longer time period:
Disconnect electrical power supply.
Close and disconnect compressed air line.
Disconnect electrical lines to the loader device.
Disconnect the compressed air line to the loader device.
Remove the loader device from the CARD G FIT.
Remove mechanical accessories (flange etc.) from the CARD G FIT.
Disconnect electrical lines to external devices (external alarm contact, …).
Clean the drying hopper on the inside.
Use the original packing to store the CARD G FIT at a protected place.
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Page 25
OPERATION BASICS
11. OPERATION BASICS
It is strongly recommended to read this
manual before operating the CARD G FIT unit. The information provided in this manual is very
helpful and may help preventing damages and injuries.
Only qualified personnel are permitted to set up, install, operate or perform maintenance on
CARD G FIT units. Contact or its representative if you are unsure or have any
question before operating the unit and accessories delivered with it.
ATTENTION!
The switch cabinet panel and all other housing parts of the CARD G FIT must
remain attached to the unit and secured at all times. Only qualified personnel
are permitted to open the switch cabinet with the main power switch in OFF
position.
The CARD G FIT is powered on and off through the main switch on the back of the unit. The
display of the FIT-controller illuminates when power is on.
Check the resin type in the drying hopper and the recommended drying
temperature before starting any drying process and before making any changes
to the drying temperature. Check the actual unit setting (°C or °F) before setting
or changing the drying temperature.
DO NOT CHANGE operational, function, control or alarm parameters without
knowing the consequence resulting from the parameter change. Read this
manual before changing any parameters and contact or its
representative if you are unsure or have any questions. Changing parameters
has a great influence on the unit’s performance and may cause injuries or
damage to the equipment.
The drying process is to be stopped by pressing the keys , allowing
enough time for heater cooling and the shut down process before moving the
main power switch into OFF position.
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Page 26
MENU STRUCTURE
12. MENU STRUCTURE
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Page 27
MENU STRUCTURE
12.1 EASY MODE
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Page 28
MENU STRUCTURE
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Page 29
MENU STRUCTURE
12.2 EXTENDED MODE
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Page 30
MENU STRUCTURE
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Page 31
MENU STRUCTURE
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Page 32
MENU STRUCTURE
12.3 SYSTEM PARAMETERS
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Page 33
MENU STRUCTURE
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Page 34
DATA INPUT
13. DATA INPUT
The method of data input has been changed compared to the previous version of the FIT-
controller. The EDITOR SCREEN must be retrieved first, and then the required value entered and
confirmed to change a parameter.
Using the key clears wrongly entered values in the EDITOR SCREEN.
The lower part of the EDITOR SCREEN informs about the permitted range of values being entered by
the operator. If a wrong value is entered, the operator will be pointed out by a red blinking
maximum or minimum value.
The wrong value must be cleared with the key before a new value can be entered.
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Page 35
DATA INPUT
Numbers with decimals must be entered without decimal point in the EDITOR SCREEN. For example,
if the value 5.0 is required, the number 50 must be put in.
Non-numeric values are altered with the key .
In certain menus, parameters are released or hidden depending on the setting of the nonnumeric value.
The key or needs to be pressed to move the cursor to the next or previous position.
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Page 36
DATA INPUT
The former screen can be accessed by pressing the key . Using this key several times
always leads the operator from any screen back to the MAIN SCREEN.
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Page 37
NAVIGATION
14. NAVIGATION
The display of the FIT-controller implies key symbols which help to guide through the different
screens. Sub menus are basically accessed through the numeric keys, some other screens
through the arrow keys. The menu for parameter input is selected from the MAIN SCREEN with the
key .
Some screens include multiple pages which can be accessed through the arrow keys.
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Page 38
NAVIGATION
It is recommended to try the appropriate keys shown in the display to explore
the possibilities of the FIT-controller.
The START SCREEN appears every time the CARD G FIT unit is powered on. It can also be attained
from the MAIN SCREEN by pressing the keys simultaneously for 5 seconds.
In this case, the MAIN SCREEN is not automatically loaded again until the desired operating mode
is selected from the operator.
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Page 39
START SCREEN AND LANGUAGE SELECTION
15. START SCREEN AND LANGUAGE SELECTION
The START SCREEN appears on the FIT-controller every time the CARD G FIT unit is
powered on. If there is not made any selection by the operator, this screen remains displayed for
8 seconds before the MAIN SCREEN or the FAULTS SCREEN (in case of an alarm) is loaded
automatically.
Pressing the key activates the EASY MODE which allows the operator to enter only set point
for the drying temperature and suction time for a vacuum loading device (if connected to the
CARD G FIT – see chapter 16 on page 39).
Pressing the key activates the EXTENDED MODE which allows the operator to edit all
parameters in the FIT-controller (see chapter 17 on page 40).
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Page 40
START SCREEN AND LANGUAGE SELECTION
The LANGUAGE MENU appears when the key is pressed. The desired language can be
selected through the key assigned to the appropriate language.
The display returns to the START SCREEN after a choice has been made. The MAIN SCREEN is not
loaded automatically until the desired operating mode is selected from the operator
The START SCREEN can be activated from the MAIN SCREEN at any time through the keys
being pressed simultaneously for 5 seconds (see chapter 14 on page 35).
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Page 41
EASY MODE
16. EASY MODE
The EASY MODE supplies
less information in the MAIN SCREEN and allows the operator only to set the most important
parameters.
Only the set point of the drying temperature as well as the suction time for a vacuum loading
device – provided that connected to the CARD G FIT – may be altered in the EASY MODE. The
suction time for loading will only be displayed if device HL (Hopper Loader) is chosen in the menu
for the CONVEYING PARAMETERS which can only be accessed in the EXTENDED MODE operation.
The data screens as well as FAULTS SCREEN and STATUS REPORT are available both in EASY MODE
XTENDED MODE operation. A detailed description of these screens can be found in chapter 17
and E
on page 40.
CARD G / FIT 39 V 6.15 E / April 2010
Page 42
EXTENDED MODE
17. EXTENDED MODE
In the EXTENDED MODE, all parameters can be accessed by the operator.
17.1 MAIN SCREEN AND OPERATION
The MAIN SCREEN offers two pages with different information in the middle part of the display
which can be switched with the keys and .
The set value of the drying temperature (SET) and the actual value of the process air temperature
(ACT) are displayed at the top of the screen. OFF is displayed for 8 seconds in turn with the set
value for 2 seconds when the dryer is switched off.
The screen in the upper middle part notifies how to operate the unit and to input parameters. The
keys used to operate the unit can always be applied independent of the screen currently shown.
The key used to input set value and other parameters can only be applied in the MAIN SCREEN.
CARD G / FIT 40 V 6.15 E / April 2010
Page 43
EXTENDED MODE
A green light on the left hand side indicates that the named process is switched on. When the
process is switched off, the light will become white.
In general, following keys are to be used to operate the CARD G FIT unit:
Starts and stops the drying process.
(The loading process must once be switched on to get automatically
activated and deactivated with the drying process).
Starts and stops the loading process.
Activates and deactivates the SLEEP-MODE manually.
After the drying process has been switched off, the message „COOL DOWN“ flashes until the
heater is cooled down properly.
The CARD G FIT is allowed to get switched off by the man power switch only
after the cool down period has expired or in case of an emergency.
Drying temperature is traced to a graphic chart in the lower part of the display. It illustrates the
drying process over a certain period of time and helps the operator to quickly detect and react in
case of an insufficient drying process.
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Page 44
EXTENDED MODE
250 values may be recorded as a maximum until the oldest value is overwritten. The sample rate
is factory-set to 30 seconds which results in a drying characteristic over 125 minutes. The sample
rate may be changed by the operator (see chapter 17.10.3 on page 72). The data of the drying
process are additionally recorded in the FIT-controller which can be accessed at any time (see
chapter 17.3 on page 48).
The lowest part of the display is shown in all screens and informs about current date and time
and about the CARD G FIT type detected by the FIT-controller.
The CARD G FIT type is automatically detected by the FIT-controller. In case of
a faulty identification, the correct type needs to be adjusted manually (see
chapter 17.10.3 on page 72).
Drying process data are displayed in the lower middle part of the screen. Values of SLEEP- and
RAMP-MODE will only be visible, if the appropriate mode is released in the menu DRYING
PARAMETERS (see chapter 17.4 on page 50). The dewpoint temperature will only be shown if an
optional dew point meter is mounted in the CARD G FIT and the dew point measurement is
activated in the SYSTEM PARAMETERS.
Recipes from the integrated database of the FIT-controller can be loaded from the operator
(menu RECIPES) to define the drying program. The name of the recipe is thereby shown in the top
line. The hint NO RECIPE will appear if no recipe is chosen from the database in the FIT-controller,
or the data of a loaded recipe has been altered in the menu DRYING PARAMETERS.
Once the process air temperature has been reached the set point within the alarm limits after
activating the drying process, the expiring timer is indicated by a red flashing line. Depending on
the active timer, the set value in the middle part of the upper display appears in a different color.
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Page 45
EXTENDED MODE
The SLEEP-MODE set value (SL-SET) is loaded when the SLEEP-TIME has expired. The line with the
SLEEP-MODE data stops flashing and lights permanently red.
According to upper illustrations following drying program would be executed:
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Page 46
EXTENDED MODE
The second page of the MAIN SCREEN provides information about compressed air and energy
consumption of the current drying process.
Data like total and current power consumption, total and current compressed air consumption in
the process circuit and the total drying time are shown in this area.
CARD G / FIT 44 V 6.15 E / April 2010
Page 47
accessed from the MAIN SCREEN with the key .
EXTENDED MODE
17.2 ENERGY AND DATA SCREENS
17.2.1 ENERGY SCREEN
The ENERGY SCREEN is
The energy consumption of the process heater and the compressed air consumption of the
CARD G FIT are shown in this screen over a specified period.
The field “TOTAL CONSUMPTION” displays the energy data of the dryer since the first start-up.
The field “DRYING CONSUMPTION” represents the energy data of the current drying process.
The values are reset to 0 when a new drying process will be started.
The field “USER CONTROLLED” shows the energy data over a period of time determined by the
operator using the keys .
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Page 48
EXTENDED MODE
17.2.2 INPUT STATUS SCREEN
The INPUT STATUS SCREEN is attained from the ENERGY SCREEN with the key .
This screen is helpful for troubleshooting in case of alarms at the CARD G FIT. It shows the status
of the digital inputs connected to the FIT-controller.
Value 1 means the appropriate input is ON, value 0 means the input is OFF.
The actual and the maximum temperature inside the FIT-controller are also displayed.
CARD G / FIT 46 V 6.15 E / April 2010
Page 49
from the INPUT STATUS SCREEN with the key .
EXTENDED MODE
17.2.3 OUTPUT STATUS SCREEN
The OUTPUT STATUS SCREEN is attained
This screen is helpful for troubleshooting in case of alarms at the CARD G FIT. It shows the status
of the digital outputs connected to the FIT-controller.
Value 1 means the appropriate output is switched ON, value 0 means the appropriate output is
switched OFF.
Pressing the key returns the operator to the MAIN SCREEN
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Page 50
EXTENDED MODE
17.3 PROCESS DATA SCREEN
Pressing the key in the MAIN SCREEN activates the PROCESS DATA SCREEN.
Two levels with data are available which can be switched with the ARROW LEFT and ARROW RIGHT
keys.
Important process data are continuously recorded into 250 data sets on 10 pages. They can be
accessed with the keys and . The page number appears at the right-hand side in the
lower part of the display.
If more than 250 data sets recorded, each new data set will replace the oldest one.
The temperature characteristics displayed in the MAIN SCREEN refer to the data saved herein.
Further important process data are additionally saved.
CARD G / FIT 48 V 6.15 E / April 2010
Page 51
EXTENDED MODE
The shortcuts in the header of the columns have following meanings and refer to the time shown
in the respective line in the left column:
ST Set point of drying temperature
AT
DP
[W]
[kWh]
[Nm³/h]
[Nm³]
Temperature in the process circuit
Dew point (if optional dew point meter is installed)
Power consumption of process heater
Total power consumption since drying has been activated
Compressed air consumption
Total compressed air consumption since drying has been started
Date and time are written as “08. / 15:31”. The first value shows the day of the current month, the
other two values describe the time of recording.
The key can be used at any time to return from the PROCESS DATA SCREEN back to the MAIN
SCREEN.
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Page 52
EXTENDED MODE
17.4 DRYING PARAMETERS
The DRYING PARAMETERS are accessed from the MAIN SCREEN with the key . Important data to
define the drying process can be entered in this screen. This and all following input screens are
only available in EXTENDED MODE operation.
All further input screens can be attained from the screen with the DRYING PARAMETERS by using
the keys described in the lower part of the display.
Following parameters can be set in this menu:
SET Temperature
The material is dried with this temperature.
If desired, the allowed minimum and the maximum input value being entered can be changed in the
menu with the R
EGULATING PARAMETERS (see SYSTEMS MANUAL CARD G FIT).
FACTORY SETTING: 60°C [140°F]
CDOWN Timer
When the drying hopper is filled the first time, the material must be pre-dried for a certain time. The
CDOWN (Countdown) T
The timer is to be set to the recommended drying time specified by the material supplier. As soon as the
drying process is activated and the temperature in the process circuit is reached within the alarm limits,
the CDOWN timer starts to expire. Once the CDOWN timer has elapsed, the dried material can be
supplied to the production process.
The time is to be set to 0h 0m if the CDOWN T
IMER informs the operator as soon as dried material can be removed.
IMER is not required.
FACTORY SETTING: 0h 0m
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Page 53
EXTENDED MODE
Hint:
There is an output on the FIT-controller which supplies 24V DC as soon as
CDOWN timer and RAMP timer (if activated) are expired. If both timers are set
to 0h 0m, the output will supply 24V DC immediately after the drying process
has been started.
If a retrofit is desired, contact or its local representative for
further instructions.
SLEEP Temperature
FACTORY SETTING: 50°C [122°F]
The SLEEP MODE protects the resin in the CARD G FIT against degradation. As soon as the SLEEP TIMER
has expired (see next parameter) or the keys have been pressed, the drying temperature is
lowered to the SLEEP T
This value must never be higher than the value SET
EMPERATURE.
TEMPERATURE. If so, it is automatically corrected by
the FIT-controller.
SLEEP Timer
The SLEEP TIMER is released from a loading unit or from an external signal connected to the
CARD G FIT unit. The timer will be reset to its initial value if the signal is revoked.
The air temperature will be lowered to the SLEEP
SLEEP
TIMER has expired. The SET TEMPERATURE is loaded as soon as the SLEEP SIGNAL is released again.
The time is to be set to 0h 0m if the SLEEP
MODE is not desired.
TEMPERATURE (see previous parameter) after the
FACTORY SETTING: 0h 0m
Pressing at the same time allows the operator to activate or
deactivate the SLEEP
MODE immediately provided that the drying process is
switched on.
If a loading device is not used to fill the drying hopper, the SLEEP TIMER can be
controlled by an external signal which needs to be connected to the plug (3.2)
on the CARD G FIT.
RAMP Temperature
If the RAMP TIMER (see next parameter) is activated, the resin will first be heated up to this temperature
after the drying process has been started.
This value is set as a difference to the SET T
automatically corrected by the FIT-controller.
CARD G / FIT 51 V 6.15 E / April 2010
EMPERATURE. It must never be higher than that one. If so, it is
FACTORY SETTING: -30°C [-54°F]
Page 54
EXTENDED MODE
RAMP Timer
Starting the drying process heats the material in the CARD G FIT up to RAMP TEMPERATURE (see
previous parameter) for the time set in this parameter.
The RAMP M
getting stuck together.
The time is to be set to 0h 0m if the RAMP
ODE is used to achieve a soft heating-up process of certain materials to avoid the resin
MODE is not desired.
FACTORY SETTING: 0h 0m
Further information about the different set temperatures and timers can be
found in chapter 17.1 on page 40).
The key can be used at any time to return from this screen back to the MAIN SCREEN.
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Page 55
EXTENDED MODE
17.5 CONVEYING PARAMETERS
The CONVEYING PARAMETERS are
accessed from the screen with the DRYING PARAMETERS with the key .
This chapter refers to parameters for a hopper loader of both types (venturi and vacuum loaders)
as well as standard and blending unit. The hopper loader equipment must be connected to the
CARD G FIT unit to allow its operation through the FIT-controller. Furthermore, the control of a
pneumatic slide can be activated herein.
LOADING
The values AJ, HL, AJX, HLX or SLD can be selected in this parameter.
Choose AJ for venturi type loaders to convey from one material bin, AJX for venturi type loaders to
convey and mix two different materials, HL for vacuum type loaders to convey from one material bin and
HLX for vacuum type loaders to convey and mix two different materials. FIT will control the loading
equipment if they are connected to the appropriate plugs on the CARD G FIT unit.
If SLD is selected, a pneumatic slide to unload the drying hopper is opened for a certain time (can be
adjusted by the operator) as soon as a signal from a proximity switch or similar device is detected.
Related parameters become uncovered or hidden depending on the selection.
FACTORY SETTING: AJ
SUCTION TIME
FACTORY SETTING: 8.0s
This timer controls the suction time of a vacuum loader.
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Page 56
EXTENDED MODE
ATTEMPTS
The FIT-controller alarms the operator and prompts LOADING ALARM if a vacuum hopper loader fails to
fill the drying hopper after the number of attempts set in this parameter.
FACTORY SETTING: 2 x
CLEANING
Self contained vacuum loaders require filter cleaning before the suction process is started. Here the
operator can choose how many times the filter is cleaned.
FACTORY SETTING: 2 x
CHANNEL A
This parameter can be set if two materials are conveyed and mixed.
Material A is drawn for this time period. The suction time for vacuum loaders is automatically corrected
by the program (according time settings of CHANNEL A and CHANNEL B).
FACTORY SETTING: 5.0s
CHANNEL B
FACTORY SETTING: 3.0s
This parameter can be set if two materials are conveyed and mixed.
Material B is drawn for this time period. The suction time for vacuum loaders is automatically corrected
by the program (according time settings of CHANNEL A and CHANNEL B).
The key can be used at any time to return from this screen back to the screen with the
DRYING PARAMETERS.
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Page 57
EXTENDED MODE
17.6 RECIPES
17.6.1 STANDARD RECIPES
This screen includes a database
with preassigned drying data for the most common materials. They can be loaded into the drying
program. The user may decide to keep the preassigned data or alter the existing data. It is
recommended to use the CUSTOMER RECIPES (see chapter 17.6.2 on page 57) menu to program
custom recipes.
The STANDARD RECIPES are accessed from the screen with the DRYING PARAMETERS with the
key .
The STANDARD RECIPES database contains 30 preassigned recipes. To scroll through the various
records, the cursor must be moved to the parameter RECIPE-ID. Pressing the key
shows the next record.
The keys and can be used to decrease or increase the R
ECIPE-ID by 5.
To load a record into the drying program, the keys need to be pressed simultaneously.
The screen D
RYING PARAMETERS is opened and allows checking the loaded values once more. If
necessary, changes can be made again.
After pressing the key
the MAIN SCREEN appears.
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Page 58
EXTENDED MODE
The drying process is now executed according to the loaded recipe data.
Following keys must be used to change the name of the material:
Open the
Choose former character.
Choose next character.
Move cursor to character on the left-hand side.
Move cursor to character on the right-hand side.
Confirm the new recipe name.
EDITOR SCREEN.
The character which is currently adjusted by the operator is marked white. 12 characters can be
used for the name as a maximum.
The values for set temperatures and timers are entered through the numeric keypad on the FITcontroller.
The meaning of set temperatures and timers are explained in chapter 17.4 on page 50. The same
rules for the adjustment need to be considered.
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Page 59
EXTENDED MODE
17.6.2 CUSTOMER RECIPES
The CUSTOMER RECIPES are attained from the screen with the STANDARD RECIPES with the key .
Recipes specified by the customer can be programmed in this screen. The same rules as
described in chapter 17.6.1 STANDARD RECIPES on page 55 apply for changing and loading this
data.
The key can be used at any time to return from this screen back to the screen with the
DRYING PARAMETERS.
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Page 60
EXTENDED MODE
17.7 WEEKLY TIMER
17.7.1 WEEKLY TIMER GENERAL
The drying process can be activated and deactivated automatically by the weekly timer. The
TIMER MODE must be set to AUTO to activate the weekly timer.
The switching times become visible as soon as the weekly timer is activated. One ON-time and
one OFF-time can be set per day.
The GENERAL WEEKLY TIMER is accessed from the screen with the DRYING PARAMETERS with the
key .
To avoid an ON-switching or an OFF-switching action on a certain day the appropriate time must
be set to 0:00, or the ON- and OFF-time must be set to the same value.
According to upper illustration, the following weekly timer program would take place:
On Monday at 8:00 a.m. the drying is started, and on Wednesday at 5:00 p.m. it is stopped again.
There is no switching action on Tuesday because both times are set to 0:00, and there is no OFFswitching action on Monday because this value is also set to 0:00. The ON-time on Wednesday
shows 0:00 with no switching action, either.
The drying is activated again on Thursday at 9:30 a.m. and continues to work until 12:45 p.m. on
Saturday, because all prior switching times are set to 0:00.
On Sunday the drying remains deactivated, because ON- and OFF-time show the same value.
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Page 61
EXTENDED MODE
Pressing the key
for 3 seconds
initializes all switching times to 0:00 (as described in the lower part of the display).
Three weekly timer programs have been pre-set which can be retrieved by pressing the key ,
or for 1 second. A number in the upper display on the left-hand side indicates the
selected program.
No pre-set program is activated in case of a missing number.
Customized data can be programmed and saved into the FIT-controller using one of these three
keys. The respective program is overwritten in this case.
The green message SAVED will occur if a program is stored to the FIT.
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Page 62
EXTENDED MODE
The lower part of the display provides information which keys are to be used to load and save
different weekly timer programs.
Independent of the weekly timer, the drying process may always be stopped or
started with the keys . The weekly timer activates or deactivates the
drying process at the next valid switching time.
Loading can be started and stopped with the drying process through the
general weekly timer. The loading process must once be switched on with the
keys at activated drying process to get automatically activated and
deactivated with the drying process.
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Page 63
EXTENDED MODE
17.7.2 WEEKLY TIMER LOADING
The loading of the drying hopper can be
started and stopped through a discrete weekly timer.
The WEEKLY TIMER LOADING is accessed from the screen WEEKLY TIMER GENERAL with the
key .
The switching times become visible as soon as the weekly timer is activated. One ON-time and
one OFF-time can be set per day.
The same rules as described in chapter 17.7.1 WEEKLY TIMER GENERAL on page 58 apply for setting
the switching times.
Three weekly timer programs have been pre-set which can be enabled or reprogrammed by the
operator (see chapter 17.7.1 WEEKLY TIMER GENERAL on page 58 for detailed information).
Only the drying process will be controlled by the G
ENERAL WEEKLY TIMER if the
WEEKLY TIMER FOR LOADING is activated. It can be deactivated without affecting
the proper function of the W
EEKLY TIMER FOR LOADING.
Independent from which weekly timer and switching program is chosen, the
loading process can always be activated or deactivated by using the keys
at the same time. The weekly timer starts or stops the loading process
at the next valid switching time.
CARD G / FIT 61 V 6.15 E / April 2010
Page 64
EXTENDED MODE
17.7.3 DATE AND TIME
The menu to set DATE AND TIME is accessed from the screen WEEKLY TIMER GENERAL or WEEKLY
TIMER GENERAL LOADING with the key .
The accurate date and time are important to get correct information in the STATUS REPORT and in
the FAULTS SCREEN. Using automatic operation through the WEEKLY TIMERS also depends on the
correct settings for date and time in this screen.
Pressing simultaneously activates the setting procedure.
The time stops, and a blinking cursor appears. The EDITOR SCREEN needs to be used to enter the
numeric values. The weekday can be directly selected with the key.
To accept the new values the keys
need to be pressed at the same time.
The key is to be pressed to abandon this screen.
CARD G / FIT 62 V 6.15 E / April 2010
Page 65
EXTENDED MODE
17.8 FAULTS SCREEN
The FAULTS SCREEN is
automatically activated in case of an alarm on the CARD G FIT. It can also be attained from the
screen with the DRYING PARAMETERS with the key .
The type of error with date and time of appearance and elimination are shown in this screen. The
yellow number in the header informs how many faults currently exist.
Using the keys
and
allows the operator to scroll through the different pages.
As long as an existing alarm is not acknowledged, the strobe light and the F
AULTS SCREEN are
flashing.
CARD G / FIT 63 V 6.15 E / April 2010
Page 66
EXTENDED MODE
To acknowledge any fault message the keys
must be pressed at the same time – as described in the lower part of the display. The strobe light
and the FAULTS SCREEN stop flashing.
Once all alarms are eliminated and acknowledged, the MAIN SCREEN appears automatically.
For trouble shooting and fault diagnosis - see chapter 18 on page 75.
CARD G / FIT 64 V 6.15 E / April 2010
Page 67
EXTENDED MODE
17.9 STATUS REPORT
The STATUS REPORT is
accessed from the FAULTS SCREEN with the key and facilitates trouble shooting and fault
diagnosis.
This screen shows the last 200 alarm and event messages. If there are more than 200 entries, the
oldest one will be replaced.
Additional process data are saved with the fault (or event):
Drying set value
Process air temperature
Temperature on the board of the FIT-controller
Dew point (if a dew point sensor is mounted)
Operating status of loading
Heater control signal
Compressed air consumption
The number in the upper display on the right hand side shows how many entries are present. The
number on the left hand side shows the running position of the displayed record.
The keys and must be used to scroll through the different records.
Pressing the key for 3 seconds displays the last (oldest) record.
Pressing the key for 3 seconds displays the first (youngest) record.
CARD G / FIT 65 V 6.15 E / April 2010
Page 68
EXTENDED MODE
17.10 SYSTEM PARAMETERS
The SYSTEM PARAMETERS include data which need to be changed only in case of special
applications (for detailed information see SYSTEMS MANUAL CARD G FIT). The parameters can
be accessed after a password has been entered.
The PASSWORD SCREEN is attained from the screen with the DRYING PARAMETERS with the key .
To enter the password, the key must be pressed. A blinking field prompts the operator to
input the password using the numeric keypad. Pressing the key confirms the value.
The message below appears in case of wrong password.
Pressing the key allows the password to be entered once more. The procedure to input the
password can also be abandoned with the key . To return to the MAIN SCREEN the key
needs to be pressed.
CARD G / FIT 66 V 6.15 E / April 2010
Page 69
EXTENDED MODE
If the password is accepted, the screen CONVEYING MODE will be shown. The other screens can
be accessed through the numeric keys illustrated in the lower part of the display.
The key is to be pressed to abandon the SYSTEM PARAMETERS at any time.
CARD G / FIT 67 V 6.15 E / April 2010
Page 70
EXTENDED MODE
17.10.1 DATA TRANSFER
The parameters for DATA TRANSFER are attained from the screen CONVEYING MODE with the key
.
Process data of the CARD G FIT can be recorded through the serial port or through a USB-stick
plugged into the FIT-controller.
Data logging through the serial port is barely used anymore but still offered to keep the
compatibility to the former model of the FIT-controller. Detailed information can be found in the
SYSTEMS MANUAL CARD G FIT if this type of logging still wants to be used.
Data recording through a USB-stick is a simple and efficient way to document the drying
process. This method requires a USB-stick plugged into the FIT-controller inside of the
CARD G FIT.
A record is made every 300 seconds (5 minutes). This time can be changed by the operator but it
is recommended to retain this value, so that the amount of data is kept within an acceptable
range. A USB-stick with a memory size of 2 Gigabytes will be able to store process data up to 50
years using the pre-set time interval.
A new file with data is automatically created every day. The file name is build from the date of
recording. 288 data records will be written to such a file per day if the time interval is set to 300
seconds. This prevents a file becoming too big which simplifies the data evaluation and
minimizes the risk of data loss in case of a corrupted file.
Data are saved in a comma separated value (csv)-file and can easily be imported and analyzed in
various programs (e.g. Microsoft Excel, Lotus etc.).
Fault and event messages are saved in a text file.
Following parameters are available in this menu:
CARD G / FIT 68 V 6.15 E / April 2010
Page 71
EXTENDED MODE
Transfer RS232
FACTORY SETTING: OFF
The values OFF, DATA, FAULTS, TOTAL and STATUS can be selected in this parameter.
The setting defines which data are transferred to the serial port on the back of the CARD G FIT. The
particular meaning is explained in parameter T
RANSFER USB.
Cycle RS232
The value set in this parameter determines the time interval of data transfer through the serial port (only
valid if DATA or TOTAL is selected in parameter T
The factory setting enables data transfer every 300 seconds.
RANSFER RS232).
FACTORY SETTING: 300s
Transfer USB
The values OFF, DATA, FAULTS, TOTAL and STATUS can be selected in this parameter.
OFF deactivates the data transfer.
DATA transfers only process data to the USB interface.
FAULTS transfers only alarm messages with date and time to the USB interface.
TOTAL transfers process data and alarm messages to the USB interface.
STATUS is used to transfer the data from the S
be pressed!).
TATUS REPORT to the USB interface (additional keys must
FACTORY SETTING: OFF
It is essential to set parameter TRANSFER USB to OFF before the USB-stick is
disconnected from the FIT.
Removing the USB-stick without setting parameter
TRANSFER USB to OFF may
corrupt the data file and result in data loss.
Cycle USB
The value set in this parameter determines the time interval of data transfer to the USB-stick connected
on the FIT-controller (only valid if DATA or TOTAL is selected in parameter T
The factory setting enables data transfer every 300 seconds.
FACTORY SETTING: 300 s
RANSFER USB).
CARD G / FIT 69 V 6.15 E / April 2010
Page 72
EXTENDED MODE
The other parameters in this screen allows the operator to select the process data which are to
be included in the data recording.
The appropriate data will be transferred if ON is chosen.
The appropriate data will not be transferred if OFF is chosen.
Unintended power failures on the CARD G FIT unit may cause corrupted data
on the USB-stick. It is strongly recommended to backup these data
periodically.
The data on the USB-stick can be accessed through an Ethernet connection to
the FIT-controller. The IP addresses needs to be adjusted according to the
local network requirements (see chapter 17.10.2 on page 71). The process data
can then be accessed on drive c/ on the FIT-controller using the File Transfer
Protocol (FTP).
The key is to be used to return from this screen back to the screen CONVEYING MODE.
The key is to be pressed to return to the MAIN SCREEN.
CARD G / FIT 70 V 6.15 E / April 2010
Page 73
EXTENDED MODE
17.10.2 LAN SETTINGS
To establish an Ethernet
connection to the FIT-controller, the network addresses must be set to the local network
requirements. This can be done in the screen LAN-PARAMETERS which is activated from the
screen DATA TRANSFER through the key .
The EDITOR SCREEN must be used to set the addresses as desired. To confirm the altered data, the
keys
need to be pressed.
A message will be shown in the display when the values are accepted.
Finally, the CARD G FIT must be powered off and on again to accept the new LAN parameters.
The drying process must be deactivated and the cool down period must be expired before the
unit may be powered off.
The key is to be applied to return from this screen back to the screen DATA TRANSFER.
CARD G / FIT 71 V 6.15 E / April 2010
Page 74
EXTENDED MODE
17.10.3 UNIT SELECTION
The parameters for UNIT SELECTION are accessed from the screen CONVEYING MODE with the key
. Among other parameters, the displaying units for air flow and temperature can be adjusted
in this screen.
CARD G Type
The values 1G, 3G and 6G might be selected in this parameter
This parameter can only be changed if parameter T
As a standard, the FIT-controller detects the correct CARD G FIT type automatically. A manual
adjustment will only be required if the automatic detection fails or a special drying process is required.
FACTORY SETTING: Automatic detection
YPE MANUAL is set to ON.
Type manual
The values OFF and ON might be selected in this parameter.
This parameter must be set to ON to allow the adjustment of the parameter CARD
OFF in this parameter, the FIT-controller detects the correct CARD G FIT type automatically.
A manual adjustment will only be required if automatic detection fails or a special drying process is
required.
FACTORY SETTING: OFF
G TYPE. With setting
Unit Air Flow
FACTORY SETTING: [Nm3/h]
The values [Nm3/h] and [cfm] might be selected in this parameter.
Depending on this adjustment, the air flow values are indicated as cfm (cubic feet per minute) or as
Nm³/h (standard cubic meters per hour) in different screens.
CARD G / FIT 72 V 6.15 E / April 2010
Page 75
EXTENDED MODE
Unit Temperature
FACTORY SETTING: [C]
The values [C] and [F] might be selected in this parameter.
Depending on this adjustment, the temperature values are indicated as °C (centigrade) or as °F (degree
Fahrenheit) in different screens.
Process Data Cycle
The values for the characteristics of the drying temperatures in the MAIN SCREEN and for the data table
in the P
parameter.
If more than 250 data sets recorded, each new data set will replace the oldest one.
Retaining the factory setting of 30 seconds traces the drying temperatures in the M
data in the P
ROCESS DATA SCREEN (see chapter 17.3 on page 48) are recorded at the time interval set in this
ROCESS DATA SCREEN over the past 125 minutes.
FACTORY SETTING: 30s
AIN SCREEN and the
Dew Point Sensor max.
The highest value of the measurement range of the optional dew point meter is set in this parameter.
The appropriate value can be found on the name plate of the dew point meter.
FACTORY SETTING: +20°C
Dew Point Sensor min.
FACTORY SETTING: -60°C
The lowest value of the measurement range of the optional dew point meter is set in this parameter. The
appropriate value can be found on the name plate of the dew point meter.
Voltage
Based on the standard supply voltage of 230 Volts, the electrical power consumption in the ENERGY
SCREEN is calculated.
This value may be altered if the supply voltage to the CARD G FIT unit differs from 230 Volts.
FACTORY SETTING: 230V
Offset [kWh]
An offset might be set to correct deviations between a measured and the calculated value for the power
consumption displayed in the E
The deviation must be entered as a value in percentage.
NERGY SCREEN.
FACTORY SETTING: + 0.0 %
CARD G / FIT 73 V 6.15 E / April 2010
Page 76
EXTENDED MODE
Offset [Nm3/h or cfm]
An offset might be set to correct deviations between a measured and the calculated value for the
compressed air consumption displayed in the E
The difference must be set as an absolute value.
NERGY SCREEN.
FACTORY SETTING: + 0.0
The key is to be used to return from this screen back to the screen CONVEYING MODE.
The key is to be pressed to return to the MAIN SCREEN.
CARD G / FIT 74 V 6.15 E / April 2010
Page 77
FAULTS AND REMEDY
18. FAULTS AND REMEDY
The following pages contain an overview of
faults which may occur on the CARD G FIT with appropriate troubleshooting.
NOTE:
The numbers mentioned between parentheses in this chapter are references to
part numbers in the schematic drawing in chapter 6 on page 9, and the
numbers mentioned between brackets are references to the wiring diagram at
the end of this manual.
18.1 FAULTS WITH DISPLAY TEXT
The pressure switch (1.3) [2S5] in the process air circuit reports no or low air pressure.
No or low compressed air at the inlet of the
CARD G FIT unit (1.1).
Leaks in the compressed air line inside the
CARD G FIT unit.
Compressed air alarm is only detected when
the hopper loader is running.
The compressed air inlet of the CARD G FIT unit
is blocked.
The compressed air switch (1.3) [2S5] is not
correctly set.
The pressure regulator (1.4) is not correctly set.
The compressed air pressure switch (1.3) [2S5]
is defective.
Solenoid valve (1.2) [3Y14] does not open when
drying is activated.
Check if compressed air supply matches the
requirements (see chapter 7 on page 11).
Check for leaks and seal any leaking fitting.
External compressed air lines are too small
or the external air pressure is too low (see
the requirements in chapter 9.1 on page 15).
Check compressed air supply and the inlet of
the compressed air in the CARD G FIT unit.
Use the adjusting screw on the pressure
switch to adjust the alarm set point to 3.0bars
[40PSI].
Contact or its exclusive
representative for the correct setting.
24V DC must be measurable at both terminals
(to ground) of the switch when compressed
air is available. Replace the switch if needed.
Check voltage supply 24VDC to valve; if OK,
replace valve.
CARD G / FIT 75 V 6.15 E / April 2010
Page 78
FAULTS AND REMEDY
The FIT-controller shut down the process heater preemptively to avoid excess temperature in the
heater.
Solenoid valve (1.2) [3Y14] does not open when
drying is activated and pressure switch (1.3)
[2S5] is defective.
Compressed air is missing and pressure switch
(1.3) [2S5] is defective.
Solid state relay [1V7] is defective. There must be 220V...230V AC between L-
Heater (1.7) [1E7] defective. Check heater resistance (290Ohm); if
24V DC must be measurable at both
terminals (to ground) of the switch when
compressed air is available. Replace the
switch if needed
Check voltage supply 24VDC to valve; if OK,
replace valve.
Restore compressed air supply and replace
pressure switch.
and N-(L2)wire of the heater when the solid
state relay is powered (green LED is ON) if
not, replace SSR.
necessary, replace heater.
This fault cannot be eliminated before is pressed to switch off the drying process.
The safety thermostat of the process air heater (1.9) [3S8] has tripped.
Solenoid valve (1.2) [3Y14] does not open when
drying is activated and pressure switch (1.3)
[2S5] is defective.
Compressed air is missing and pressure switch
(1.3) [2S5] is defective.
Solid state relay [1V7] is shorted. There must not be 220V...230V AC between L-
Heater (1.7) [1E7] defective. Check heater resistance (290Ohm); if
24V DC must be measurable at both
terminals of the switch when compressed air
is available. Replace the switch if needed
Check voltage supply 24VDC to valve; if OK,
replace valve.
Restore compressed air supply and replace
pressure switch.
and N-(L2)wire of the heater when the solid
state relay is not
dark) replace SSR if necessary.
necessary, replace heater.
powered (green LED is
This fault cannot be eliminated before is pressed to switch off the drying process.
CARD G / FIT 76 V 6.15 E / April 2010
Page 79
FAULTS AND REMEDY
The contactor of the heater [3K8] is activated although the drying is deactivated.
The output X6-3 on the FIT-controller is
defective (see the wiring diagram at the end of
this manual).
Replace the FIT-controller if 24VDC is
measured on the output x6-3 of the FITcontroller while the drying process is
deactivated.
The process air heater (1.7) [1E7] is deactivated and the compressed air flow is shut off because
the measured temperature is more than +20°C [+36°F] than the set temperature. This is to avoid
melting the material in the drying hopper.
See fault SAFETY THERMOSTAT on page 76
and fault TEMPERATURE TOO HIGH on page 78.
Remedy as described in fault SAFETY
THERMOSTAT on page 76 and fault
TEMPERATURE TOO HIGH on page 78.
This fault cannot be eliminated before is pressed to switch off the drying process and
the temperature is lowered to the set point.
No continuity in the temperature sensor of the heater (1.8) [2B14].
The conductivity of the PT1000 sensor (1.8)
[2B14] is not available on one of the wires.
PT1000 sensor (1.8) [2B14] defective. Replace the sensor.
Re-connect or replace the wire.
The temperature sensor of the heater (1.8) [2B14] shorted out.
The PT1000 sensor (1.8) [2B14] is shorted out on
one of the wires.
PT1000 sensor (1.8) [2B14] defective. Replace the sensor.
Repair or replace the wire.
CARD G / FIT 77 V 6.15 E / April 2010
Page 80
FAULTS AND REMEDY
The set temperature of the process air is not reached within the time limit after starting the
drying process.
Process air flow is too high. The pressure
regulator (1.4) is not correctly adjusted.
Solid state relay [1V7] is defective. There must be 220V...230V AC between wire
The relay [3K8] is not pulling in. Make sure that 24V DC is measurable on the
Heater (1.7) [1E7] defective. Check heater resistance (290Ohm); if
Contact or its representative to
obtain the right settings and set the valves
correctly.
L- and N-(L2) of the heater when the solid
state relay is powered on (green LED on SSR
is ON) if not, replace SSR.
terminals A1, A2 on the contactor from FIT-
controller x6-3 through the thermostat [3S8]
to the contactor (see the wiring diagram at
the end of this manual); if voltage is OK,
replace relay.
necessary, replace heater.
The temperature of the process air is above the limit settings (set value plus 10°C [18°F]).
The solid state relay [1V7] shorted out. Replace the SSR if voltage between the
phases is available while the drying process
is deactivated.
PID parameters are not correctly set. Set the PID values to factory settings
(contact ).
The heater (1.7) [1E7] is defective. Check if there is an earth connection or a
short circuit in the heater; replace it if
required.
The temperature of the process air is below the limit settings (set value minus 10°C [18°F]).
The alarm has been generated by another
alarm (e.g. NO COMPRESSED AIR), since the
temperature in the heater has dropped.
See also TEMP. NOT REACHED on page 78. Remedy according this alarm (see page 78).
Acknowledge alarm and monitor if the
temperature rises to the set value again.
CARD G / FIT 78 V 6.15 E / April 2010
Page 81
FAULTS AND REMEDY
The temperature of the process air exceeded the limit settings three times within 30 minutes.
See alarm „TEMPERATURE TOO HIGH“ on
page 78.
Fault remedy according instructions for
„TEMPERATURE TOO HIGH“ on page 78.
This fault cannot be eliminated before is pressed to switch off the drying process and
the temperature is lowered to the set point.
The hopper loading is activated but the hopper is not full within the limit settings
or the allowed suction attempts.
No material at the material source. Make sure that material is available.
Loading hose is not properly connected. Re-connect and seal the hose.
The suction wand or the hose is blocked. Remove blockage and clean.
Material flow is too low. Re-adjust the suction wand for ideal air flow.
Compressed air is not enough (venturi type). Ensure that hose and fittings are correctly
sized; check compressed air pressure and
flow.
Alarm time is set too short (venturi type). Extend the alarm time (see SYSTEMS
MANUAL CARD G FIT).
The proximity switch [2B10] for venturi loader
does not switch on.
The solenoid valve for venturi hopper loader
does not open.
Check 24V DC is available on the terminal
xP4 (see wiring diagram) and insure voltage
available.
Check if the switch LED is working (move
your hand close to the switch). Check if the
signal is detected by the FIT-controller
(parameter S
on page 46). Re-connect or replace the
switch if necessary.
Put a bridge between the pins 2 und 3 on the
terminal xP4 (see wiring diagram) and check
the function of the FIT controller. Check
jumper settings on FIT-board or replace the
FIT if necessary.
Check 24V DC is available on the terminal
xP6 (see wiring diagram) and on the valve.
Re-connect or replace the valve if needed.
IGNAL LOADING in chapter 17.2.2
CARD G / FIT 79 V 6.15 E / April 2010
Page 82
FAULTS AND REMEDY
Defective flapper gate signal of vacuum loader. Check the wiring between the flap sensor
and the terminal xP4. Re-connect if loose.
Move the flap gate manually and watch the
input on the FIT-controller (parameter Signal
Loading in chapter 17.2.2 on page 46). Reconnect or replace the sensor if necessary.
Put a bridge between the pins 2 und 3 on the
terminal xP4 (see wiring diagram) and check
the function of the FIT controller. Check
jumper settings on FIT-board or replace the
FIT if necessary.
The vacuum loader does not run. Check the signal between the terminal xP6
and the vacuum loader. Re-connect if
needed.
Check 24V DC is available when the loading
process is activated (parameter Motor
Loading – see chapter 17.2.3 on page 47 –
must show 1) and hopper loader setting is
correctly set in the Conveying Parameters
(see chapter 17.5 on page 53). Check wiring
and signal between the pins 2 and 4 on the
terminal xP6 and replace the FIT if
necessary.
On venturi type loaders (VacuJet), the loading process is monitored via the proximity switch
mounted on the material separator. In case of faulty switching operations, the loading sensor’s
sensitivity can be adjusted by turning the yellow screw on the proximity sensor.
CARD G / FIT 80 V 6.15 E / April 2010
Page 83
FAULTS AND REMEDY
The flap has been opened during the suction period of the loading process with a vacuum loader.
There is a leak in the suction line. Check the suction line and repair the leak
The flap in the vacuum loader is defective. Check the flap and repair or replace it.
The atmospheric dew point of the compressed air supply is too high.
No dew point sensor installed and dew point
measuring is activated.
The compressed air dew point is too high. Check the compressed air supply source and
The alarm set value is set too low. Reset the alarm set point (see SYSTEMS
The dew point sensor is defective. Check the wiring between the sensor and
Deactivate dew point measuring (see
SYSTEMS MANUAL CARD G FIT) or install
dew point sensor.
the operation of the refrigeration dryer at the
mains (the pressure dew point at 7bars
[102PSI] must not be higher than 5°C [41°F]).
MANUAL CARD G FIT).
the FIT-controller. Replace the sensor if
needed.
The drying process was unintentionally switched off because of power outage.
Voltage monitoring is activated. Deactivate this function if so desired (see
SYSTEMS MANUAL CARD G FIT).
Electrical power supply outage. Check the reason for power outage. Make
sure that sufficient drying time elapses
before using material.
CARD G / FIT 81 V 6.15 E / April 2010
Page 84
FAULTS AND REMEDY
18.2 FAULTS WITHOUT DISPLAY TEXT
FIT-display remains dark after switching on the main power switch.
No external power supply. Check the main power supply to the unit.
External fuses too small or external shortage. Check for short circuit and fuse sizes.
The LED on 24V DC power supply unit [1G12] is
off.
No 24V DC power even when the wires on the
24V DC side of the power supply unit [1G12] are
disconnected and 220...230V AC supply is
available.
Short circuit on the 24V DC side of the power
supply unit; disconnect wires from 24V DC
connectors; if LED shines again, follow wires
and remedy short circuit.
Check 220...230V AC supply to the power
supply unit; restore supply – if necessary
Replace the power supply unit.
CARD G / FIT 82 V 6.15 E / April 2010
Page 85
MAINTENANCE
19. MAINTENANCE
THE CARD G IS VIRTUALLY MAINTENANCE FREE!
It is recommended to periodically
check the compressed air quality and to clean the exhaust air filter (6.5) on the lid of the
CARD G FIT unit.
Check and clean periodically the air filters of the optional hopper loader device if used.
CARD G / FIT 83 V 6.15 E / April 2010
Page 86
SPARE PARTS LIST
20. SPARE PARTS LIST
NOTE:
The numbers mentioned between parantheses in this chapter are references to
part numbers in the schematic drawing in chapter 6 on page 9, and the
numbers mentioned between brackets are references to the wiring diagram at
the end of this manual.
[1A2]
Main power switch
1 pc.
A
Main power supply cord
(1.2) [3Y14]
E10356
1 pc.
E 10303
B
C
CARD G / FIT
Solenoid valve 1/8“
inclusive coil 24V DC
1 pc.
84
E 10311
V 6.15 E / April 2010
Page 87
SPARE PARTS LIST
(1.3) [2S5]
Pressure switch, 1-10bar, ¼“
1 pc.
Pressure regulator, ¼“
E 10008
(1.4)
1 pc.
M 20040
D
E
(1.7) [1E7]
Heater inclusive housing, strain relief and
power cords
1 pc.
Temperature limiter, 340°C [645°F]
E 10202k (180W)
(1.9) [3S8]
1 pc.
F
G
CARD G / FIT
E 10001
85
V 6.15 E / April 2010
Page 88
SPARE PARTS LIST
(1.8) [2B14]
PT1000 – temperature sensor
inclusive cable
1 pc.
E 10049
[3K8]
Heater relay 24V DC
inclusive socket and clamp
1 pc. each
H
I
relay socket clamp
E 10142 E 10147 E 10148
[1V7]
Solid state relay, 230V
inclusive varistor
1 pc.
E 10208 (SSR) E 10209 (varistor)
J
CARD G / FIT 86 V 6.15 E / April 2010
Page 89
SPARE PARTS LIST
[1G12]
24VDC power supply
1 pc.
E 10233
(5.2) [2D2]
FIT-controller
K
L
1 pc.
E 10516
[xP3]
Sub-D connector, 9-poles inclusive screws
1 pc.
E 10060k
M
CARD G / FIT 87 V 6.15 E / April 2010
Page 90
SPARE PARTS LIST
(5.3) [3H9]
CARD 3G, CARD 6G
Strobe light, 24V DC
1 pc.
E 10177
(5.3) [3H9]
CARD 1G
Alarm horn, 24V DC
N.1
N.2
1 pc.
E 10005
(6.7)
CARD 1G CARD 3G, CARD 6G
Sight glass
M 20348 M 20211
1 pc.
O
CARD G / FIT 88 V 6.15 E / April 2010
Page 91
SPARE PARTS LIST
Hinge
1 pc.
M 20014
(6.5)
Air outlet filter
1 pc.
M 20374
P
Q
CARD G / FIT 89 V 6.15 E / April 2010
Page 92
Page 93
ANNEX
Page 94
Page 95
Page 96
Page 97
Page 98
Page 99
Page 100
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