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TRANSCRIPT
Central Drying System with MDB Dehumidifying Dryers
Mechanical Manual
Part Number: 882.02569.00 Bulletin Number: DRY2-600.00
Effective: August 18, 2014
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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. DCN No. ____________ © Copyright 2014 All rights reserved.
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Shipping Info Unpacking and Inspection You should inspect the Central Drying 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. Do not 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 the packing list. You should have:
þ Dehumidifying Dryer, Drying Hoppers, and any other equipment that has been ordered for your drying system.
þ Bill of lading
þ Packing list
þ Operating and Installation packet
þ Electrical schematic and panel layout drawings
þ Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during unpacking.
If the Shipment is Not Correct If the shipment is not what you ordered, contact the shipping department immediately. For immediate assistance, please contact the correct facility located in the technical assistance section of this manual. Have the order number and item number available. Hold the items until you receive shipping instructions.
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Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department.
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.
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Table of Contents CHAPTER 1: SAFETY .............................................................. VII
1-1 How to Use This Manual ............................................................................................ vii Safety Symbols Used in this Manual .................................................................... vii
1-2 Warnings and Precautions .......................................................................................... ix 1-3 Responsibility .............................................................................................................. x
General Responsibility .......................................................................................... x Operator Responsibility ......................................................................................... x Maintenance Responsibility ................................................................................. xii Reporting a Safety Defect .................................................................................... xii
CHAPTER 2: GENERAL INFORMATION ................................ 13
2-1 Models Covered in This Manual ................................................................................ 13 2-2 Necessary Documents .............................................................................................. 13 2-3 General Description .................................................................................................. 13
The Process/Regeneration Cycle ....................................................................... 15 Material Overdrying Protection (DryPro Control Only) ........................................ 15
2-4 Central Drying System Options ................................................................................. 17 Mechanical Options ............................................................................................. 17
CHAPTER 3: INSTALLATION .................................................. 18
3-1 Positioning Your Dryer .............................................................................................. 18 3-2 Connecting the Process and Return Air Hoses ......................................................... 18 3-3 Drying Hopper ........................................................................................................... 21
Removing the Rust Inhibitor .................................................................................... 21 Air Trap Considerations ......................................................................................... 21
3-4 Positioning Your Hopper ........................................................................................... 21 3-5 Optional Damper Valve ............................................................................................. 21 3-6 Optional Pressure Orifice (Required with Damper Valve) ......................................... 22 3-7 Optional Bypass Valve ............................................................................................. 23
CHAPTER 4: OPERATION ....................................................... 24
4-1 Pre-Startup Checks ................................................................................................... 24 4-2 Using the Optional Isolation Valves .......................................................................... 24
CHAPTER 5: MAINTENANCE ................................................. 25
5-1 Work Rules ................................................................................................................ 25 5-2 Optional Damper Valve Maintenance ....................................................................... 25 5-3 Optional Bypass Valve Maintenance ........................................................................ 26 5-4 Replacing the Process Heaters ................................................................................. 27 5-5 Preventative Maintenance Checklist ......................................................................... 28
CHAPTER 6: TROUBLESHOOTING ....................................... 29
Determining Temperature Controller Errors or Sensor Errors ................................... 32
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CHAPTER 7: APPENDIX .......................................................... 33
7-1 Technical Assistance ................................................................................................ 33 Parts and Service Department ............................................................................ 33 Sales and Contracting Department ..................................................................... 33
7-2 Annex B Information .................................................................................................. 34 7-3 Drawings and Schematics ......................................................................................... 35 7-4 Revisions to Manual .................................................................................................. 36
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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 the Central 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 General Information section outlines models covered, standard features, and safety features. Additional sections within the manual provide instructions for installation, pre-operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup of the Central 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 dryer. These instructions are intended to supplement standard shop procedures performed at shift, daily, and weekly intervals.
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 the dehumidifying dryer 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 indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation or practice that, if not avoided, could result in death or serious injury.
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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Dryer Safety Tags
Hazard Alert Symbol Description/Explanation Preventative Maintenance
High Voltage Hazard. The electrical enclosure is supplied with 3-phase electrical power. Use caution when using or maintaining this product.
Every six months inspect all electrical connections for secure attachment
Auto start Hazard. Equipment may start at any time. Lock out/tag out before servicing the machine.
Every month inspect all electrical connections for secure attachment and that all warning labels are in place.
Hot Surface Hazard. When the unit operates above 212F (100C) the surface of the unit may reach excessive temperatures. Use caution when using or maintaining this product.
Every month check heater elements for continuity using an ohmmeter. For further information see the Maintenance Chapter in this manual.
Mandatory Symbol Description/Explanation
Read Operators Manual. This equipment must be operated and maintained by properly trained personnel. The information contained within this manual must be read and understood prior to operating this equipment.
Lock Out. This equipment is operated with 3-phase electrical power. Therefore, when performing any maintenance operations we recommend following the local standards for performing a lock-out/tag-out procedure.
Prohibition Symbol. Do not reach into any of the equipment while the equipment is running and/or the power is on. Lock out all power before performing maintenance on the machine(s).
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1-2 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.
To avoid possible personal injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices:
þ 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.
þ Follow all SAFETY CODES.
þ Wear SAFETY GLASSES and WORK GLOVES.
þ Work only with approved tools and devices.
þ Disconnect and/or lock out power before servicing or maintaining the equipment.
þ Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipment.
þ Operate this equipment within design specifications.
þ OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment. You should remove the fuses and carry them with you.
þ Make sure the equipment and components are properly GROUNDED before you switch on power.
þ 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 nearby and ready for use if needed.
þ Do not restore power until you remove all tools, test equipment, etc., and the equipment and related components are fully reassembled.
þ 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.
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1-3 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 machines should become familiar with their 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 matter 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.
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 closely 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.
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n NEVER place your hands or any part of your body in any dangerous location. n NEVER operate, service, or adjust the dryer without appropriate training and
first reading and understanding this manual. n NEVER try to pull material out of the dryer with your hands while it is
running! n Before you start the dehumidifying dryer, check the following:
• Remove all tools from the dryer;
• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the area;
n If your dryer has been inoperative or unattended, check all settings before starting.
n At the beginning of your shift and after breaks, verify that the controls and other auxiliary equipment are functioning properly.
n 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.
n 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.
n Report the following occurrences IMMEDIATELY: • unsafe operation or condition
• unusual dryer action
• leakage
• improper maintenance
n NEVER stand or sit where you could slip or stumble into the dehumidifying dryer while working on it.
n DO NOT wear loose clothing or jewelry, which can be caught while working on the dryer. In addition, cover or tie back long hair.
n Clean the dehumidifying dryer and surrounding area DAILY, and inspect the machine for loose, missing or broken parts.
n Shut off power to the dryer when it is not in use. Turn the switch to the OFF position, or unplug it from the power source.
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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 and pneumatic power. Attach warning tags to the disconnect switch and air shutoff valve.
When you need to perform maintenance or repair work on a dehumidifying dryer above floor level, use a solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your dryer, use it. The work platform should have secure footing and a place for tools and parts. DO NOT climb on the dehumidifying dryer, 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 dehumidifying dryer until all persons are clear of the area. DO NOT start and run the dryer until you are sure all parts are functioning correctly.
BEFORE you turn the dehumidifying dryer over to the operator for production, verify all 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/tagout), or failure to maintain a clean and safe working area.
General Information 13
Chapter 2: General Information 2-1 Models Covered in This Manual
This manual will cover the information necessary for operating your Central Drying System. Other manuals and guides will be provided for the conveying equipment used in your system.
2-2 Necessary Documents The documents listed below are necessary for the operation, installation, and maintenance of Central Drying Systems. You can obtain additional copies from the manufacturer. Make sure that the appropriate personnel are familiar with these documents:
þ This manual.
þ The schematic and assembly drawings included in the customer information packet.
þ The Customer Parts List included in the information packet.
þ Operation and installation manuals for any optional controls or auxiliary equipment in the drying system.
2-3 General Description
Moisture removal from hygroscopic (moisture attracting) plastic pellets is an essential step in the manufacture of high-quality plastic products.
Our Dehumidifying Dryers are used by the plastics industry to generate very low dewpoint air that is heated to a controlled temperature for drying plastic pellets and regrind.
The drying system consists of a dry air source and drying hoppers with process heating controls. The dry air source controls two primary sub-systems, the process air and the regeneration circuit. Each dryer has a left and a right desiccant bed so that one bed can regenerate while the other is in use.
The drying system can be configured for more than 3 hoppers (consult factory for your application requirements). The process air heater can be located on the dryer or on each individual drying hopper. Heaters that are located on the drying hoppers can be set up with their own independent controls or can be controlled centrally using the main dryer controller.
General Information 14
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General Information 15
The Process/Regeneration Cycle There are two desiccant beds in each of the dryers. While one desiccant 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. The desiccant will become saturated with moisture and need to be regenerated. The dryer automatically redirects the process airflow to the second bed and starts regenerating the first bed.
During regeneration, air is heated to approximately 550°F and forced through the saturated desiccant. The moisture driven off the desiccant is bled to the atmosphere. The regeneration heater is then turned off while the regeneration blower continues to blow air through the desiccant bed until it is cooled.
Material Overdrying Protection (DryPro Control Only) Material Overdrying Protection is an automatic system used to reduce the chance of over-drying, and possibly melting, the resin in the drying hopper. Material Overdrying Protection activates when the return temperature reaches the Setback@ value, indicating that all the resin in the hopper is dry.
When the return air temperature reaches the Setback@ value, the process heaters adjust their temperature to the Setback Setpoint. As soon as the return air reaches the Setup@ value, the heaters begin to heat up again to their original setpoint. The graph below illustrates how the settings control the temperatures.
General Information 16
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 National Fire Protection Agency (NFPA 70&79) are just a few of the organizations that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the dehumidifying dryer; 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.
Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air) sources prior to servicing or cleaning the dehumidifying dryer. Failure to do so may result in serious injury. No one but the person who installed the lockout may remove it.
General Information 17
2-4 Central Drying System Options Options can tailor your dehumidifying dryer system to meet the exact requirements of the drying task being performed. Consult ACS for any additional options that your application may require.
Mechanical Options þ WH Series Stainless Steel Drying Hoppers (30-800 Liter Capacities)
þ Hopper Mounted Heater Boosters (Consult Factory for available kW)
þ Isolation Valves
þ Premium Slidegate
þ Different Size Manifolds (Insulated or Non-Insulated)
þ Self-balancing Damper Valves for regulation of hopper airflow
þ Manual or Automated Bypass Valve
þ Take-Off Boxes for Conveying Dried Resins from the Hopper
þ Pressure Orifice (Required with the Damper Valve)
Installation 18
Chapter 3: Installation 3-1 Positioning Your Dryer
It is important to leave room to access the dryer from the front, rear, and at least one side, for repair and regular maintenance. Keep in mind the amount of hoppers in your system so that ample room is set aside.
þ Some dryers are equipped with durable casters, so the dryer may be wheeled into the appropriate place.
þ Place the dryer near any water or convey lines that are applicable to your system’s needs.
þ Allow enough room above the dryer for the exhaust to escape. The exhaust can be extremely hot so keep the exhaust port away from any objects that may be damaged by the heat.
þ To position the hoppers, a forklift may have to be used. Only properly trained personnel may operate the forklift.
þ Position the hoppers so that they are facing the same direction. This is important so that the manifolds behind each hopper may be connected.
Use caution and observe safety rules when placing your dryer!
Do not lift a hopper if it contains material!
3-2 Connecting the Process and Return Air Hoses
Due to the size of the Central Drying System and the number of hoppers, the process and return air hoses from the dryer cannot directly be attached to a hopper inlet and outlet. Instead the two main hoses are clamped to the two manifolds on the very first drying hopper next to the dryer. The arrows on the manifolds indicate the direction of the airflow and what air hose should be attached to it. On the subsequent hoppers and hopper carts in the system, use just enough dryer hose to connect the manifold to the one directly across from it, until all the manifolds are connected in a row. The very last manifold gets a Bypass Valve or a plug at the very end of the line.
Each cart has two manifolds, one for the process air and one for the return air. Each manifold has a tube stub that corresponds to that cart’s hopper. Run just enough hose from the tube stubs to the inlet and outlet, and make sure that the correct connections are made. The airflow diagram in the previous section provides an illustrated look at how the hosing should be connected.
Make sure the hoses are properly clamped to the manifolds, inlets, and outlets to ensure maxiumum efficiency while drying. Minimize bends in the dryer hose and try to reduce the hose length to the hoppers.
Installation 19
Return Air Manifold: Air returns to the Dryer Inlet
Process Air Manifold: Air travels to the Hopper Inlet
Process Air Hose: Connected to a Heater Booster at the Hopper Inlet
Return Air Hose: Air returns to the Dryer from the Hopper Outlet
Installation 20
This is the optional heater booster, which is attached to the hopper inlet. The air coming from the dryer passes through here before entering the hopper.
Installation 21
3-3 Drying Hopper
Removing the Rust Inhibitor Rust preventative may have been applied to internal unfinished surfaces. Remove rust inhibitor before using the drying hopper.
Using a non-water based degreasing agent, clean all inside surfaces of the drying hopper. Allow components to dry thoroughly.
Inspect the inside of the drying hopper for loose connections, foreign objects, or a blocked diffuser.
Air Trap Considerations The air trap assembly in the top of the drying hopper prevents ambient air from contaminating the material being dried.
þ Keep the material level at the midpoint of the air trap for maximum efficiency.
þ Use a hopper loader or vacuum conveying system to maintain the proper material level.
3-4 Positioning Your Hopper
Each hopper arrives on its own cart and skid so that each may be placed in its destination with little difficulty. When placing your drying hoppers, use care and follow all safety rules while operating the forklift. It is important that you face all of the hoppers in the same direction, so that all of the access doors are on one side, and all of the manifolds are on one side. Remember that all of the manifolds have to be connected via hose and you want to use as little hose as possible to maximize your dryer’s efficiency. Pay attention to the arrows on the manifolds, as they indicate the direction of the airflow and what main dryer hose should be attached to it.
3-5 Optional Damper Valve
If your Central Drying System is using the optional damper valve, it will be located below the hopper on the return air hose. Make sure the valve operates properly. This valve helps regulate the airflow flowing through the hoppers. It helps prevent one hopper from robbing more process from the other hoppers, which can occur if a hopper is only partially full of material. You will want to check that the shaft is properly installed in the actuator and in the manifold. Refer to the maintenance section to verify that all of the parts labeled on the drawing are present. The rotation of the actuator is preset at the factory and should not be adjusted. Changing the rotation direction on the actuator may cause an adverse change in drying efficiency.
Refer to the Maintenance section for further details.
Installation 22
3-6 Optional Pressure Orifice (Required with Damper Valve)
Another optional component that is available on each of the hoppers in your system, is the pressure orifice device located on the hopper outlet hosing. There are some tube connections that need to be installed to ensure proper operation. The image to the right indicates where the manifold is located and the connections that should be present. The tubing at the top of the manifold should run to the “HI” input on the transducer in the hopper control box. The lower tubing should be connected to the “LO” input.
**An example of the possible transducer used. Transducers vary by application.**
The Pressure Orifice device is specifically sized for each drying hopper that it is attached to. These devices should not be swapped between drying hoppers, as this will affect your drying
system’s performance. If you need a replacement, ACS will be able to replace any components that you may need.
Installation 23
3-7 Optional Bypass Valve
If your system required it, the Bypass Valve would be located at the very last manifold at the end of the system. The airflow schematic can illustrate the location. The purpose of the valve is to send excess delivery air into the return stream. This excess air pushes up on a plunger inside the valve and enters the return air hosing. Make sure the valve is placed correctly before operating your system. It is important that the valve is not flipped because you do not want the return air to contaminate the process air.
Operation 24
Chapter 4: Operation 4-1 Pre-Startup Checks
1. Review the Installation Section preceding this one for important information on specific components.
2. Verify that the drying hoppers are clean of rust-prohibitive oil or any foreign objects.
3. Verify that process and return hose connections are tight.
4. Check to make sure that all of the hose connections are tight at the manifolds behind each hopper, and at the hopper inlets and outlets.
5. Verify that the thermocouples are in their proper location and orientation. Consult the additional manual(s) accompanying this one for details.
6. Check to make sure that the Dewpoint sensor and the Dirty Filter switch are connected to the correct fittings.
7. If your dryer has a water-cooled Aftercooler/Precooler, make sure that sufficient cooling water flows properly through the coil and that you have bled any trapped air from the system. Make sure that the Aftercooler/Precooler has the proper supply water temperature.
8. If you are using the optional valves or pressure orifice, ensure that they are properly connected to their respective devices.
9. Check all companion equipment, such as the sight glass loader and drying hopper loader; verify that all convey tubing is in place and the loading system is ready for operation.
Clean the rust-preventing oil from inside the drying hopper. Failure to clean the hopper fouls the desiccant and voids your warranty!
4-2 Using the Optional Isolation Valves
If you requested Isolation Valves on each cart in your Central Drying System, then they may be used any time before, during, or after running the system. The valve should be closed when emptying the hopper or to take the hopper offline. Simply use the handle to adjust the valve plate to the desired position.
Maintenance 25
Chapter 5: Maintenance 5-1 Work Rules
The installation, operation, and maintenance of this equipment is to be conducted in accordance with all applicable work and safety codes for the installation location. This may include, but is not limited to, OSHA, NEC, CSA, and any other local, national, and international regulations.
In addition, you must observe the following specific work rules:
þ Keep these operating instructions on hand and follow them when installing, operating, or maintaining your CDS System.
þ If these instructions become damaged or unreadable, you can obtain additional copies from the manufacturer.
þ Only qualified personnel familiar with this equipment should work on or with this unit.
þ Work only with approved tools and devices.
Disconnect power before servicing your dryer. If the disconnect switch you installed has a lockout, lock it in the OFF position before you perform any maintenance or service.
5-2 Optional Damper Valve Maintenance
1. Damper Valve Housing
2. Bearing Flange
3. 12mm Shaft
4. 12mm Fastener
5. Damper Valve #822.99894.00
6. Actuator #044.01245.00
7. M6 Flat Washer
8. 0.25 Lock Washer
9. M6x1.0x16 SBHCS
10. M4x0.7x10 SBHCS
Maintenance 26
5-3 Optional Bypass Valve Maintenance
1. Valve Cover
2. Bearing Housing
#822.00857.00
3. Bearing #822.00856.00
4. Shaft #822.00855.00
(located inside spring)
5. Hex Nut 3/8x16
6. 3/8 Flat Washer
7. Aluminum Plate #822.00860.00
8. Valve Seal #W00054021
9. ¾” Retaining Ring
10. Gasket #W00017812
11. Set Screw 1/4x20x1/4
12. HHC Screw 1/4x20x0.63
13. SHC Screw 1/4x20x5/8
14. Aluminum tubing
15. Spring #098.00001.00
16. Valve Body
Maintenance 27
5-4 Replacing the Process Heaters
This refers only to replacing the heater elements in the heater booster located on the drying hopper(s). For replacing the heaters inside of your dryer, refer to the other operation and installation manual(s) accompanying this manual.
Before replacing any heaters in your Central Drying System, power must be turned off and disconnected. If your dryer was running recently, allow the heaters ample time to cool down. Failure to allow cool down may cause serious injury due to excessive temperatures.
1. Remove the screws that are bolting the cover onto the NEMA Box
2. Remove the Screws and washers bolting the heater to the box frame
3. Remove any wiring that is connected to the heater and make note of their orientation on the heater element. Try and place the heater back into the box in the exact position that it was taken out.
4. Slide out the heater element and remove the gasket placed between the element and the box frame. Set the gasket aside for reuse or replace if needed.
5. After checking the new heater element for proper functionality, slide it back into the box frame and rewire as required.
Maintenance 28
5-5 Preventative Maintenance Checklist
Dehumidifying Dryer Systems System model #
Serial #
Every week Date/ By
Date/ By
Date/ By
Date/ By
Date/ By
Date/ By
Date/ By
Date/ By
Date/ By
Date/ By
Date/ By
Date/ By
Date/ By
Inspect all filters for wear, replace/clean if dirty or worn.
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 Next scheduled inspection
Actual inspection Date/By
Next scheduled inspection
Actual inspection Date/By
Inspect desiccant. Replace if brown or broken.
Every two years Scheduled
replacement date Actual replacement Date/Work done by
Scheduled replacement date
Actual replacement Date/Work done by
Replace desiccant.
- Photocopy this page for your maintenance records –
Troubleshooting 29
Chapter 6: Troubleshooting Problem Possible cause Corrective action
Little or no air coming from the process delivery tube.
Dirty filter. Clean or replace filter. Desiccant beds are contaminated by material or plasticizer leaking into the system.
Replace desiccant.
Blower overload has tripped. Repair the condition and reset the overload.
Blower fins filled with dust or contaminants.
Remove blower side plate, clean baffles, replace.
Suction in delivery tube, pressure from the return tube.
Phase is reversed on power drop coming into the dryer.
Stop the dryer. If the dryer was connected to the drying hopper, check to see if the desiccant and process air heater has been contaminated with resin. If so, replace the desiccant and remove any resin carry-over. Otherwise, change the phase of two legs of the three-phase power drop.
Loss or reduction of process air temperature.
Process heaters are faulty. Check for open heaters. Replace if required.
Solid-state Relay faulty. Replace Solid State Relay.
Process temperature was improperly adjusted.
Review product for proper setting. Train plant personnel about proper temperature set point and operation.
Loss or reduction in drying capacity.
Process heaters are faulty. Replace. Desiccant beds are contaminated. Replace desiccant.
Material being dried differs from material specified at the time of purchase.
Drying systems are designed for the material which was originally specified. Different materials may need a longer residence time or different drying temperature.
Break in flex hose to/from drying hopper.
Inspect for air leaks; replace if necessary.
Troubleshooting 30
Problem Possible cause Corrective action
Loss or reduction in drying capacity. (Cont’d.)
Airflow valve sticking or failing to shift.
Check for proper operation of valve actuators. Repair or replace if necessary.
Blower fins filled with dust or contaminants.
Remove blower side plate, clean baffles, replace. Replace filter elements.
PLC Regeneration Bed LED indicators both off.
Insufficient power to PLC (Power LED is off).
Check power supply and power wiring to PLC.
Faulty PLC (PLC Power light is on, Run light is off, and/or Error light is on).
Replace PLC.
PLC Regeneration Heater Left/Right output indicators both off.
Regenerating bed cool down. None.
Blower Input indicator is off. Verify that blower contactor is on. Check input wiring to PLC.
Process air in high-temperature condition. None.
Insufficient power to PLC (Power light is off).
Check power supply and power wiring to PLC.
Faulty PLC (PLC Power light is on, Run light is off, and/or Error light is on).
Replace PLC.
Material in drying hopper cakes, or meltdown occurs.
Process temperature set too high due to operator error.
Check resin manufacturer’s data sheet for proper drying temperature. Make sure plant personnel are aware of the correct process temperature set point.
High temperature alarm not set properly.
Reset high temperature alarm.
Process set point is out of acceptable range.
Restore temperature controller to factory pre-sets.
Function set for degrees Celsius (ºC), set point at degrees Fahrenheit (ºF).
Verify correct Celsius or Fahrenheit settings.
Poor dew point performance.
Burned out regeneration heater. Repair or replace.
Contaminated or worn out desiccant. Replace.
Leaking process air hoses. Repair or replace. Dryer operates beyond its capacity.
Check dryer and drying hopper sizing.
Bad dew point sensor. Replace. Fouled dew point sensor manifold.
Clear obstruction. Air should flow freely through sensor.
Troubleshooting 31
Problem Possible cause Corrective action
Nothing displays when the PID controller is turned on.
The Din PID controller is not inserted firmly in the housing.
Properly insert the controller into the housing.
The power supply is not connected to its terminals properly.
Properly connect the power supply to the power supply terminals.
No power is supplied, or the supplied power is not within the specified range.
Supply a voltage of 85 to 240 VAC, or 20-29 VAC/DC to the power supply terminals of the controller.
Disconnect switch or Control Power switch not set to ON. Control Power fuse blown.
Check control power fuse for continuity. Turn disconnect switch and control power switch ON.
Process value is abnormal or not obtained.
Input polarity on thermo-couple is wrong or connection is wrong.
Properly wire the terminals. Negative is always Red.
No compensating lead wires used for extension of the thermocouple.
Use proper compensating lead wires and terminals.
Thermocouple and controller are connected by wires other than proper lead wires.
Use a dedicated thermo-couple connector. If a connector is a metal different from the thermocouple and controller, a temperature error may result.
Sensor is broken or short-circuited. Replace with a good sensor.
The controller is influenced by noise or other induction.
Separate input wires as far as possible from the origin of the noise.
Celsius temperatures used instead of Fahrenheit or vice versa.
Setup mode level 2 display d-U. S-V display shows setting.
Grounded Thermocouple Use un-grounded Thermocouple
Troubleshooting 32
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.
Using a Platinum Resistance Thermometer
If the controller displays a temperature of about 0.0°C (32ºF) when you insert a 100-ohm resistor between terminals A and –B of the controller, and you short-circuit controller terminals +B and –B, the controller is normal and the sensor is probably broken, short-circuited, or incorrectly wired.
Appendix 33
Chapter 7: Appendix 7-1 Technical Assistance Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance 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 dedicated to providing excellent customer service. For immediate assistance, please contact:
• North, Central and South America, 8am – 5pm CST +1 (800) 483-3919 for drying, conveying, heating and cooling and automation. For size reduction: +1 (800) 229-2919. North America, emergencies after 5pm CST (847) 439-5855 North America email: [email protected]
• Mexico, Central & South America Email: [email protected] • Europe, Middle East & Africa +48 22 390 9720 Email: [email protected] • India +91 2032533552 Email: [email protected] • Asia/Australia +86 512 8717 1919 Email: [email protected]
Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the name of the sales representative nearest you. 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 non-union installations. For assistance with your sales or system contracting needs please Call: North, Central and South America +1 (262) 641-8600 or +1 (847) 273-7700 Monday–Friday, 8am–5pm CST
• Europe/Middle East/Africa +48 22 390 9720
• India +91 2032533552
• Asia/Australia +86 512 8717 1919
Facilities: ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at www.acscorporate.com
United States: ACS Schaumburg 1100 E. Woodfield Road Suite 588 Schaumburg, IL 60173 Phone: + 1 847 273 7700 Fax: + 1 847 273 7804 ACS New Berlin 2900 S. 160th Street New Berlin, WI 53151 Phone : +1 262 641 8600 Fax: + 1 262 641 8653
Asia/Australia: ACS Suzhou 109 Xingpu Road SIP Suzhou, China 215126 Phone: + 86 8717 1919 Fax: +86 512 8717 1916 Europe/Middle East/Africa: ACS Warsaw Ul. Działkowa 115 02-234 Warszawa Phone: + 48 22 390 9720 Fax: +48 22 390 9724
Appendix 34
7-2 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: 0 -40 degrees Celsius – Maximum
(104 degrees Fahrenheit) 3. Ambient Humidity range: 0-50% relative humidity 4. Altitude: Sea level 5. Environment: Clean and non-explosive 6. Radiation: None 7. Vibration: Minimal, i.e. machine mounting 8. Allowable voltage fluctuation: +/- 10% 9. Allowable frequency fluctuation: Continuous +/- 1%
Intermittent +/- 2% 10. Nominal supply voltage: Verify on serial number tag 11. Earth ground type: TN (system has one point directly earthed through a protective
conductor) 12. Incoming Power supply should include a ground connection. 13. Over-current protection is supplied in the dryer, but additional protection should be
supplied by the user. 14. The door-mounted disconnect serves as the electrical disconnect device. 15. Dryer is equipped with a CE mark (On applicable models) 16. Dryer is supplied with an operating manual in the language of the destination
country. 17. Cable support may be required for power cord, depending on final installation. 18. 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.
19. Doors can be opened with a screwdriver, but no keys are required. 20. Two-hand control is not required or provided. 21. Some dryers are designed to be wheeled into place. If a hopper is attached, the
hopper must be empty while moving the dryer. 22. There are no frequent repetitive cycles that require manual control⎯repetitive
functions are automatic while the dryer is operating. 23. An inspection report detailing the functional test is included with the dryer. 24. The machine is not equipped with cableless controls. 25. Color-coded (harmonized) power cord is sufficient for proper installation.
Appendix 35
7-3 Drawings and Schematics
Drawings and schematics have been shipped to you along with this manual. If you need additional copies, contact ACS with your model number(s) and new copies will be sent you right away.
Appendix 36
7-4 Revisions to Manual
Revision Bulletin Number: DRY2-600.00
Revision Date: August 18, 2014
Changes Made:
1. Initial Release