Sterling DH1-610-2, 882.00294.00 User Manual

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SDAA 25-100 Small Dryer

With AP-1 Controls

Part Number: 882.00294.00

Bulletin Number: DH1-610-2

Effective: 05/15/06

Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________

We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice.

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Shipping Information

Unpacking and Inspection

You should inspect your portable drying/conveying system for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as

broken or loose wiring and components, loose hardware and mounting screws, etc.

In the Event of Shipping Damage

According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.

Notify the transportation company’s local agent if you discover damage. Hold the damaged goods and packing material for the examining agent’s inspection.

return any goods before the transportation company’s inspection and authorization.

File a claim with the transportation company. Substantiate the claim by referring to the agent’s report. A certified copy of our invoice is available upon request. The original Bill of Lading is attached to our original invoice. If the shipment was prepaid, write us for a receipted transportation bill.

Advise customer service regarding your wish for assistance and to obtain an RMA (return material authorization) number.

If the Shipment is Not Complete

Check the packing list as back-ordered items are noted on it. You should have:

; Portable drying/conveying system ; Bill of lading ; Packing list ; Operating and Installation packet ; Electrical schematic and panel layout drawings ; Component instruction manuals

Re-inspect the container and packing material to see if you missed any smaller items during unpacking.

Do not

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the shipping department immediately. For shipments in the United States and Canada, call 1 (800) 233-4819; for all other countries, call our international desk at (630) 475-7491. Have the order number and item number available. Hold the items until you receive shipping instructions.

Returns

Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department.

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Table of Contents

CHAPTER 1: SAFETY ................................................................ 6

1-1 How to Use This Manual.............................................................................................6

Safety Symbols Used in this Manual.....................................................................6

1-2 Safety Tag Information................................................................................................7

Dryer Safety Tags .................................................................................................7

1-3 Warnings and Precautions..........................................................................................7

1-4 Responsibility..............................................................................................................8

General Responsibility...........................................................................................8

Operator Responsibility.........................................................................................9

Maintenance Responsibility.................................................................................10

Reporting a Safety Defect ...................................................................................10

CHAPTER 2: FUNCTIONAL DESCRIPTION............................ 11

2-1 Models Covered in This Manual................................................................................11

2-2 General Description...................................................................................................11

The Drying System..............................................................................................11

What is Desiccant................................................................................................11

The Process/Regeneration Cycle........................................................................11

2-3

Standard Features.....................................................................................................12

Mechanical Features...........................................................................................12

Electrical Features...............................................................................................12

Controller Features..............................................................................................12

2-4 Options......................................................................................................................13

2-5 Safety Devices and Interlocks...................................................................................13

Safety Circuit Standards......................................................................................13

Fail Safe Operation .............................................................................................14

Safety Device Lock-Outs.....................................................................................14

CHAPTER 3: INSTALLATION .................................................. 15

3-1 Uncrating the Equipment...........................................................................................15

3-2 Rigging and Placing the Dryer...................................................................................15

3-3 Electrical Connections...............................................................................................17

3-4 Setup Procedures......................................................................................................18

Checking for Proper Blower Rotation..................................................................18

Drying Hopper Air Trap Considerations (If Equipped).........................................18

Installing the Optional Aftercooler........................................................................18

3-5 Initial Start-up............................................................................................................19

Pre-Startup Checks.............................................................................................19

Starting Up the Dryer...........................................................................................19

Auto-Tuning the Dryer.........................................................................................19

Shutting Down the Dryer .....................................................................................20

CHAPTER 4: OPERATION ....................................................... 21

4-1 Controller Description and Operation........................................................................21

Identifying Control Panel Components for the AP-1 Controller...........................21

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Disconnect Switch......................................................................................21

Control Power Switch.................................................................................21

Touch Screen.............................................................................................21

Alarm Horn & Light.....................................................................................21

Process Air Temperature Controller....................................................................22

Startup Screen ....................................................................................................22

Main Menu Screen ..............................................................................................23

Dryer Status Screen............................................................................................23

Start Button .........................................................................................................24

Dryer Menu Screen .............................................................................................25

Dryer Status ........................................................................................................25

Dryer Setup ........................................................................................................25

Dryer Setup (Screen 1 of 3) Process Temperature High&Low ALarm........25

Dryer Setup (Screen 2 of 3) Choosing Degree F or Degree C....................26

Dryer Setup (Screen 3 of 3) Process return air temperature …………….. 26

Overdry Protection Setup....................................................................................26

Screen 1 of 2 (Enable or Disable the feature).............................................26

Screen 2 of 2 (Overdry Protection Parameter Settings)..............................27

Alarms .................................................................................................................28

Auto Tune............................................................................................................28

Dew Pt Setup ......................................................................................................29

Auto Start ............................................................................................................29

Main Menu...........................................................................................................30

Help Menu...........................................................................................................30

System Menu ......................................................................................................31

System Setup......................................................................................................31

Set Clock.............................................................................................................32

Set Auto Start Clock...................................................................................32

Set Alarm Clock..........................................................................................33

Hour Meters.........................................................................................................33

Input Status.........................................................................................................34

Output Status ......................................................................................................34

System Setting ……………………………………………………………………….. 34

Service Menu ......................................................................................................35

Alarm Screens.....................................................................................................35

Redundant Safety Controller Display ..................................................................36

Setting the Redundant Safety Controller.............................................................36

Restoring the WATLOW Redundant Safety Controller to Factory Setup............37

4-2 System Operation Procedures..................................................................................38

4-3 Shutting Down the Dryer...........................................................................................39

CHAPTER 5: MAINTENANCE .................................................. 40

5-1 Preventative Maintenance Schedule.........................................................................40

5-2 Preventative Maintenance.........................................................................................41

Servicing Process Air Filters................................................................................41

Servicing the Dew Point Monitor .........................................................................42

5-3 Corrective Maintenance ............................................................................................43

Symptoms of Worn Desiccant.............................................................................43

Replacing Worn Desiccant..................................................................................43

Replacing the Regeneration Heater....................................................................45

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Replacing the Process Heater.............................................................................45

Replacing/Cleaning the Cooling Coils.................................................................46

CHAPTER 6: TROUBLESHOOTING ........................................ 48

6-1 Introduction................................................................................................................48

6-2 Determining Temperature Controller Errors or Sensor Errors...................................54

Using a Thermocouple ........................................................................................54

CHAPTER 7: APPENDIX .......................................................... 55

7-1 Warranty....................................................................................................................55

Warranty Specifications.......................................................................................55

Warranty Restrictions..........................................................................................55

Warranty Liabilities..............................................................................................55

Customer Responsibilities...................................................................................56

7-2 Optional Components................................................................................................56

7-3 Technical Specifications............................................................................................56

Annex B Information............................................................................................56

Aftercooler Design Specifications........................................................................57

7-4 Drawings and Diagrams............................................................................................57

7-5 Spare Parts List.........................................................................................................60

7-6 Returned Material Policy...........................................................................................62

Credit Returns .....................................................................................................62

Warranty Returns ................................................................................................62

7-7 Dryer Identification (Serial Number) Tag...................................................................62

7-8 Technical Assistance.................................................................................................63

Parts Department ................................................................................................63

Service Department.............................................................................................63

Sales Department................................................................................................63

Contract Department...........................................................................................63

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Chapter 1: Safety

1-1 How to Use This Manual

Use this manual as a guide and reference for installing, operating, and maintaining your drying system. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity.

This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer.

The Functional Description section outlines models covered, standard features, and safety features. Additional sections within the manual provide instructions for installation, preoperational procedures, operation, preventive maintenance, and corrective maintenance.

The Installation chapter includes required data for receiving, unpacking, inspecting, and setup of the drying system. We can also provide the assistance of a factory-trained technician to help train your operator(s) for a nominal charge. This section includes instructions, checks, and adjustments that should be followed before commencing with operation of the drying system. These instructions are intended to supplement standard shop procedures performed at shift, daily, and weekly intervals.

The Operation chapter includes a description of electrical and mechanical controls, in addition to information for operating the dryer safely and efficiently.

The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service. Preventive maintenance sections are included to ensure that your drying system provides excellent, long service.

The Troubleshooting chapter serves as a guide for identification of most common problems. Potential problems are listed, along with possible causes and related solutions.

The Appendix contains technical specifications, drawings, schematics, parts lists, and available options. A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package. Refer to this section for a listing of spare parts for purchase. Have your serial number and model number ready when ordering.

Safety Symbols Used in this Manual

The following safety alert symbols are used to alert you to potential personal injury hazards. Obey all safety messages that follow these symbols to avoid possible injury or death.

DANGER! DANGER indicates an imminently hazardous situation that, if not

avoided, will result in death or serious injury.

WARNING! WARNING indicates a potentially hazardous situation or practice that,

if not avoided, could result in death or serious injury.

Caution! CAUTION indicates a potentially hazardous situation or practice that, if not

avoided, may result in minor or moderate injury or in property damage.

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1-2 Safety Tag Information

Dryer Safety Tags

Hot! Read Operation and Installation Manual

High Voltage Earth Ground

Inside Enclosure

Lifting Point Ground

1-3 Warnings and Precautions

Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations.

PE Protected Earth

To avoid possible personal injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices:

; Read and follow these operation and installation instructions when installing,

operating, and maintaining this equipment. If these instructions become damaged or unreadable, additional copies are available from the manufacturer.

; Follow all SAFETY CODES. ; Wear SAFETY GLASSES and WORK GLOVES. ; Work only with approved tools and devices. ; Disconnect and/or lock out power before servicing or maintaining the equipment. ; Use care when LOADING, UNLOADING, RIGGING, or MOVING this

equipment.

; Operate this equipment within design specifications. ; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.

You should remove the fuses and carry them with you.

; Make sure the equipment and components are properly GROUNDED before you

switch on power.

; Use EXTEREME CAUTION when working with dryer. HIGH HEAT can be

dangerous. Keep body parts, tools, clothing, and debris away from dryer.

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; When welding or brazing in or around this equipment, make sure VENTILATION is

ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with

sheet metal. An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed.

; Do not restore power until you remove all tools, test equipment, etc., and the

equipment and related components are fully reassembled.

; Only PROPERLY TRAINED personnel familiar with the information in this

manual should work on this equipment.

We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration. We expect you, as a user, to abide by the foregoing recommendations in order to make operator safety a reality.

1-4 Responsibility

These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine.

All personnel engaged in the use of the machine should become familiar with its operation as described in this manual.

Proper operation of the machine promotes safety for the operator and all workers in its vicinity.

Each individual must take responsibility for observing the prescribed safety rules as outlined. All warning and danger signs must be observed and obeyed. All actual or potential danger areas must be reported to your immediate supervisor.

General Responsibility

No mater who you are, safety is important. Owners, operators and maintenance personnel must realize that every day, safety is a vital part of their jobs.

If your main concern is loss of productivity, remember that production is always affected in a negative way following an accident. The following are some of the ways that accidents can affect your production:

• Loss of a skilled operator (temporarily or permanently)

• Breakdown of shop morale

• Costly damage to equipment

• Downtime

An effective safety program is responsible and economically sound. Organize a safety committee or group, and hold regular meetings. Promote this group from

the management level. Through this group, the safety program can be continually reviewed, maintained, and improved. Keep minutes or a record of the meetings.

Hold daily equipment inspections in addition to regular maintenance checks. You will keep your equipment safe for production and exhibit your commitment to safety.

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Please read and use this manual as a guide to equipment safety. This manual contains safety warnings throughout, specific to each function and point of operation.

Operator Responsibility

The operator’s responsibility does not end with efficient production. The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations.

Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or through a casual attitude toward machinery formed over a period of months or years. Your employer probably has established a set of safety rules in your workplace. Those rules, this manual, or any other safety information will not keep you from being injured while operating your equipment.

Learn and always use safe operation. Cooperate with co-workers to promote safe practices. Immediately report any potentially dangerous situation to your supervisor or appropriate person.

REMEMBER:

• NEVER place your hands or any part of your body in any dangerous location.

• NEVER operate, service, or adjust the equipment without appropriate training and first

reading and understanding this manual.

• NEVER try to pull material out of the equipment with your hands while it is running!

• Before you start the portable drying/conveying system check the following:

• Remove all tools from the equipment;

• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the

hopper area;

• If your portable drying/conveying system has been inoperative or unattended, check all

settings before starting the unit.

• At the beginning of your shift and after breaks, verify that the controls and other

auxiliary equipment are functioning properly.

• Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify,

or remove safety guards. Such alteration is not only unsafe, but will void the warranty on your equipment.

• When changing control settings to perform a different mode of operation, be sure

selector switches are correctly positioned. Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting.

• Report the following occurrences IMMEDIATELY:

• unsafe operation or condition

• unusual dryer/conveying system action

• leakage

• improper maintenance

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• NEVER stand or sit where you could slip or stumble into the

equipment while working on it.

• DO NOT wear loose clothing or jewelry, which can be caught while working on the

equipment. In addition, cover or tie back long hair.

• Clean the equipment and surrounding area DAILY, and inspect the machine for loose,

missing or broken parts.

• Shut off power to the equipment when it is not in use. Turn the switch to the OFF

position, or unplug it from the power source.

Maintenance Responsibility

Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety a priority to effectively repair and maintain equipment.

Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric supplies and all accessory equipment at the machine, and disconnect and lockout electrical power. Attach warning tags to the disconnect switch.

When you need to perform maintenance or repair work on equipment above floor level, use a solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your equipment, use it. The work platform should have secure footing and a place for tools and parts. DO NOT climb on machines or work from ladders.

If you need to repair a large component, use appropriate handling equipment. Before you use handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes) be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable.

Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using them to lift a load.

Be sure that all non-current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes. Install in accordance with national and local codes.

When you have completed the repair or maintenance procedure, check your work and remove your tools, rigging, and handling equipment.

Do not restore power to the equipment until all persons are clear of the area. DO NOT start and run the machine until you are sure all parts are functioning correctly.

BEFORE you turn the machine to the operator for production, verify all equipment enclosure panels, guards and safety devices are in place and functioning properly.

Reporting a Safety Defect

If you believe that your equipment has a defect that could cause injury, you should immediately discontinue its use and inform the manufacturer.

The principle factors that can result in injury are failure to follow proper operating procedures (i.e. lockout/tag out), or failure to maintain a clean and safe working environment.

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Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual provides operation, installation, and maintenance instructions for 15, 30 or 60 cfm dehumidifying dryers. Model numbers are listed on the serial tag. Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service.

Our dehumidifying mini dryers are designed to generate heated dehumidified air (at a very low dew point) at carefully controlled temperatures for use in plastic drying systems. The dryer circulates hot dehumidified air through a column of plastic resin in the large drying hopper. The resin in the hopper is discharged through a slide gate in a “first in, first out” manner.

2-2 General Description

The Drying System

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

Our dryers force hot, dry air through resin in a drying hopper, where air picks up moisture from the material and draws it back to the dryer. In the dryer, a desiccant bed strips moisture from the air. The dried process air is then re-heated and delivered back into the drying hopper for more moisture removal.

Portion of the low dew point process air is directed to the desiccant tank that is off process. This air is heated to approximately 450°F (232°C) before entering the bed that is in regeneration. The moisture is then forced from the desiccant before being exhausted into the atmosphere. A small amount of ambient air is introduced into the process return air filter to make up for the air lost during the bed regeneration. To compensate for the humidity content in the air, this dryer is supplied with the proper amount of desiccant.

What is desiccant?

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

The Process/Regeneration Cycle

Our dryers have two desiccant beds. While one bed is on-line in the process air loop, the other is off-line, being regenerated.

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

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

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2-3 Standard Features

Mechanical Features

• Rugged compact cart with handles and sturdy 4” (10 cm) casters.

• Dual desiccant beds

• Electrically-motorized air valve

• 13X Molecular Sieve

• Single regenerative process blower

• Drying temperature range of 180ºF to 250ºF (82ºC to 121ºC)

• 2.5” hose connections

Electrical Features

• Process thermocouple to be connected to drying hopper air inlet.

• Nema 12 control enclosure

• NFPA79 machinery electrical standards

• Non-fused electrical disconnect

• Branch fusing

• Solid State process heater contactor

• Regeneration temperature control

• Process high temperature alarm light

• Dirty filter indicator

• Process/regeneration heater box

• Dew Point Monitor.

• Material saver/over dry protection

• High temperature safety system (Process/Regeneration)

• 7 day timer/auto start

Controller Features

• Mitsubishi programmable relay controller

• Display of process temperature set point and actual settings

• Display of process air dew point

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2-4 Options

Options marked with “*” indicate options that can be factory installed or retrofitted in the field.

• * Process temperature up to 400ºF (204º C), including aftercooler with dryer and

silicone insulated delivery hose.

• * If the dryer is a central dry air generator, it will not have a process heater box.

• * Plasticizer trap (with cooling coil) in lieu of standard aftercooler (mounts outside on

back of dryer).

• * Drawer magnet, stainless steel construction.

• * Casters, two (2) fixed and two (2) swivels.

• * Machine mount adapter to accommodate a dryer and corresponding hopper.

• * Low temperature operation below 180ºF (82ºC), includes an internal cooler.

• * Redundant high temperature safety circuit.

• * Cart with caster with hopper mounting place.

• * Low level indicator(s).

Note: For below 180°F (82ºC), cooler needs to cool the air coming

out of the desiccant tank prior to entering the process heater box.

• * Insulated air hose for air delivery.

• * RPV for drying hopper

2-5 Safety Devices and Interlocks

This section includes information on safety devices and procedures that are inherent to the drying system. This manual is not intended to supersede or alter safety standards established by the user of this equipment. Instead, the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment.

At the completion of this section, the operator and maintenance personnel will be able to do the following:

• Identify and locate specific safety devices.

• Understand the proper use of the safety devices provided.

• Describe the function of the safety device.

Safety Circuit Standards

Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy. They also provide a means of locking out or isolating the energy for servicing equipment.

Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment. The Occupational Safety and Health Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the organizations that have joined with the plastics industry to develop safety standards.

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Every effort has been made to incorporate these standards into the design of the drying system; however, it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices.

Fail Safe Operation

If a safety device or circuit should fail, the design must be such that the failure causes a “Safe” condition. As an example, a safety switch must be a normally open switch. The switch must be held closed with the device it is to protect. If the switch fails, it will go to the open condition, tripping out the safety circuit.

At no time should the safety device fail and allow the operation to continue. For example, if a safety switch is guarding a motor, and the safety switch fails, the motor should not be able to run.

Safety Device Lock-Outs

Some safety devices disconnect electrical energy from a circuit. The safety devices that are used on this equipment are primarily concerned with electrical power disconnection and the disabling of moving parts that may need to be accessed during the normal operation of the machine.

Some of the safety devices utilize a manual activator. This is the method of initiating the safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable handle, there may be a location for a padlock. Personnel servicing the equipment should place a padlock in the lockout handle.

In addition to the safety devices listed above, these dryers are equipped with a line cord plug. This allows the operator or maintenance personnel to unplug the dryer from its power source and tag it out. The plug can then be tagged with any number of approved electrical lockout tags available at most electrical supply stores.

WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)

sources prior to servicing or cleaning this equipment. Failure to do so may result in serious injury. No one but the person who installed the lockout may remove it.

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Chapter 3: Installation

3-1 Uncrating the Equipment

Portable Drying/Conveying Systems are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box.

1. Pry the crating away from the skid.

Note: Remove the nails holding the box to the skid and lift the box

off carefully; avoiding staples in the 1’ x 4’ wood supports. Cut the steel banding.

2. Use a pry bar to remove the blocks securing the unit to the skid.

3. Lift unit from sides. Use a pry bar if necessary to carefully remove the

skid from the unit.

4. Lower slowly.

3-2 Rigging and Placing the Dryer

Take care when rigging and placing the drying and conveying system. Figure 1 below shows a suggested safe rigging diagram. It lets you lift the dryer/hopper unit vertically using a fork truck.

Caution! If you are mounting a machine-mount dryer with a magnet or transition adaptor on the

machine throat, you must provide additional support to hold the dryer securely on the machine.

Be aware that off-center static and dynamic hopper loading can occur with machine vibration. Again, provide additional support to hold the dryer securely on the machine.

For 60 cfm dryer units, you must provide additional support to stabilize these units and to protect personnel when installing on machine throats.

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

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Figure 1: Suggested Lift Rigging for Cart Mount Dryers

DO NOT

USE

PROCESS

DEW POINT

TEMPERATURE

CONTROL POWER

ALARM HORN

ON OFF

ALARM ALARM Silencer

USE

FORK

LIFT

TRUCK

Caution! Do not use a hoist to move or rig your Drying/Conveying System when it is

mounted on a cart! Moving the unit with a hoist will cause it to become unstable and may cause damage to the equipment and/or injury to personnel!

Figure 2: Suggested Lift Rigging for Cart Mounted Dryers

Note: Floor Mounted Dryers can be lifted by hoist or fork lift.

USE

Overhead

Crane

PROCESS

TEMPERATURE

CONTROL POWER ON OFF

ALARM

F F

DEW POINT

ALARM HORN

ALARM Silencer

USE

FORK

LIFT

TRUCK

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Figure 3: Suggested Lift Rigging for Cart Mounted Dryers

(

Mounting flange

TEMPERATURE

CONTROL POWER ON OFF

ALARM HORN

ALARM

ALARM Silencer

Hopper mounting flanges on 0.75 and

Notes:

and 1.5 cu. ft. (20 & 40 liter) hoppers are supplied blank so the customer

PROCESS

DEW POINT

can drill to match existing machine throat.

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

are not supplied with a cast flange

as shown).

Caution! When using a hoist to move a machine mounted dryer, ALWAYS attach

chains to the three (3) locations/lifting points on the unit! Moving the Dryer without the chains attached to all of the lifting points will cause the unit to become unstable and may cause damage to the Dryer and/or injury to personnel!

Diameter hole:

3-3 Electrical Connections

When making electrical connections to your unit, ensure that you take into consideration and make arrangements for the following:

• A qualified electrician should make all electrical connections.

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

• The serial tag lists voltage, phase, and amp draw information:

• Line voltage must be within plus or minus ten percent (±10%) of the

voltage listed on the serial tag, or damage may occur. Phase imbalance must be less than two percent (2%).

• Connect main power to the dryer at the disconnect or terminals in the upper right

corner of the control enclosure.

• Install a fused disconnect with a lockout feature in the power main leading to the dryer.

• The power drop must include a ground wire.

• Make sure all electrical connections are tight.

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3-4 Setup Procedures

This section provides the procedures necessary for configuring your portable drying/conveying system.

Configuration of your unit includes checking for proper blower rotation and installing the optional aftercooler (on 60 cfm models). We recommend that you carry out these procedures in the order given here.

Note: Before carrying out these procedures, install all equipment

Checking for Proper Blower Rotation

Three-Phase Models

Caution! In three-phase models, incorrect phasing of power leads can cause

backward rotation of blower motors and CONTAMINATION OF THE DESICCANT!

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

The blower is rotating properly when air flows from the delivery outlet.

Note: Holding your hand in front of the air return will also

as described in this section.

indicate if the blower rotates in the proper direction (by feeling suction).

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

Drying Hopper Air Trap Considerations (If Equipped)

Our exclusive air trap assembly on the top of the drying hopper prevents ambient air from contaminating the material being dried. To ensure that your unit will operate at peak efficiency, do the following:

• Keep the material level at the mid point of the air trap

This can be achieved by utilizing a hopper loader or vacuum conveying system to supply material to the drying system.

Installing the Optional Aftercooler

Water-cooled 15/30/60 cfm models use a water-to-air heat exchanger as an aftercooler. Cooling water is required for this design (3 gpm at 85°F or lower). Return air from the hopper passes through the air filter to trap fines and dust before entering the heat exchanger.

Installing Water Lines (Hose and Hose Clamp)

When installing the water lines, ensure that the aftercooler utilizes either tower, chilled or city water as warm as 85°F (29°C). Recommended flow rate is three (3 gpm) gallons per minute (11 liters per minute).

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NOTE: If the Aftercooler is used as a plasticizer trap, the water temperature of 50°F or lower is recommended.

3-5 Initial Start-up

Pre-Startup Checks

; Check the process and return hoses for tight connections. ; Check all companion equipment, such as the drying hopper; verify that the loading

system is ready for operation.

; Verify that all dryer electrical connections are tight. ; Verify that the thermocouple is properly installed at the hopper inlet.

Starting Up the Dryer

1. Turn on (energize) the disconnect switch in your power drop, then turn on the

disconnect switch on the dryer.

2. Turn the system

3. Check the display for the proper temperature scale (ºF or ºC).

4. Close the slide gate at the bottom of the drying hopper.

Make sure that the blowers turn in the right direction.

5. Fill the drying hopper with material.

6. Press the

START button on the Touch Screen to start the dryer.

ON/OFF switch to ON to energize the display panel.

The process blower starts.

7. If your dryer has a water-cooled aftercooler, make sure that sufficient cooling water

(3gpm at 85°F or lower) flows properly through the coil and that you have bled any trapped air from the system.

8. Set the process set point on the touch screen.

9. After the proper pre-drying time for the initial hopper fill has elapsed, fully open the

drying hopper slide gate.

Note: To allow proper residence time during continuous

processing, maintain the material level in the hopper at the midpoint of the air trap assembly.

Auto-Tuning the Dryer (Requires Supervisory Password)

From the “Dryer Status” screen, press “D-Menu” and select Auto Tune to gain access to this screen.

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Figure 2: Process Autotune Screen

1. The autotune feature can be enabled by pressing the START/STOP button located in the center of the screen.

AUTOTUNE IN PROGRESS or PROCESS NOT ACTIVE will inform the

operator of the current status of this feature.

3. At this point the operator can return back to the

DRYER MENU or MAIN MENU by

touching the appropriate button on the screen.

Shutting Down the Dryer

1. Turn off the conveying system supplying the drying hopper and/or machine. Press

the shutdown button for the dryer to complete its cycle.

2. When processing is complete, close the hopper slide gate and shut down any in-line

companion equipment, such as the aftercooler.

3. If the dryer is shut down using the shutdown button on the dryer status screen, the

process heater will shut off and the bed regeneration process will be completed. When the dryer is started at a later date the process air will be directed through the bed that was regenerated last.

4. If the dryer control switch is turned off without using the dryer shutdown feature, the

dryer will stop immediately. When the dryer is started at a later date, the process air will be directed through the last bed that was being used when the dryer control switch was turned off. If a bed was being regenerated when the dryer control switch was turned off, the regeneration process would begin over again on that same bed.

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Chapter 4: Operation

4-1 Controller Description and Operation

Identifying Control Panel Components for the AP-1 Controller Disconnect Switch

The Disconnect Switch is located in the front upper right hand corner of the control enclosure. It allows the user to disconnect power to the dryer for emergency shutdown, service or long periods of inactivity.

Control Power Switch

The Control Power Switch is located on the front of the control enclosure below the touch screen. The switch energizes the control circuit (PLC, touch screen, relays, etc.) within the control enclosure.

Touch Screen

The Touch Screen is located in the center of the control enclosure. Once the disconnect is on and the control circuit is energized, the machine can be started and parameters can be adjusted through the touch screen.

Alarm Horn & Light

The Alarm Horn is located in the center of the control enclosure, next to the Control Power Switch. The audible and visual indication that there is a malfunction with the system.

Alarm Light is located on the top of the enclosure. These devices give an

Figure 3: Typical Control Panel

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Process Air Temperature Controller

Control package use a PLC with a touch screen interface to control the operation of the dryer and the optional conveying system. This section of the manual will address those parameters that allow the user to optimize the drying/conveying system for specific applications.

Figure 4: Dryer Status Screen on Touch Screen Controller

Startup Screen

The screen shown above provides the operator with the following information:

• Dryer Model Number

• Temperature view (In Celsius or Fahrenheit)

• Copyright Information

• PLC Version

• Display Version

After approximately 10-12 seconds the controller will flash to the Dryer Status Screen shown in Figure 10 above.

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Main Menu Screen

The MAIN MENU provides information on the following drying/conveying system parameters:

• DRYER MENU (some submenus are password protected)

• ALARM HISTORY

• HELP MENU

• SYSTEM MENU

• NO USERS LOGGED ON

This section of the manual will focus on the dryer features portion of the controller at this time.

Press the

DRYER MENU button to return to the next section of dryer functions.

Dryer Status Screen

(Shown at Controller Power Up)

Note: Looking at the screen from Left to Right

Dryer Process

The SETPOINT button allows the operator to set the process air temperature. The ACTUAL button will give you a reading of what the actual process air temperature is entering the drying hopper.

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Machine Status

The area in the lower left portion of the touch screen conveys two lines of information relating to the overall operation of the dryer. The following is a list of typical machine/dryer summary status line text messages:

1. Left Bed In Process

8. Left Bed Heat

2. Right Bed In Process

3. Process Offline

4. Valve Changing Position

5. Auto start Timer Enabled

6. Autotune in Progress

7. Dryer Offline

9. Left Bed Cool

10. Left Bed Ready

11. Right Bed Heat

12. Right Bed Cool

13. Right Bed Ready

14. Over-dry Protect Active

Start Button

The START BUTTON allows the user to stop and start the dryer manually. When the start button is pressed, the dryer begins to operate. The text in the button will change from

START to SHUTDOWN. The next time the button is pressed, the dryer will go into a

sequence shutdown and the button text will change to

RESTART. The process heater will

shut off, the current bed regeneration will be completed and then the blower will stop. If sequence shutdown is not desired, turning the

POWER SWITCH off will turn off all

components of the dryer immediately and the optional conveying system will be turned off also.

Setting Values

By pressing and holding the numbers in the SETPOINT button, the following screen will be displayed:

Enter the values you would like to set in the screen by pressing the number keys. Press ENT (Enter) when you are finished to set the new values or CLR (Clear) to erase the current values and reenter new ones. To set the values in the next field, press ENT (Enter) to close the screen shown above. Then select the next number field to enter new values.

Dryer Menu

Pressing this button will take the user to another screen where more machine parameters can be viewed and adjusted.

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Dryer Menu Screen

The screen shown above will allow the operator to set/review operating parameters for the following:

• DRYER STATUS

• DRYER SETUP (requires supervisory password)

• OVERDRY PROTECT (requires supervisory password)

• ALARMS

• AUTO TUNE (requires supervisory password)

• DEW PT SETUP (Dew Point Setup)

• AUTO START (requires supervisory password)

• MAIN MENU

DRYER STATUS

Pressing the STATUS button will take the operator back to the original status screen shown on page 27. Pressing

MENU will return you back to the menu screen.

DRYER SETUP

By pressing the LOW or HIGH alarm buttons, the operator can enter the desired values to enable the alarm to go off at a specific deviation from set point (on the high or low side).

When these settings have been made, the operator now has a choice of returning to the

DRYER MENU, BACK (takes you back to the DRYER MENU) or pressing MORE to

take you to screen 2 of 3 of the

DRYER SETUP screen.

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Buy pressing the or degree

C. (Note; Changing the temperature scale, requires adjusting the alarm values.)

MORE screen, you can choose for the temperatures to display in degrees F

When these settings have been made, the operator now has a choice of returning to the

DRYER MENU, BACK (takes you back to the DRYER SETUP 1 of 3) or pressing MORE

to take you to screen 3 of 3 of the DRYER SETUP screen.

NOTE: At this display, before you change any of the settings, you need to test the thermocouple readings in Ice water (32°F at sea level, and boiling water 212°F at sea level). Then you may change these settings accordingly to make sure the controller is displaying the correct temperature.

Setting Values

By pressing and holding the numbers in the LOW TEMP ALARM or the HIGH TEMP

ALARM

buttons, the following screen will be displayed:

Over-Drying Protection

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The PROCESS RETURN AIR TEMPERATURE displays the air temperature as it leaves the drying hopper. If this temperature is above 150°F, an aftercooler is required.

By pressing the DISABLE or ENABLE the operator disable or enable this feature of the dryer.

This feature is used to prevent the over drying of the plastic resin in the drying hopper. At this point the operator has the choice of pressing

MAIN MENU, DRYER MENU, or

MORE to access the screen 2 of 2 of the OVERDY PROTECTION for adjusting values.

SET BACK VALUES;

The SETPOINT is the secondary drying temperature set point. This is the temperature at which the drying temperature will be reduced to after a certain delay time and when the return air temperature has exceeded its set point..

The

TEMP is the set point for the return air temperature of the drying hopper. When the

return air temperature exceeds this value, after a certain delay time, the process temperature will be reduced to its secondary value (SETPOINT) to eliminate over drying of the plastic material.

The

DELAY is the time which will take for the dryer to switch the drying temperature set

point from primary drying temperature to secondary drying temperature or back to the primary drying temperature set point.

SET UP TEMP;

The SETUP TEMP is the secondary temperature setting for the return air temperature. When the return air temperature of the drying is lower than this set point, after a certain delay time, the process temperature set point will switch back to the primary drying temperature set point.

Once the parameters have been set for the drying process, the operator can return to the

DRYER MENU, MAIN MENU, or BACK to the screen 1 of 2 of the OVERDRY

PROTECTION.

Setting Values

By pressing and holding the numbers in the SET BACK DELAY button, the following screen will be displayed:

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Enter the values you would like to set in the screen by pressing the number keys. Press (Enter) when you are finished to set the new values or CLR (Clear) to erase the current values and reenter new ones.

ENT

The next feature in the

DRYER MENU is the ALARMS button/screen.

Alarms (Retains 100 of the most recent alarms)

This screen allows the operator to review the number and type of issues that the Dryer has encountered during its operation. The “Alarm History” screen is NOT reset-able.

Problems can be viewed by Date, Hour, and Comment. Because of the size of the screen, only three (3) comments/alarms can be viewed at a time.

To view alarms not visible on the screen, press the alarm, press the

Pressing the system. You will only get

UP button to scroll upward in the alarm history.

CNV (Convey) in this screen will take the operator to the CONVEY STATUS of

CNV alarms when conveying options are enabled (Nomad

DOWN button. To return to a particular

only). At this point the operator can return back to the

DRYER MENU or MAIN MENU by

touching the appropriate button on the screen.

Auto Tune

This screen allows the operator to automatically tune the process air temperature control algorithm to a specific drying application. The autotune sequence should be initiated if the user feels there are unacceptable fluctuations in the process air temperature. The calculated P, I, and D variables will be shown in the lower left hand portion of the screen for reference purposes.

The autotune feature can be enabled by pressing the

AUTOTUNE

button.

PUSH TO START PROCESS

AUTOTUNE IN PROGRESS or PROCESS NOT ACTIVE will inform the operator of

the current status of this feature. At this point the operator can return back to the

DRYER MENU or MAIN MENU by

touching the appropriate button on the screen.

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Dew Pt Setup

This screen allows the operator to set the dew point alarm value.

HIGH LIMIT ALARM VALUE is an audible/visual alarm which will sound when

The the process air dew point rises to this value. Values can be set for degrees Fahrenheit between – 40 through +15 degrees and degrees Celsius between -40 through -10 degrees.

Setting Values

By pressing and holding the numbers in the HIGH DEW PT ALARM, the ALARM

STARTUP DELAY

or the ALARM BED SW DELAY buttons, the following screen will

be displayed:

Once this feature has been set, the operator can return back to the

by touching the appropriate button on the screen.

DRYER MENU or MAIN

Auto Start

This screen allows the operator to set the time and day that the dryer will start

automatically. Reference page 32, Make sure the clock is set to current date ant time.

Pressing select the day they desire the dryer to start. Pressing

NEXT DAY allows the operator to scroll forward through the days of the week to

PREV DAY allows the operator to

scroll backward through the days of the week to select the day they desire the dryer to start.

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By touching the

ON TIME and OFF TIME sections on the screen, the operator can enter the

values for the time they wish the dryer to turn on and off. See the next page for instructions on setting values for this feature.

Pressing the Pressing

Once this feature has been set, the operator can return back to the

AUTOSTART TIMER DISABLED button will activate this dryer feature.

AUTOSTART TIMER ENABLED will deactivate this feature.

DRYER MENU or MAIN

by touching the appropriate button on the screen.

Setting Values

Main Menu

This screen allows you to jump to the different areas of the controller to set, monitor, and operate different features of the Drying/Conveying System. Conveying screens are used only with Nomad dryers.

NO USER LOGGED ON, indicates that the password to access certain features of the dryer is not entered. USER LOGGED ON, indicates that the password to access certain features of the dryer is still active and these features can be accessed and changed.

Help Menu

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System Menu

The screen shown above will allow the operator to set/review operating parameters for the following:

The above screen will allow the operator to set/review operating parameters;

• SYSTEM SETUP

• SET CLOCK

• HOUR METERS

• ALARM HISTORY

• I / O STATUTUS (Input and output status)

• SYSTEM BACKUP

• SERVICE

• MAIN MENU

SYSTEM SETUP

This screen allows the operator to set alarm and password features.

ALARM OFF DUR is the amount of time (0-99 minutes) that the alarm and horn will stay

off after the alarm silence button is pushed. (When this function is set to 0, this feature will never turn off. When it is set to 99, it will stay off until another alarm occurs.)

OPER PW is the four (4) digit number that allows access to the station and pump status

screen and the station operator screen. (When this feature is set to 0000 these screens are not password protected.)

OPER PW DUR is the amount of time (5-99 minutes) the password will allow access to the

associated screens. The screen changes to the station status screen when the time expires.

SETUP PW is the four (4) digit number that allows access to the setup screens. (When this

is set to 0000 there is no password protection.). Store password in a secure location.

SETUP PW DUR is the amount of time (5-99) the password will allow access to the

associated screens. When the time expires, the screen changes to the station status screen.

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Note: If password(s) feature is enabled, please write down y

passwords and file them in a secure location.

our

At this point the operato

r can return back to the

touching the appropriate button

on the screen.

MAIN MENU or SYSTEM MENU by

Set Clock

This menu allows the operator to set the AUTOSTART CLOCK and the ALARM CLOCK. Press the

SET AUTOSTART CLOCK or the SET ALARM CLOCK buttons to set the

times and dates on these features.

Set Auto Start Clock

This screen allows the user to set the 7-day timer which can be programmed for daily or weekly (over midnight) on/off operation. An internal battery backup holds the settings in memory when the dryer is de-energized.

Setting Values

By pressing the numbers (Month, Day, Ye previous screen sh

own above, the following screen will appear:

ar, Hours and Minutes) under Set Clock on the

Pressing the When the new information has been entered into the controller, the operator can r

to the

SET TIME button will enter the new information into the controller.

eturn back

MAIN MENU or SYSTEM MENU by touching the appropriate button on the

screen.

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Set Alarm Clock

In this screen the user can set the variables which are used to time and date stamp alarms. This feature works in conjunction with the ALARM screen (See page 31) to notify the user of issues which the Dryer had encountered during its operation.

Setting Values

Pressing the individual numbers in the second row of the scree can select the field

(Month, Day, Year, Hours and Minutes) he wishes to change.

Enter the values you would like to set by pressing the number keys. Press you are finished to set the new values or new ones. Press

Press the

SYSTEM MENU button in the CLOCK MENU SCREEN to return back to the

END to return back to the CLOCK MENU screen.

CLR (Clear) to erase the current values an

n shown above, the operator

ENT (Enter) when

d reenter

system menu screen and the next set of programmable features.

Hour Meters

This screen monitors the number of hours that the dryer, machine blower, and dryer blower have operated.

In addition to monitoring the total number of hours of equipment operation, it also has resettable fields whic

h allow the operator to set the counter back to zero. This is useful for

monitoring hours between equipment maintenance periods. Press the

DRYER RESET button, MB RESET button, and/or DB RESET button to

the counters. When and if the counters have been reset on the controller, the operator can return back to the

MAIN MENU

or SYSTEM MENU by touching the appropriate button on the screen.

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reset

Page 34

Input Status (UPDATE)

This screen allows the operator to view the status of the variables contributing to the input of material into the drying system. It also is useful in troubleshooting system issues (i.e. a dirty filter or low material level in a hopper).

At this point the operator may choose the menu, or

MAIN MENU to return to main menu, or press OUTPUTS to access the output

SYSTEM MENU button to go back to the system

screen.

Output Status (UPDATE)

This screen allows the operator to view the status of variables contributing to the disbursement of material from the drying system to the molding machine.

At this point the operator may choose the menu, or

MAIN MENU to return to main menu, or press OUTPUTS to access the output

SYSTEM MENU button to go back to the system

screen.

SYSTEM SETTINGS

The SAVE SETTING button will save the current dryer parameter settings.

RESTORE SETTINGS button will restore the dryer parameter settings that were saved

The previously.

The RESTOR FACTORY DEFAULTS button will restore the initial dryer parameter settings as the dryer was shipped from the factory.

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At this point the operator may choose to return to the SYSTEM MENU or MAIN

MENU by pressing the appropriate buttons.

Service Menu

This service menu screen is PASSWORD PROTECTED and meant for manufacturer personnel use only.

Press the

RETURN key to go back to the SYSTEM MENU.

Touching the back to the overall menu screen.

MAIN MENU button in the SYSTEM MENU screen, will return the operator

Alarm Screens

This screen allows the operator to review the number and type of issues that the Drying/Conveying System has encountered during its operation.

Problems can be viewed by Date, Hour, and Comment.

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Because of the size of the screen, only three (3) comments/alarms can be viewed at a time. To view alarms not visible on the screen, press the alarm, press the

UP button to scroll upward in the alarm history.

DOWN button. To return to a particular

Pressing the system. You will only get

At this point the operator can return back to the

CNV (Convey) in this screen will take the operator to the CONVEY STATUS of

CNV alarms with a Nomad dryer.

DRYER MENU or MAIN MENU by

touching the appropriate button on the screen.

Alarm Screen Example

This is an example of what a typical Alarm screen looks like. The user will see the message causing the alarm in the top half of the display with an

ALARM SILENCE button in the

lower half. To turn off the alarm, the user must press the ALARM SILENCE button. This will cancel the

alarm.

Redundant Safety Controller Display

Optional

The Redundant Safety Controller limits the process air temperature from exceeding specific temperatures in case of a catastrophic failure of the primary PLC process air temperature control system. The controller is a modular, self-contained unit removable from the mounting housing. All parameters are factory set and adjusted; normally, no field adjustment to the internal controls are necessary.

Figure5: Typical Redundant Safety Controller Display

Setting the Redundant Safety Controller

The Redundant Safety Controller alarm setting is changed by pressing the up and down keys to input the alarm value. The upper display reading indicates the Process Value, while the

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lower display indicates the High Point Setting alarm value. The factory setting for the High Point Alarm Value

(L1-hi ) is 150°F (-23°C).

Restoring the WATLOW Redundant Safety Controller to Factory Setup

If the preset parameters on the controller have been tampered with and it no longer functions properly, call the Service Department.

Note: This controller is not meant to be modified.

WATLOW Operating Parameters

The WATLOW controller has only one mode selection; ALARM. The factory has set the security level to protect the critical parameters from being accidentally

changed. Below is an explanation of the modes you will have access to and the manufacturer default settings.

Entering Operating Parameters to Select Modes

To enter the display:

1. Press both the Up

and Down keys for three seconds from the home page.

The word SEE will appear in the upper display and PAGE will appear in the lower display.

2. Press the Advance Key

3. Press the Up

or Down keys to change the parameter value.

to move through the parameter prompts.

4. Press the RESET Key at any time to return to the Home Page display.

Figure 6: Setting List for Redundant Safety Controller (WATLOW), Part No. A0568961

Mode Parameter Setting range Default Manuf.

setting

SEn Sensor Type 0-3 0 -

Lin Thermocouple Linearization 0-10 0 H (1)

C-F Temperature Units Fahrenheit / Celsius F -

S.dEC Temp. Decimal Places 0 – 0.0 0 -

IS.En INFOSENSE™ Yes / No No Sc.Lo Process Scale Low 4.00 to 20.00 mA

1.00 to 10.00V

Sc.hi Process Scale High 4.00 to 20.00 mA

1.00 to 10.00V

CAL Calibration Offset -999 to 999 0 -

Ftr.E Input Filter Off, DiSP, Cont, both OFF -

Ot 1 Output 1 Function Limit (2) (2) LSd1 Output 1 Limit Sides Both, High, Low Both High hyS1 Limit 1 Hysteresis 0.0 to 999.0 1.0 -

Ot2 Output 2 Function Off / Process Alarm / Limit (2) OFF -

LSd2 Output 2 Sides Both / high / low Both -

4.00 mA

1.00V

20.00 mA

5.00 V

400

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None, Process Value, Limit 1 Low Set, Limit 1 High Set, Limit 2 Low Set, Limit

UdSP Upper Display Look

LdSP Lower Display Look

LOC Lockout

2 High Set, Alarm 2 Low Set, Alarm 2 High Set, Limit 3 Low Set, Limit 3 High Set, Alarm 3 Low Set, Alarm 3 High Set None, Process Value, Limit 1 Low Set, Limit 1 High Set, Limit 2 Low Set, Limit 2 High Set, Alarm 2 Low Set, Alarm 2 High Set, Limit 3 Low Set, Limit 3 High Set, Alarm 3 Low Set, Alarm 3 High Set (0) no lockout, (1) Programming and Setup Page Locked, (2) Limit Set Points are the only Operation Page parameters accesible, (3) Full Lockout.

Process -

Limit 1

High Set

0 2

4-2 System Operation Procedures

1. Turn the disconnect switch on the control panel to the ON position. Power is applied to the voltage

line fuses and line side of the control power switch.

2. Turn the control power switch to the

ON position. Power is applied to the PLC and touch screen.

Push the start button on the PLC and the valve will move to the start position as follows:

a. The valve motor rotates until the cam switch makes 2 transitions. b. If the cam switch does not make a transition within 10 seconds, a valve

motor fault alarm is generated. The alarm horn and light are activated. The valve motor, heaters, and blower shut off. Pressing the

ALARM SILENCE

pushbutton will deactivate the alarm horn and light.

Note: Cycle control power to restart the dryer.

c. The valve will normally complete one full cycle (revolution). If sequence

shutdown is not initiated (in 10 Seconds) and control power switch or disconnect are turned off:

1. The bed in process at power-down will remain in

process.

2. The bed in regeneration at power-down will remain in

regeneration.

3. The regeneration timing cycle will restart from the

beginning.

3. Once the control power is on and no fault conditions exist, turning the Off-On switch to the ON

position and pressing the

START button on the touch screen will start the dryer as follows:

a. The process heater is turned on and controlled by the PLC. b. The process/regen blower is started. c. The regen heater is turned on and the regeneration timing sequence is

initiated. The regen heater is controlled by the PLC.

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4. If either the left or right bed safety temperature switch opens, a

generated. The alarm horn and light are activated. The process heater, regen heater, and process/regen blower are turned off. Pressing the will deactivate the alarm horn and light.

ALARM SILENCE button on the touch screen

REGEN TEM SAFETY is

5. Turn the

dryer. If the switch is still open, the dryer will not restart.

6. If the PLC/touch screen faults, the optional redundant high temperature safety device opens, or the

process heater safety switch opens, a process heater fault is generated. The alarm horn and light are activated. The process heater, regen heater, and process/regen blower are turned off. Pressing the

ALARM SILENCE pushbutton will deactivate the alarm horn and light.

7. Turn the

fault condition still exists, the dryer will not restart.

8. If the process blower overloads trips, a

and light are activated. The process heater, regen heater, and process/regen blower are turned off. Pressing the

9. Reset the motor overload and turn the

button on the touch screen to restart the dryer.

10. The valve position limit switch enables the right bed heater and provides an input signal to the PLC

when actuated by the cam lobe. Each heater is controlled by the PLC.

11. Upon completion of the

by the PLC and the

12. Once the

transition. Upon making a transition, the timing sequence is restarted for the new bed.

13. When a

light will activate. Press

POINT

Off-On switch to the ON position and push the touch screen START button to restart the

Off-On switch to the ON position and push the START button to restart the dryer. If the

PROCESS BLOWER FAIL is generated. The alarm horn

ALARM SILENCE button will deactivate the alarm horn and light.

Off-On switch to the ON position and push the START

HEAT portion of the regeneration sequence, the regen heaters are disabled

COOL time begins.

COOL time has expired, the valve motor is turned on until the cam switch makes a

HIGH DEW POINT alarm is generated by the dew point controller, the alarm horn and

ALARM SILENCE to deactivate the alarm until the next HIGH DEW

alarm occurs.

14. The dryer is shut off by pushing the

On/Off switch to the OFF position.

15. Refer to the schematic drawing enclosed in the control enclosure.

SHUTDOWN button on the PLC or turning the control power

4-3 Shutting Down the Dryer

1 Turn off the conveying system supplying the drying hopper and/or machine. Press the

SHUTDOWN button for the dryer to complete its cycle.

2 When processing is complete, close the hopper slide gate and shut down any in-line companion

equipment, such as the aftercooler.

3 If the dryer is shut down using the

heater will shut off and the bed regeneration process will be completed. When the dryer is started at a later date the process air will be directed through the bed that was regenerated last.

4 If the dryer control switch is turned off without using the dryer shutdown feature, the dryer and the

on board conveying system will stop immediately. When the dryer is started at a later date, the process air will be directed through the last bed that was being used when the dryer control switch was turned off. If a bed was being regenerated when the dryer control switch was turned off, the regeneration process would begin over again on that same bed.

SHUTDOWN button on the dryer status screen, the process

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Page 40

Chapter 5: Maintenance

5-1 Preventative Maintenance Schedule

The checklist below contains a list of items which should be inspected and/or replaced to keep your Portable Drying/Conveying System operating at peak efficiency. Perform each inspection at the regular intervals listed below.

System model #

Serial #

Every Day

Inspect all filters for wear, replace/clean if dirty or worn.

Date/

Every week

Check to make sure that all hose connections are air tight.

Date/

Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Lock out electrical power and inspect electrical wiring for integrity. Lock out electrical power and check heater elements for continuity using an ohmmeter. Check dew point and temperature tracking with an external dew point monitor and pyrometer. Visually inspect the shifting of the airflow valve during one cycle.

Every year

Inspect desiccant. Replace if brown or broken.

Next scheduled

inspection

Actual inspection

Date/By

Next scheduled

inspection

Actual inspection

Date/By

Every two years

Replace desiccant.

Scheduled

replacement date

Actual replacement

Date/Work done by

Scheduled

replacement date

Actual replacement

Date/Work done by

- Photocopy this page for your maintenance records -

Date/

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Page 41

5-2 Preventative Maintenance

This section describes maintenance procedures which will increase the longevity and efficiency of your Portable Drying/Conveying System. Perform them at the regular intervals listed on the checklist on the previous page.

Servicing Process Air Filters

Caution! Operating the dryer without the process air filter installed voids your

warranty!

Filter cleaning is an important part of your dryer maintenance program.

Dehumidifying dryers have a single cartridge canister-type filter in the process air loop. The filter protects blowers from plastic fines drawn in from the drying hopper and prevents the desiccant from being contaminated. Regular filter cleaning is essential to keep your dryer operating at peak efficiency.

You can blow or vacuum the dirt out of the filter with compressed air, but remember, it could become damaged from high-pressure blowing.

Recommendations for Cleaning and Replacing Filters

• Turn off and/or lock out electrical power to the dryer.

• Remove the threaded fastener securing the filter access cover, then remove the cover.

• Remove the nut on the center retaining rod to remove the filter cartridge.

Figure7: Air Filter Location and Disassembly

Air In

Air Out

Thumb Nut

Clamp

Dust Can

Filter

Cartridge

Filter Housing

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Page 42

Vacuuming

Try vacuum-cleaning a soiled filter first. Vacuuming removes most large particles and surface contaminants, and may suffice for the first time you clean a filter. Use a commercialduty (recommended) or household vacuum cleaner. Vacuum the filter from the air intake (dirty) side only.

Cleaning with Compressed Air

Blow clean, dry compressed air up and down the pleats, blowing out the filter from the inside out. Remove loose dirt from the filter with compressed air or vacuum from the outside.

Caution! DO NOT clean/wash filter with water!

After each cleaning:

• Inspect the filter element. Briefly hold a light bulb behind the

element and look for any

fatigued paper or residual dirt. Inspect for

holes and tears by looking though the filter toward a bright light. Check for damaged gaskets or dented metal parts. Do not re-use a damaged filter!

• Check the gasket for damage. A damaged gasket allows

contaminants into the process. Replace as needed.

Servicing the Dew Point Monitor

The accuracy of the dew point monitor on mini dryer systems depends on proper operation of the dew point sensor and the control board. The dew point sensor is in the process air stream and is therefore susceptible to contamination.

Dew point sensor life depends on:

• Air temperature and flow passing over the sensor.

• The amount of fines (dust) in the process air.

• The amount of plasticizer vapor in the process air.

Once every six months, the dryer operator should monitor the initial dew point sensor readings and establish a periodic replacement schedule as needed.

Caution! Do not attempt to check the continuity or resistance of the dew point sensor.

The sensor will be destroyed!

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5-3 Corrective Maintenance

This section provides you with the information necessary to correct or repair any issues which might appear during the normal operation of your dehumidifying dryer. Although we have listed how to perform these procedures, it is recommended that you call the Service Department to have any in-depth maintenance performed.

Symptoms of Worn Desiccant

The moisture absorption capacity of the desiccant used in your dehumidifying dryer degrades after an indefinite period of time. Useful life depends on variables such as the condition of the process filter, how much dust and fines have been passed through the filter and got into the desiccant chamber, and plasticizer vapors in the return air.

WARNING! Handling desiccant material is HAZARDOUS.

Wear an N-100 type safety filter mask or equivalent to avoid prolonged breathing of desiccant dust. Wear safety goggles and gloves to avoid contact with eyes and skin.

• Handle with adequate ventilation.

• Wash hands thoroughly after handling.

+ FIRST AID +

In case of eye contact, immediately flush eyes

with plenty of water for at least 15 minutes.

SEE A PHYSICIAN IMMEDIATELY IF IRRITATION PERSISTS.

Replacing Worn Desiccant

Caution! DESICCANT BEDS ARE HOT DURING OPERATION.

To avoid burn hazard, make sure desiccant beds are sufficiently cool before replacing worn desiccant.

To access the Desiccant Bed:

1. Disconnect electrical power to the dryer.

2. Using a 1/8” Allen wrench, remove the four (4) 10-32 button head screws holding the

Desiccant Cap to the Regeneration Heater.

3. Remove the Desiccant Cap.

4. With a shop vacuum, carefully remove all desiccant from each tower.

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Page 44

Figure 8: Desiccant Bed Location and Disassembly

13X Molecular Sieve

8x12 Beads

Regeneration Heater

Regeneration

Thermocouple

Hi Temperature

Snap Switch

Undo (4) 10-32 Button

Desiccant Cap

(2) 4-40 screws

Undo (4) 10-32 Button Head Screws using 1/8

Head Screws using 1/8

Head Screws using 1/8 Allen Wrench

Allen Wrench

1" Wide x 1/8" Thick Silicon

Strip and Stick Gasket

16 Mesh 0.028 Diameter Wire

Stainless Steel Screen

1" Wide x 1/8" Thick High

Temperature Gasket

Caution! You should properly dispose of any discarded desiccant.

Consult local disposal regulations for more information.

Inspect each lower desiccant screen for tears or holes where desiccant burned-through. Replace as needed.

1. After cleaning each chamber, add the full amount of bead desiccant specified per bed. Amounts are

listed in the Desiccant Amounts Table below. Smooth the top level, and finally add another layer of the remaining bead desiccant to the top. Make sure this layer is level and smooth.

Tap the chambers with a rubber melet gently for one or two minutes to make sure the desiccant is packed tight. Add more desiccant if required.

2. Repeat the previous step for the other bed.

3. 3. Inspect the gaskets and replace if necessary. Place the screen in between the desiccant tank and the

cap.

4. Reconnect all the hoses and panels when done.

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Page 45

Figure 9: Required Desiccant Amounts

Dryer 8 x 12 bead Total

model Part no. lbs. Kg

15 cfm 7.0 3.25 30 cfm 15.75 7.25 60 cfm

W00018051

37.5 17.0

Replacing the regeneration heaters Procedures (see figure 8).

1. Sketch the heater wiring configuration so you can properly re-wire the heater. 5 Remove the ceramic nuts and wires to the heater plate assembly being removed or replaced. 6 Remove the six (6) 10-32 button head screws securing the process heater plate using a 1/8” Allen

wrench and slide out the assembly.

7 Remove the heater(s) from the mounting plate by removing the large brass nuts and washers. 8 Re-install the heater(s) and heater plate assemblies in reverse order. Install new heater gaskets and

securely tighten all fasteners.

Caution! Heater loops should not touch each other.

“Hot spots” lead to premature heater failure!

2. Reinstall the wires based on the sketch you made earlier.

Reinstall the ceramic nuts to each heater terminal.

Replacing the Process Heater

The dehumidifying dryers utilize a single-phase Calrod-type heater element. This heater element is mounted in the center compartment below the desiccant beds. Although the replacement procedure is the same for each heater, the wattage varies by model, voltage, temperature range, etc.

WARNING! Hazardous electrical current present.

Disconnect and lock out power before you replace heater elements!

Figure 10: Process Heater Location and Disassembly

Undo (6) 10-32 Button

1" Wide x 1/8" Thick High

Temperature Gasket

Head Screws using 1/8 Allen Wrench

(2) 4-40 screws

Hi Temperature

Snap Switch

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Page 46

Procedures

1. Sketch the heater wiring configuration so you can properly re-wire the heater.

2. Remove the ceramic nuts and wires to the heater plate assembly being removed or

replaced.

3. Remove the six (6) 10-32 button head screws securing the process heater plate using

a 1/8” Allen wrench and slide out the assembly.

4. Remove the heater(s) from the mounting plate by removing the large brass nuts and

washers.

5. Re-install the heater(s) and heater plate assemblies in reverse order. Install new

heater gaskets and securely tighten all fasteners.

Caution! Heater loops should not touch each other.

“Hot spots” lead to premature heater failure!

6. Reinstall the wires based on the sketch you made earlier.

7. Reinstall the ceramic nuts to each heater terminal.

Replacing/Cleaning the Cooling Coils

WARNING! Hazardous electrical current present. Disconnect and lock out power before you replace heater elements!

Figure 11: Cooling Coil Location and Disassembly

1" Wide x 1/8" Thick High

Temperature Gasket

Undo (4) 10-32 Button Head Screws using 1/8 Allen Wrench

Use compressed air or a steam cleaner to blow the dust off or clean any oily residue on the coil.

Water flow requirement: If used as an After-Cooler: 3 to 4 GPM @80F. If used as a Plasticizer Trap: 3 to 4 GPM @ 40F to 45F.

Note: To clean the cooling coil, use compressed air or a steam

cleaner to blow the dust off or clean any oily residue on the coil.

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Page 47

Replacement Procedures

1. Shut down the dryer, tag out and lock out the controls if necessary.

2. Shut the water off to the cooling coil.

3. Remove the four 10-32 bolts.

4. Gently slide the cooling coil out.

5. Visually inspect the coil for leaks, dirt, and ant sign of volatiles.

6. Blow the dust out, or if the coil is covered with plasticizer, steam clean it.

7. Place the coil back in its housing. Make sure the gasket is OK, replace if necessary.

8. Inset the four 10-32 bolts back in place.

9. Turn the water to the cooling coil back on.

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Page 48

Chapter 6: Troubleshooting

6-1 Introduction

The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal trouble-shooting must be accomplished with the power off, line fuses removed, and with the machine tagged as out of service.

The use of good quality test equipment cannot be over-emphasized when troubleshooting is indicated. Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine. Be sure that the voltmeter has at least minimum impedance of 5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales. Popular combination meters, VOM and VTVM can be selected to provide the necessary functions.

Before making haphazard substitutions and repairs when defective electrical components are malfunctioning, we recommend that you check the associated circuitry and assemblies for other defective devices. It is common to replace the obviously damaged component without actually locating the real cause of the trouble. Such hasty substitutions will only destroy the new component. Refer to wiring diagrams and schematics.

Locating mechanical problems, should they occur, is relatively straightforward. When necessary, refer to the parts catalog section.

Alarm Message Cause Corrective Action Dryer Status

VALVE POSITION

FAULT

VALVE MOTOR

OVERIDE

The limit switch on the valve may not have been wired correctly.

The valve has made enough rotations and the correct position of the valve was not detected.

The switch is indicating the incorrect desiccant tank is in regeneration. Check the wiring of the switch against the wiring diagram. Make sure all the wire connections are tight.

Limit switch may be out of position. Re-adjust the switch to make sure it trips when it is at the high position, and it does not touch the cam when it is at the low position.

Limit switch may be faulty. Replace the switch and make sure the wires are connected correctly.

- Dryer Shuts down:

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm light is ON

- Alarm horn is ON.

- Dryer Shuts down:

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm light is ON

- Alarm horn is ON.

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Alarm Message Cause Corrective Action Dryer Status

PROCESS

SENSOR FAIL

REGEN

SENSOR FAIL

PROCESS HIGH TEMP

The process temperature thermocouple is open.

The Regeneration temperature thermocouple is open.

The process temperature has exceeded the alarm set point.

The process temperature thermocouple is not connected to the temperature controller. Make sure the connections are correct and tight.

The process temperature thermocouple is damaged. Replace the thermocouple.

The regeneration temperature thermocouple is not connected to the temperature controller. Make sure the connections are correct and tight. The regeneration temperature thermocouple is damaged. Replace the thermocouple.

Make sure the process filter is clean. Clean or replace if necessary. Double check the alarm set point. 35°F Check the positioning of the thermocouple inside the air inlet of the drying hopper. The tip of the thermocouple should be centered to the tube, and not touching any metal part of the tube. The drying temperature set point is lower than dryer capabilities. Check the dryer specs. Make sure all the hose connections are tight. Make sure the regeneration timing cycle matches the specs. If not contact Service department.

- Dryer Shuts Down:

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm light is ON

- Alarm horn is ON.

- Dryer Shuts Down:

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm light is ON

- Alarm horn is ON.

- Dryer Shuts Down:

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm light is ON

- Alarm horn is ON

Portable Drying/Conveying Systems Chapter 6: Troubleshooting 49 of 63

Page 50

Alarm Message Cause Corrective Action Dryer Status

PROCESS

SENSOR FAIL

REGEN

SENSOR FAIL

PROCESS HIGH TEMP

The process temperature thermocouple is open.

The Regeneration temperature thermocouple is open.

The process temperature has exceeded the alarm set point.

The process temperature thermocouple is not connected to the temperature controller. Make sure the connections are correct and tight.

The process temperature thermocouple is damaged. Replace the thermocouple.

- Dryer Shuts Down:

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm light is ON

- Alarm horn is ON.

- Dryer Shuts Down:

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm light is ON

- Alarm horn is ON.

- Dryer Shuts Down:

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm light is ON

- Alarm horn is ON

Portable Drying/Conveying Systems Chapter 6: Troubleshooting 50 of 63

Page 51

Alarm Message Cause Corrective Action Dryer Status

REGEN LOW

TEMP

PROCESS LOOP BREAK

HIGH DEW POINT

The regeneration temperature did not get within the alarm set point.

The process drying air temperature has not made any improvement toward the drying temperature set point for more than 480 seconds.

The dew point reading has exceeded the dew point alarm set point.

Make sure all the hose connections inside the dryer are tight.

Check the regeneration heater fuses. Replace if necessary.

Check the heater contactors. Replace if necessary. Check the heaters. Replace if necessary.

Check incoming voltage to the dryer specs.

Check the positioning of the thermocouple inside the air inlet of the drying hopper. The tip of the thermocouple should be centered to the tube, and not touching any metal part of the tube. Make sure all the hose connections are tight. For drying temperature of 250°F or higher, delivery air hose should be insulated. Check the heater contactors. Replace if necessary.

Check the heaters. Replace if necessary. Check incoming voltage to the dryer specs. Make sure the process air filter is clean. Clean or replace if necessary. Make sure all the hose connections and all the components of the dryer have proper seals on them (desiccant tanks, heater box, filters, after-cooler … ). Tighten the connections and replace any damaged seals. Make sure the regeneration timing cycle matches the specs. If not contact Service department. Desiccant may be contaminated and blocking the air flow. Check desiccant, replace if necessary.

- Dryer Normal :

- Process blower ON.

- Process heaters ON.

- Regen heaters ON.

- Alarm Message ON.

- Alarm horn is OFF.

- Dryer Shuts Down :

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm Message ON.

- Alarm horn is ON.

- Dryer Normal :

- Process blower ON.

- Process heaters ON.

- Regen heaters ON.

- Alarm Message ON.

- Alarm horn is OFF.

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Page 52

Alarm Message Cause Corrective Action Dryer Status

PROCESS BLOWER FAIL

PROCESS HEATER FAIL

DIRTY FILTER

The process blower pressure switch did not detect enough pressure.

Process blower overload has tripped. Process blower motor has failed.

The process heater safety contactor is not responding.

The filter pressure differential switch has tripped.

Make sure the process air filter is clean. Clean or replace if necessary.

Check the rotation of the blower. Check the pressure switch hose connection. Replace hoses or the pressure switch.

Check the over load rating against the wiring diagram. Adjust accordingly. Check the wiring of the blower. Make sure it is wired for the proper voltage. Check the process blower fuses for any fault. Replace if necessary. Check the blower motor starter. Replace if necessary. Check the blower motor. Replace if necessary. Check the incoming voltage against the name plate of the dryer. Check the heater fuses, replace if necessary.

Make sure the wiring is correct and wire connections are tight. Check the process heater safety contactor. Replace if necessary. Make sure the process air filter is clean. Clean or replace if necessary

Make sure the filter housing is installed correctly, and the connections are tight. Check the hoses to the filter pressure differential switch is connected correctly, are not damaged, and all the connections are tight. Replace the hoses if necessary. Check the wiring connections to filter pressure differential switch against the print. Tighten the connections.

- Dryer Shuts Down :

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm Message ON.

- Alarm horn is ON.

- Dryer Shuts Down :

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm Message ON.

- Alarm horn is ON.

- Dryer Normal :

- Process blower ON.

- Process heaters ON.

- Regen heaters ON.

- Alarm Message ON.

- Alarm horn is OFF.

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Alarm Message Cause Corrective Action Dryer Status

DIRTY FILTER

VALVE MOTOR FAIL

P RETURN SENSOR FAIL

PROCESS TEMP SAFETY

REGEN TEMP SAFETY

The filter pressure differential switch has tripped.

The limit switch on the valve may not have been wired correctly.

The return air temperature thermocouple is open or failed.

The high temperature snap switch of the process heater box has tripped.

The high temperature snap switch on of the regeneration heater boxes has tripped

Check the pressure setting of the filter pressure differential switch against the print. Adjust accordingly. Check the filter pressure differential switch to make sure it is functioning. Replace is necessary. The switch is indicating the incorrect desiccant tank is in regeneration. Check the wiring of the switch against the wiring diagram. Make sure all the wire connections are tight. The return air temperature thermocouple is not connected to the temperature controller. Make sure the connections are correct and tight. The return air temperature thermocouple is damaged. Replace the thermocouple. Make sure the process air filter is clean. Clean or replace if necessary.

Make sure all the hose connections are tight. The process heater contactor has failed in the closed position. Check heater contactor, replace if necessary. Check the high temperature snap switch, replace if necessary. Make sure the process air filter is clean. Clean or replace if necessary.

Make sure all the hose connections are tight. The Regeneration heater contactor has failed in the closed position. Check heater contactor, replace if necessary. Check the high temperature snap switches, replace if necessary.

- Dryer Normal :

- Process blower ON.

- Process heaters ON.

- Regen heaters ON.

- Alarm Message ON.

- Alarm horn is OFF.

- Dryer Shuts Down :

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm Message ON.

- Alarm horn is ON.

- Dryer Normal :

- Process blower ON.

- Process heaters ON.

- Regen heaters ON.

- Alarm Message ON.

- Alarm horn is OFF.

- Dryer Shuts Down :

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm Message ON.

- Alarm horn is ON.

- Dryer Shuts Down :

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm Message ON.

- Alarm horn is ON.

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6-2 Determining Temperature Controller Errors or Sensor Errors

Using a Thermocouple

If the controller displays a temperature that is close to room temperature (70ºF/21ºC) when you short-circuit controller input terminals, the controller is normal and the sensor is probably broken, short-circuited, or incorrectly wired.

Other service problems or questions can be answered by contacting the Service Department.

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Chapter 7: Appendix

7-1 Warranty

Unless otherwise specified, this product includes a Standard ONE YEAR PARTS.

Warranty Specifications

The manufacturer hereby expressly warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions, as set forth in the operating manuals for such equipment. THE FOREGOING EXPRESS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, GUARANTIEES, AGREEMENTS, AND SIMILAR OBLIGATIONS OF THE COMPANY AND/OR MANUFACTURER (UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE PAGE OR LIMITED BY THE MANUFACTURERS’ WARRANTY FOR PARTS). The Company’s obligation is limited to repair or replace FOB the factory any parts that are returned, prepaid, within one year of equipment shipment to the original purchaser, and which in the Company’s opinion, are defective. Any replacement part assumes the unused portion of this warranty.

Warranty Restrictions

This parts warranty does not cover any labor charges for replacement of parts, adjustment repairs, or any other work. This warranty does not apply to any equipment which, in the Company’s opinion, has been subjected to misuse, negligence, or operation in excess of recommended limits, including freezing or which has been repaired or altered without the Company’s express authorization. If the serial number has been defaced or removed from the component, the warranty on that component is void. Defective parts become the property of the warrantor and are to be returned immediately, without any further use or handling.

Warranty Liabilities

THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT RESULT FROM THE USE OF THIS PRODUCT. Some states do not allow the exclusion or limitation of special, consequential or incidental damages, so the above limitation may not apply to you. The Company’s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts. The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty. No person, agent, manufacturer, distributor, dealer, installer or company is authorized to change, modify or extend the terms of this warranty in any manner whatsoever.

The time within which an action must be commenced to enforce any obligation of the Company’s arising under this warranty, or under any statute or law of the United States or any state thereof, is hereby limited to the duration of this warranty. Some states do not permit this limitation, so the above may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. For transactions involving the potential applicability of international law or that of a foreign country, this warranty policy and the procedures hereunder shall be governed by

Portable Drying/Conveying Systems Chapter 7: Appendix 55 of 63

Page 56

applicable federal and state law, but not by the United Nations Convention on Contracts for the Sale of Goods.

Customer Responsibilities

Any sales, use, or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser.

7-2 Optional Components

The following is a list of options which your Portable Drying/Conveying System may have been equipped with:

• High Temperature Option (with Aftercooler)

• Casters.

7-3 Technical Specifications

Annex B Information

The following design information is provided for your reference:

1. No modifications are allowed to this equipment that could alter the CE compliance

2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit)

3. Humidity range: 50% relative humidity

4. Altitude: Sea level

5. Environment: Clean, dust-free and non-explosive

6. Radiation: None

7. Vibration: Minimal, i.e. machine mounting

8. Allowable voltage fluctuation: +/- 10%

9. Allowable frequency fluctuation: Continuous +/- 1%

10. Nominal supply voltage: 460/3/60 (Verify on serial number tag)

11. Earth ground type: TN (system has one point directly earthed through a

protective conductor)

12. Power supply should include a ground connection.

13. Over-current protection is supplied in the dryer and conveying system, but

additional protection should be supplied by the user.

14. The door-mounted disconnect serves as the electrical disconnect device.

15. Dryer and conveying system are not equipped with local lighting.

16. Functional identification

17. Dryer and conveying system are equipped with a CE mark

18. Dryer and conveying system are supplied with an operating manual in the

language of the destination country.

19. Cable support may be required for power cord, depending on final installation.

20. No one is required to be in the interior of the electrical enclosure during the

normal operation of the unit. Only skilled electricians should be inside the enclosure for maintenance.

21. Doors can be opened with a screwdriver, but no keys are required.

Intermittent +/- 2%

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Page 57

22. Two-hand control is not required or provided.

23. All dryers and conveying equipment should be moved around and set in a place

with a lift truck or equivalent.

24. There are no frequent repetitive cycles that require manual control⎯repetitive

functions are automatic while the drying and conveying system is operating.

25. An inspection report detailing the functional test is included with the dryer and

conveying system.

26. The machine is not equipped with cable less controls.

27. Color-coded (harmonized) power cord is sufficient for proper installation.

Aftercooler Design Specifications

Entering water temp.

ºF ºC

85ºF

50°F (If used as Plasticizer trap)

10°C (If used as Plasticizer trap)

29ºC

7-4 Drawings and Diagrams

Figure 12: Standard Model (180°F to 250°F) Air Flow Schematic

Dryer valve

Utilizing -40F dew

point air to regenerate

and cool the

desiccant.

13X Molecular

Sieve 8x12

beads.

Double wall

constructed heater

housing and

desiccant

container.

Regeneration

thermocouple,

monitors and

controls the regeneration temperature

Pressure switch, makes

sure the blower is

functioning correctly.

2”

Hose

2” Hose

2”

Hose

Regeneration

2”

Hose

Process /

Air Filter

Make-Up

Air

Low watt density

heaters, can

operate safely

with minimum air

flow.

High

temperature

snap switches,

monitor the heat

status of the

heater housings.

High pressure peripheral

2-1/2” Hose

Process Air

Temperature

Thermocouple

Position

regenerative blower.

Return Air

Temperature

Thermocouple

Position

Insulated stainless steel drying hopper

2-1/2” Hose

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Page 58

Figure 13: High Heat Model (180°F to 400°F) Air Flow Schematic

Pressure switch, makes

sure the blower is

Dryer valve

Utilizing -40F dew

point air to regenerate

and cool the

desiccant.

13X Molecular

Sieve 8x12

beads.

Double wall

constructed heater

housing and

desiccant

container.

Regeneration

thermocouple,

monitors and

controls the

regeneration

temperature

functioning correctly.

2”

Hose

2” Hose

2”

Hose

Process /

Regeneration

Air Filter

Low watt density

heaters, can

operate safely

with minimum air

flow.

High

temperature

snap switches,

monitor the heat

status of the

heater housings.

2-1/2” Hose

High pressure peripheral

regenerative blower.

Optional Return

Air Cooler

Hose

Process Air

Temperature

Thermocouple

Position

2”

Return Air

Temperature

Thermocouple

Position

Insulated stainless steel drying hopper

2-1/2” Insulated

Delivery Air Hose

Portable Drying/Conveying Systems Chapter 7: Appendix 58 of 63

Page 59

Figure 14: Low Heat Model (120°F to 250°F) Air Flow Schematic

High pressure

peripheral

regenerative blower.

housings.

Dryer valve

Utilizing -40F dew

point air to

regenerate and cool

the desiccant.

13X Molecular

Sieve 8x12

beads.

Double wall constructed

heater housing

and desiccant

container.

Regeneration

thermocouple,

monitors and

controls the

regeneration

temperature

Pressure switch, makes

sure the blower is

functioning correctly.

Process /

Regeneration

Air Filter

Low watt density

heaters, can

operate safely with

minimum air flow.

High temperature

snap switches,

monitor the heat

status of the heater

2-1/2”

Hose

2”

Hose

Return Air

Temperature

Thermocouple

Position

Insulated

stainless steel

drying hopper

Optional Pre-Cooler for

Low Temperature

Operation 120F to 180F

Portable Drying/Conveying Systems Chapter 7: Appendix 59 of 63

Page 60

7-5 Spare Parts List

Figure 15: Level 1 Spare Parts List (Electrical & Mechanical)

DRYER SPARE PARTS LIST AD15, AD30, AD60

LEVEL 1 ( Electrical Components )

PART # SIZE Description A0568932 2 Fuse for the Heater Elements 3 A0568933 2.5 Fuse for the Heater Elements 3 3 A0568934 3 Fuse for the Heater Elements 3 A0534039 3.5 Fuse for the Heater Elements 3 A0534040 4 Fuse for the Heater Elements 3 A0534041 5 Fuse for the Heater Elements 3 3 3 3 A0534042 6 Fuse for the Heater Elements 3 3 3 A0534043 7 Fuse for the Heater Elements 3 3 3 3 A0534044 8 Fuse for the Heater Elements 3 3 3 3 A0534046 10 Fuse for the Heater Elem ents 3 A0534047 12 Fuse for the Heater Elem ents 3 3 A0534048 15 Fuse for the Heater Elem ents 3 3 3 3 3 3 3 A0534049 20 Fuse for the Heater Elem ents 3 3 A0568936 25 Fuse for the Heater Elem ents 33 A0434051 30 Fuse for the Heater Elem ents 3 A0568909 1 Fuse for the Process Blower 3 A0568910 1.125 Fuse for the Process Blower 3 A0568911 1.25 Fuse for the Process Blower 3 A0534804 2 Fuse for the Process Blower 3 A0568917 2.5 Fuse for the Process Blower 3 3 3 A0550577 3 Fuse for the Process Blower 3 A0568919 3.2 Fuse for the Process Blower 3 A0568921 4.5 Fuse for the Process Blower 3 A0550593 5.6 Fuse for the Process Blower 3 3 A0538062 6 Fuse for the Process Blower 3 A0568922 6.25 Fuse for the Process Blower 3 A0568923 7 Fuse for the Process Blower 3 A0568926 10 Fuse for the Process Blower 3 A0538069 12 Fuse for the Process Blower 33 A0536892 1.25 Fuse for the transformer 2 2 2 A0536894 1.6 Fuse for the transformer 2 2 2 A0536895 1.8 Fuse for the transformer 2 2 2 A0538001 3.2 Fuse for the transformer 2 2 2 2 2 2 A0538002 3.5 Fuse for the transformer 2 2 2 A0568941 2.8 Fuse for the transformer 1 (ALL) A0558078 0. 3- 1 Motor Overload 1 1 A0558079 1-2.9 Motor Overload 1 1 1 1 1 1 1 1 1 1 1 1 1 A0558082 1. 6- 5 Motor Overload 111

15CFM

30CFM

60CFM

208V 3PH

220V 50 HZ 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

220V 50 HZ 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

220V 50 HZ 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

60CFM

575V 60 HZ 3PH

LEVEL 1 ( Mechanical Components )

PART # SIZE Description W00015435 Dew Point Sensor Insert Cabl e 1 1 1 A0548556 Dew Point Sensor 1 1 1 A0566467 Val ve switch 1 1 1 W0005247 Process Air Filter 1 1 1 W00018051 13X molecul ar Sieve Desiccant ( 8 X 12 Beads ) 4.75 Lbs. 12. 25 Lbs. 27.5 Lbs. W00013983 High Temperature Gasket. 135 Inches 163 Inches 188 Inches A0566676 High Temperature Snap Switch. 3 3 3

Portable Drying/Conveying Systems Chapter 7: Appendix 60 of 63

Page 61

Figure 16: Level 2 & 3 Spare Parts List (Electrical & Mechanical)

DRYER SPARE PARTS LIST AD15, AD30, AD60

15CFM

30CFM

60CFM

LEVEL 2 ( Electrical Components )

PART # SIZE Description A0558000 Motor Starter 1 1 1

208V 3PH

230V 3PH

220V 50 HZ 3PH

460V 3PH

400V 50 HZ 3PH

208V 3PH

230V 3PH

460V 3PH

208V 3PH

575V 60 HZ 3PH

220V 50 HZ 3PH

400V 50 HZ 3PH

575V 60 HZ 3PH

230V 3PH

220V 50 HZ 3PH

A0548555 * Dew Point Circuit B oard 1 1 1

LEVEL 2 ( Mechanical Components )

PART # SIZE Description A0548621 Ceramic Cap for the End of Heater Elements 4 5 7 A0566478 750 W att s Heater element 208/220 Volts 2 2 0 0 A0566479 750 W att s Heater element 230 Volts 2 0 0 A0566480 750 W att s Heater element 400 Volts 2 0 0 A0566481 750 W att s Heater element 460 Volts 2 0 0 A0566482 750 W att s Heater element 575 Volts 2 0 0 A0566483 1250 Wat t s Heater Element 208/220 Volts 2 2 5 5 4 4 A0566484 1250 Wat t s Heater Element 230 Volts 2 5 4 A0566485 1250 Wat t s Heater Element 400 Volts 2 5 4 A0566486 1250 Wat t s Heater Element 460 Volts 2 5 4 A0566487 1250 Wat t s Heater Element 575 Volts 2 5 4 A0566601 2500 Wat t s Heater Element 208/220 Volts 0 0 3 3 A0566602 2500 Wat t s Heater Element 230 Volts 0 0 3 A0566603 2500 Wat t s Heater Element 400 Volts 0 0 3 A0566604 2500 Wat t s Heater Element 460 Volts 0 0 3 A0566605 2500 Wat t s Heater Element 575 Volts 0 0 3 A0568139 Screen Cover for the Desiccant Tanks 2 A0568140 Screen Cover for the Desiccant Tanks 2 A0568141 Screen Cover for the Desiccant Tanks 2 A0566682 1/4" OD Teflon Tube. 5 Feet 5 Feet 5 Feet A0566415 Washer / Gasket for the Heater Elements 8 10 14

DRYER SPARE PARTS LIST AD15, AD30, AD60

LEVEL 3 ( Electrical Components )

15CFM

30CFM

60CFM

PART # SIZE Description A0567921 Power Disconnect 1 1 1

A0568961 Redundant Temperature Safety Controller 1 1 1

LEVEL 3 ( Mechanical Components )

PART # SIZE Description A0534059 2" O.D. by 12 Ft Long Hi Temp Hose. 1 1 1 A0534060 2-1/2" O.D. by 12 Ft Long Hi T emp Hose. 1 1 1 A0566535 Return Air Cool i ng Coi l 1 1 1 A0536628 208/460 Volt Process Blower. 1 1 1 1 1 A0536629 575 Volt Process Blower 1 A0534079 208/460 Volt Process Blower. 1 1 1 1 1 A0535351 575 Volt Process Blower 1 A0552439 208/460 Volt Process Blower. 11111 A0552440 575 Volt Process Blower 1 W00015335 Dew Point Sensor Manifold 1 1 1 A0548558 Gasket for the Dew Point Sensor 1 1 1

208V 3PH

230V 3PH

220V 50 HZ 3PH

460V 3PH

400V 50 HZ 3PH

208V 3PH

230V 3PH

460V 3PH

208V 3PH

575V 60 HZ 3PH

220V 50 HZ 3PH

400V 50 HZ 3PH

575V 60 HZ 3PH

230V 3PH

220V 50 HZ 3PH

60CFM

460V 3PH

400V 50 HZ 3PH

575V 60 HZ 3PH

60CFM

460V 3PH

400V 50 HZ 3PH

575V 60 HZ 3PH

Portable Drying/Conveying Systems Chapter 7: Appendix 61 of 63

Page 62

7-6 Returned Material Policy

Credit Returns

Prior to the return of any material authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned.

Reason for requesting the return must be given. ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00

minimum) restocking charge. ALL returns are to be shipped prepaid. The invoice number and date or purchase order number and date must be supplied. No credit will be issued for material that is not within the manufacturer’s warranty period

and/or in new and unused condition, suitable for resale.

Warranty Returns

Prior to the return of any material, authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned.

Reason for requesting the return must be given. All returns are to be shipped prepaid. The invoice number and date or purchase order number and date must be supplied. After inspecting the material, a replacement or credit will be given, at the manufacturer’s

discretion.

If the item is found to be defective in materials or workmanship, and it was

manufactured by our company, purchased components are covered under their specific warranty terms.

7-7 Dryer Identification (Serial Number) Tag

(Located on back of Dryer)

Company Logo

XXX Series Dryer Model Number XXX-15

Max Drying Capacity HR

460V Serial Number 060701R 1Ǿ Date of Manufacture 06/2003

4.5A Over-current Protection Device (s) 4.5A Total Frequency 50/60Hz Compressed air supply None

Dryer Mass 400 lbs/(180 KG) Electrical Diagrams & Pneumatic Diagram

Street Address City, State Zip Code Telephone Number

Portable Drying/Conveying Systems Chapter 7: Appendix 62 of 63

Page 63

7-8 Technical Assistance

Parts Department

Call toll-free 7am–5pm CST [800] 423-3183 or call [630] 595-1060, Fax [630] 475-7005 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specific ations, which will maximize your equipment’s performa nce and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedic ated to providing excellent customer service.

Service Department

Call toll-free 8am–5pm CST [800] 233-4819 or call [630] 595-1060 Emergencies after 5pm CST, call [847] 439-5655

We have a qualified service department ready to help. Service contracts are available for most products.

Sales Department

Call [630] 595-1060 Monday–Friday, 8am–5pm CST Our products are sold by a world-wide network of independent sales representatives. Contact our Sales Department for the name of the sales representative nearest you.

Contract Department

Call [630] 595-1060 Monday–Friday, 8am–5pm CST Let us install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or nonunion installations.

Portable Drying/Conveying Systems Chapter 7: Appendix 63 of 63

Sterling DH1-610-2, 882.00294.00 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1: Safety

1-1 How to Use This Manual

Safety Symbols Used in this Manual

Dryer Safety Tags

1-3 Warnings and Precautions

General Responsibility

Operator Responsibility

REMEMBER:

Maintenance Responsibility

Reporting a Safety Defect

Chapter 2: Functional Description

2-1 Models Covered in This Manual

The Drying System

What is desiccant?

The Process/Regeneration Cycle

2-3 Standard Features

Mechanical Features

Electrical Features

Controller Features

Chapter 3: Installation

3-1 Uncrating the Equipment

3-2 Rigging and Placing the Dryer

Checking for Proper Blower Rotation

Three-Phase Models

Drying Hopper Air Trap Considerations (If Equipped)

Installing the Optional Aftercooler

3-5 Initial Start-up

Pre-Startup Checks

Starting Up the Dryer

Auto-Tuning the Dryer (Requires Supervisory Password)

Shutting Down the Dryer

Chapter 4: Operation

4-1 Controller Description and Operation

The Disconnect Switch is located in the front upper right hand corner of the control enclosure. It allows the user to disconnect power to the dryer for emergency shutdown, service or long periods of inactivity.

Control Power Switch

Touch Screen

Alarm Horn & Light

Process Air Temperature Controller

Startup Screen

Main Menu Screen

Dryer Status Screen

(Shown at Controller Power Up)

Dryer Process

Machine Status

Start Button

Setting Values

Dryer Menu

Dryer Menu Screen

DRYER STATUS

DRYER SETUP

Setting Values

Over-Drying Protection

Setting Values

Alarms (Retains 100 of the most recent alarms)

Auto Tune

Dew Pt Setup

Setting Values

Auto Start

Setting Values

Main Menu

Help Menu

System Menu

SYSTEM SETUP

Set Clock

Set Auto Start Clock

Setting Values

Set Alarm Clock

Setting Values

Hour Meters

Input Status (UPDATE)

Output Status (UPDATE)

Service Menu

Alarm Screens

Alarm Screen Example

Redundant Safety Controller Display

Optional