ASD, SDA, & CDA Series 15, 30, & 60 cfm Compact Dehumidifying Dryers Part Number: 882.00201.00 Bulletin Number: DH1-635 Effective: 10/1/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement.
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Shipping Information Unpacking and Inspection You should inspect your dryer 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.
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.
Table of Contents CHAPTER 1: SAFETY................................................................ 7 1-1 1-2 1-3 1-4 How to Use This Manual ............................................................................................. 7 Safety Symbols Used in this Manual .....................................................................7 Dryer Safety Tags .................................................................................................8 Warnings and Precautions .........................
4-2 4-3 Process Air Temperature Controller ....................................................................24 Setting the Process Air Temperature ..................................................................24 Restoring the Process Air Temperature Controller (E5CN) to Factory Settings..24 Process Air Dew Point Display ............................................................................24 Setting the High Dew Point Alarm ......................................................................
Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your dehumidifying dryer. 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.
Dryer Safety Tags Hot! Read Operation and Installation Manual High Voltage Earth Ground Inside Enclosure PE Lifting Point 1-2 Protected Earth Ground 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.
; 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.
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.
• Clean the dryer and surrounding area DAILY, and inspect the machine for loose, missing or broken parts. • 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. 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.
1-4 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: 0 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.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 15 and 30 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 carefully controlled temperatures for use in plastic drying systems.
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. Absorbed water is driven from saturated desiccant by heating it to a high temperature (reducing desiccant capacity to hold water) and forcing air through it. This moisture removal process is called regeneration. The Process/Regeneration Cycle Our dryers have two desiccant beds.
Controller Features • Mitsubishi programmable relay controller • Display of process temperature set point and actual settings 2-4 Options Options marked with “*” indicate options that can be factory installed or retrofitted in the field. • Process temperature up to 400ºF (or below 180ºF), including aftercooler on back of dryer and silicone insulated delivery hose. Note: For below 160°F, cooler needs to be outside, between dryer and drying hopper.
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. Every effort has been made to incorporate these standards into the design of the 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.
Chapter 3: Installation 3-1 Uncrating the Equipment Dehumidifying Dryers 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.
Caution! Do not use a hoist to move or rig your Dryer when it is mounted on a cart! Moving the Dryer with a hoist will cause it to become unstable and may cause damage to the Dryer and/or injury to personnel! Figure 2: Cart Mounted Dryer Dimensions A B C D E F ASD15 ASD30 PROCESS TEMPERATURE DEW POINT CONTROL POWER ON OFF ON OFF ALARM C D E F POWER ON B A A 15 cfm 30 cfm 60 cfm B C In. Cm. In. Cm. 27 ½ 69.9 23 58.4 36 91.4 36 5/16 15, 30, & 60 cfm Compact Dryers 92.
Figure 3: Suggested Lift Rigging for Floor Mounted Dryers PROCESS TEMPERATURE DEW POINT CONTROL POWER ON DEW POINT CONTROL POWER ON ON OFF PROCESS TEMPERATURE OFF ON OFF POWER ON ALARM OFF POWER ON ALARM Note: Floor Mounted Dryers can be lifted by hoist or fork lift.
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! Figure 14: Machine-Mount Dryer Dimensions Mounting flange E G E G C Diameter hole: F PROCESS TEMPERATUR E DEW POINT CONT ROL POWE R ON O FF ON POWER ON ALAR M OFF B D A Model Hopper Si
3-3 Electrical Connections When making electrical connections to your dryer, 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.
Making Dryer/Drying Hopper Process Air Connections Floor Mount Models When making process air connections to your floor mounted dryer, ensure that you take into consideration and make arrangements for the following: • Use high-temperature flexible dryer hose or rigid tubing to connect the dryer to the drying hopper. • Keep the delivery hose to the drying hopper as short as possible to minimize heat loss. We strongly recommend insulated hose for maximum energy savings.
; 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. Caution! Clean the rust-preventing oil from inside the drying hopper. Failure to clean the hopper fouls the desiccant and voids your warranty! ; Verify that the dryer’s thermocouple is properly connected in the center of the drying hopper’s delivery tube.
Auto-Tuning the Dryer 1. Apply power to the control circuit. 2. Press and hold the Level Key and the Mode Key at the same time for 3 seconds. This will get you into the “protection screen” which will probably be set at 2. 3. From this screen, use the Down Key to change the (2) green setting to 0. PV SV 4. Exit the protection screen by pressing and holding the Level Key and the Mode key at the same time. The control should only display the Set Point (green) and actual temperature (red). 5.
Shutting Down the Dryer 1. When processing is complete, close the hopper slide gate and shut down any in-line companion equipment, such as the aftercooler. 2. Turn the Dryer ON/OFF power switch to OFF. 3. Turn the system ON/OFF switch to OFF. 4. If needed, empty the drying hopper. 5. For maintenance or a long term shutdown, open (de-energize) the electrical disconnects at the dryer and at the power drop.
Chapter 4: Operation 4-1 Controller Description and Operation Identifying Control Panel Indicator Lights and Switches for the Standard Controller Switches Main Power. This switch allows the dryer to receive power from the main power supply (3 phase only). Dryer Control ON/OFF Switch. This switch energizes or de-energizes control power to the indicator panel and starts the dryer. (The controller cannot be energized without the dryer running.) Indicator Lights Alarm Light.
Optional Controller – Optional Three Phase Control Panel shown with Optional Dew Point Monitor Process Air Temperature Controller Our dryers use a microprocessor-based PID temperature controller for maintaining process air temperature. The controller is a modular, self-contained unit you can remove from the mounting housing. All parameters except for the process air set point are factory set and adjusted; normally, no field adjustment to the internal controls is necessary.
Identifying Process Air Temperature Controller LED Indicators Indicator Name Description PV Process Value Numeric LED During normal operation, the process value (PV) numeric LED indicator displays the process temperature at the To Process thermocouple. It also lists parameters during setup and error messages if any errors occur. Set Value Numeric LED During normal operation, the set value (SV) numeric LED indicator displays the process set point temperature selected for the dryer.
Setting the Process Air Temperature When setting the process air temperature, consult with the resin manufacture for the recommended drying temperature. To change the process air temperature set point with the dryer running: • Press to raise the set point to the temperature you want. • Press to lower the set point to the temperature you want.
Indicator Name Description preprogrammed by the operator. Proportional Band Mode (P) This setting controls the amount in which the manipulated variable (MV) is proportionate to the deviated value or controller error. Integral Time Mode (I) Setting this feature, gives the control an action that is proportionate to the time integral of the control error.
Figure 7: Settings for Process Temperature Controller (E5CN), Part No. A0567917 Mode Operation Mode Adjustment Parameter Run/Stop Alarm value 1 Setting range Run/Stop -1999 to 9999 Default Run 0 Manuf. setting 25 Parameter AT execute/cancel Temperature input shift Proportional Band Integral Time Derivative Time Setting range ON, OFF -199.9 to 999.9 0.1 to 999.9 0 to 3999 0 to 3999 Default OFF 0.0 8.0 233 40 Manuf.
Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup If the preset parameters on the controller have been tampered with and it no longer functions properly, call the Service Department. This controller is not meant to be modified. Note: The dew point alarm monitors and indicates a deviation from the set point. 4-2 Dryer Operation Procedures Controller Operation 1. Turn the disconnect (if applicable) on the control panel to the ON position.
c. The regen heater is turned on and the regeneration timing sequence is initiated. For default timing settings for regeneration, see the table below. Model 15 cfm 30 cfm 60 cfm Heating Cooling 15 45 N/A N/A 4. If either the left or right bed safety temperature switch opens, a regen heater fault is generated. “HIGH TEMP” is displayed on the relay screen. The alarm light is activated. The process heater, regen heater, and process/regen blower are turned off. 5.
Alarm Display Messages Note: The relay screen which contains the Alarm Display Messages is located inside the controller enclosure.
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 Dehumidifying Dryer operating at peak efficiency. Perform each inspection at the regular intervals listed below. System model # Every week Serial # 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.
5-2 Preventative Maintenance This section describes maintenance procedures which will increase the longevity and efficiency of your dehumidifying dryer. Perform them at the regular intervals listed on the dryer 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.
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 vaccum from the outside.
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.
4. Remove four (4) nuts at each corner of the top casting. 5. Disconnect all hoses and dew point air lines. 6. Pickup and place the top casting in a safe place. 7. Using a 1/8” Allen wrench, remove the four (4) 10-32 button screws holding the desiccant cover to the canister. 8. Remove the cover. 9. Pickup the desiccant can and turn it upside down over an empty container to remove all desiccant. 10. Dispose of properly using MSDS sheet.
14. Inspect the gaskets. Replace if necessary. 15. Re-install all components and reconnect all of the wiring and hoses. Figure 11: Required Desiccant Amounts (13X Type) Dryer Model 15 30 60 8 x 12 bead Total Part no. lbs. 6.5 W00018051 9.7 13.5 Kg 2.9 4.4 6.1 Replacing the Process/Regeneration Heater The dehumidifying dryers utilize a single-phase Calrod-type heater element. This heater element is mounted in the center compartment in the desiccant beds.
Procedures 1. Disconnect electrical power to the dryer. 2. Using a 1/8” Allen wrench, remove the 10-24 button head screws holding the top, back and side panels to the dryer frame. 3. Disconnect the plug for the valve motor, valve switch, and blower (15 only). 4. Remove the four (4) nuts at each corner of the top casting. 5. Pickup and place the top casting in a safe place. 6. Pickup the desiccant can to reveal the heater. 7. Using a 1/8” Allen wrench, remove the four (4) 10-32 screws on the heater plate. 8.
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.
Problem Loss or reduction of process air temperature. Possible cause Corrective action Process heaters are faulty. Check for open heaters. Replace if required. Solid-state temperature controller faulty. Replace. Process temperature was adjusted in error by plant personnel. Process heaters are faulty. Desiccant beds are contaminated. Material being dried differs from material specified at the time of purchase. Loss or reduction in drying capacity. Break in flex hose to/from drying hopper.
Problem Poor dew point performance. Nothing displays when the controller is turned on. Possible cause Corrective action Burned out regeneration heater. Contaminated or worn out desiccant. Leaking process air hoses. Dryer operates beyond its capacity. Bad dew point sensor. Fouled dew point sensor manifold. Dirty filter. The internal mechanism is not inserted properly into the housing. The power supply is not connected. No power is supplied, or the supplied power is not within the specified range.
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. Using a Platinum Resistance Thermometer If the controller displays a temperature of about 0.
Chapter 7: Appendix 7-1 Warranty The manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. 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.
7-2 Drawings and Diagrams 15, 30, & 60 cfm Compact Dryers Chapter 7: Appendix 47 of 57
15, 30, & 60 cfm Compact Dryers Chapter 7: Appendix 48 of 57
15, 30, & 60 cfm Compact Dryers Chapter 7: Appendix 49 of 57
PART # A0572358 A0534060 A0566535 A0570437 A0570294 A0534282 A0535350 A0552439 A0552440 A0548558 W00015436 A0568022 042.00016.00 042.00017.00 132-00007-00 A0566466 A0547006 A0570444 A0567917 A0566096 SIZE Description 1" O.D. by 12 Ft Long Hi Temp Hose. 2-1/2" O.D. by 12 Ft Long Hi Temp Hose. Return Air Cooling Coil 115 Volt Process Blower. 115 Volt Process Blower. 208/460 Volt Process Blower. 575 Volt Process Blower 208/460 Volt Process Blower.
HI-CORE DESICCANT DRYER 15/30/60 CFM UNITS 15 CFM Item Qty Part # Description 21 1 A0571669 SCHEMATIC, 15 CFM POWER 25 26 27 28 1 1 1 1 A0566840 A0571672 A0534258 A0538062 120 VAC 1 GRAPHIC, ASD CONTROL, 1∅ COMMON PARTS, 120VAC CONTROL FUSE BLOCK, 2P 30A CC FUSE, PROC BLOWER, LP-CC-5 25 26 27 28 1 1 1 1 A0566840 A0571673 A0534258 A0550577 220VAC 1 ∅ GRAPHIC, ASD CONTROL, 1∅ COMMON PARTS, 220VAC CONTROL FUSE BLOCK, 2P 30A CC FUSE, PROC BLOWER, LP-CC-3 24 28 31 32 1 1 1 2 A0571675 A0538062 A
33 3 A0568935 33 3 A0534048 33 3 A0534041 33 3 A0568935 33 3 A0534041 33 3 A0534044 33 3 A0534039 33 3 A0534042 230VAC 3∅ LOW HEAT FUSE, HEATERS, KTK-R-9 230VAC 3∅ HIGH HEAT FUSE, HEATERS, KTK-R-15 400VAC 3∅ LOW HEAT FUSE, HEATERS, KTK-R-5 400VAC 3∅ HIGH HEAT FUSE, HEATERS, KTK-R-9 460VAC 3∅ LOW HEAT FUSE, HEATERS, KTK-R-5 460VAC 3∅ HIGH HEAT FUSE, HEATERS, KTK-R-8 575VAC 3∅ LOW HEAT FUSE, HEATERS, KTK-R-3.5 575VAC 3∅ HIGH HEAT FUSE, HEATERS, KTK-R-6 30 CFM Item Qty.
32 40 41 2 1 1 A0534800 A0558000 A0558078 FUSE, XFMR, PRIMARY, FNQ-R-0.5 CONTACTOR, IEC, 9A, 120VAC COIL RELAY, OVERLOAD, IEC, .
32 40 41 2 1 1 A0536889 A0558000 A0558079 FUSE, XFMR, PRIMARY, FNQ-R-0.6 CONTACTOR, IEC, 9A, 120VAC COIL RELAY, OVERLOAD, IEC, 1-2.9A 24 28 31 32 40 41 1 1 1 2 1 1 A0571675 A0534802 A0558192 A0534800 A0558000 A0558079 575VAC 3∅ COMMON PARTS, 3∅ POWER FUSE, XFMR SECONDARY, LP-CC-3.5 TRANSFORMER, 575X120 PSF FUSE, XFMR, PRIMARY, FNQ-R-0.5 CONTACTOR, IEC, 9A, 120VAC COIL RELAY, OVERLOAD, IEC, 1-2.
A0571673 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 220V CONTROL COMMON PARTS QTY PART # 1 A0571676 1 A0570597 DESCRIPTION SUBPANEL, 16.75X9.75 CONTROL PANEL, 5.
7-4 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.
7-5 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 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.
