SDAA 25-100 (15-60 cfm) Dehumidifying Dryers Part Number: 882.00290.00 Bulletin Number: DH1-640 Effective: 12/06/05 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.
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.
Table of Contents CHAPTER 1: SAFETY................................................................V 1-1 1-2 1-3 How to Use This Manual ............................................................................................. v Safety Symbols Used in this Manual ..................................................................... v Warnings and Precautions ......................................................................................... vi Responsibility .......................................
-3 4-4 4-5 Restoring the Process Air Temperature Controller (E5CN) to Factory Settings..28 Process Air Dew Point Display ............................................................................31 Setting the High Dew Point Alarm .......................................................................31 Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup ................31 Redundant Safety Controller Display ..................................................................
Service Department.............................................................................................59 Sales Department................................................................................................59 Contract Department ...........................................................................................
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.
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.
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 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.
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.
Dehumidifying Dryers Chapter 1: Safety x
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 15, 30, and 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 carefully controlled temperatures for use in plastic drying systems.
A small amount of ambient air is introduced into the process air stream to make up for the air lost during the bed regeneration. Because the process air is typically much drier than the ambient air, the air mixture maintains drying efficiency at a consistently high level. This air is heated to 500° F (260° C) before entering the bed that is on regeneration forcing moisture from the desiccant before exhausting.
• NFPA79 machinery electrical standards • Non-fused electrical disconnect • Branch fusing • Mercury process heater contactor • Regeneration temperature control • Process high temperature alarm light • Process/regeneration heater box • High temperature safety system (Process/Regeneration) • Dew point monitor with digital read-out Controller Features • Mitsubishi programmable relay controller • Display of process temperature set point and actual settings 2-4 Options Options marked with “*” indicate options
• 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.
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.
Figure 16: Machine-Mount Dryer Dimensions Mounting flange C E E Diameter hole: F Notes: Hopper mounting flanges on 0.75 and and 1.5 cu. ft. (20 & 40 liter) hoppers are supplied blank so the customer can drill to match existing machine throat. PROCESS TEMPERATURE DEW POINT OFF ON B CONTROL POWER ALARM HORN ON OFF ALARM ALARM Silencer 3.0 cu. ft. (80 liter) hoppers and larger are not supplied with a cast flange (as shown).
Figure 17: Floor-Mount Dryer Dimensions CONTROL POWER ON OFF ALARM HORN ALARM Silencer C B D ALARM DEW POINT OFF ON PROCESS TEMPERATURE A E Dimension A B C D E Dehumidifying Dryers 15, 30, 60 cfm floor-mount dimensions in inches/cm 15 cfm 30 cfm in. cm in. cm 20 51 20 51 32.5 83 32.5 83 30 76 30 76 30 76 30 76 23.75 60 23.75 60 Chapter 3: Installation 60 cfm in. 24 32.
Figure 1: Suggested Lift Rigging for Cart Mounted Dryers DO NOT USE DEW POINT ALARM HOR N ALARM OFF ON PROCESS TEMPERATURE CONTROL POWER ON OFF ALARM Silencer USE FORK LIFT TRUCK 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! Recommended Dryer Lifting Hardware Item 1 2 3 4 Quantity 1 2 1 1 Description Adjustable alloy chain sling Exis
Figure 3: Suggested Lift Rigging for Machine Mounted Dryers DEW POINT ALARM HORN ALARM Caution! 3-3 OFF ON PROCESS TEMPERATURE CONTROL POWER ON OFF ALARM Silencer 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! Electrical Connections When making
3-4 Setup Procedures This section provides the procedures necessary for configuring your Dehumidifying Dryer. Configuration of your dryer includes checking for proper blower rotation, making dryer/drying hopper process air connections and 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 as described in this section.
Drying Hopper Air Trap Considerations 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.
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. Starting Up the Dryer 1. Turn on (energize) the disconnect switch in your power drop, then turn on the one on the dryer. 2. Turn the system ON/OFF switch to ON to energize the display panel. 3.
Shutting Down the Dryer 1. Turn off the conveying system supplying the drying hopper. 2. When processing is complete, close the hopper slide gate and shut down any in-line companion equipment, such as the aftercooler. 3. Turn the Dryer ON/OFF selector switch to OFF. 4. Turn the system ON/OFF switch to OFF. 5. If needed, empty the drying hopper. 6. 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 Start-up 1. Turn on (energize) the disconnect switch in your power drop, then turn on the one on the dryer. 2. Turn the system ON/OFF switch to ON to energize the display panel. 3. Close the slidegate at the bottom of the drying hopper. Make sure that the blowers turn in the right direction. 4. Fill the drying hopper with material. 5. Turn the dryer ON switch to START to start the dryer. The process blower starts. 6.
4-2 Controller Description and Operation Identifying Control Panel Indicator Lights and Switches for the Standard Controller Switches System OFF/ON/START Switch. This switch energizes or de-energizes control power to the indicator panel and starts the dryer. (The controller can be energized without the dryer running.) Optional Alarm Silence Switch. Press this switch to silence the horn when a high temperature process/regeneration or blower failure alarm activates. Indicator Lights Alarm Light.
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.
Indicator Name Description ALARM1 ALARM 1 LED Lights in the Operation Indicator Section when the output function assigned to auxiliary output 1 turns on. The ALARM1 indicator lights when the process temperature exceeds the set point temperature by more than the alarm deviation value. Alarm output de-energizes the heaters. Heaters re-energize when the temperature falls within the acceptable range.
Restoring the Process Air Temperature Controller (E5CN) to Factory Settings If the preset parameters on the controller have been tampered with and it no longer properly controls temperature and displays dew point, you can restore the controllers to the factory setup. Call the Service Department for detailed instructions. E5CN Operating Parameters The E5CN controller has several mode selections. Within each mode are numerous parameters that can be set.
Adjustment Level Indicator Name Description Auto-Tune Mode (At) See Page 19 of Chapter 3 for instructions on how to Auto-Tune your dryer. Note: Although the controller is calibrated at the factory, the manufacturer recommends that the unit be AutoTuned prior to dryer startup. Dehumidifying Dryers Temperature Input Shift Mode (TnS) This setting is used to offset an error between the set point and the actual temperature. The entire input range is shifted by a set figure preprogrammed by the operator.
Entering Operating Parameters to Select Modes To enter the display: 1. Press the Mode Display key to view the Run/Stop & Alarm 1 Modes. and to set the higher or lower the values of the parameter or turn 2. Press that function On or Off. The SV readout displays the different values for the parameter within a mode. 3. To switch modes within a level, press and hold the (1) second. Level Display key for one The PV readout will display the different parameters within each mode. 4.
Process Air Dew Point Display Optional The Process Air Dew Point meter indicates the current process air delivery moisture content. Standard dryers use a microprocessor-based controller for displaying dew point air temperature. 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.
Redundant Safety Controller Display Optional The Redundant Safety Controller limits the process air temperature from exceeding the upper temperature range set by the E5CN Temperature Controller. Standard dryers use a microprocessor-based controller for limiting the process air temperature. 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.
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 or Down 3. Press the Up to move through the parameter prompts. keys to change the parameter value. 4. Press the RESET Key at any time to return to the Home Page display. Figure 9: Setting List for Redundant Safety Controller (WATLOW), Part No.
4-3 Dryer Operation Procedures Controller Operation (Without Optional Alarm Horn & Reset Button) 1. Turn the disconnect on the control panel to the ON position. Power is applied to the voltage line fuses, line side of the control power switch and the temperature controller. 2. Turn the control power switch to the ON position. Power is applied to the programmable relay and dew point controller. The valve will move to the start position as follows: a.
3. Once the control power is on and no fault conditions exist, turning the OFF-ONSTART switch to the START position will start the dryer as follows: a. The process heater is turned on and controlled by the E5CN controller. 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 E5C2 controller. For default timing settings for regeneration, see the table below.
11. When a dew point fault is generated by the optional dew point controller, the alarm light will activate. The alarm light will flash, indicating a non-critical fault. Press Alarm Reset to deactivate the alarm until the next dew point fault occurs. 12. The top 2 lines of the display show the HEAT and COOL times (in minutes) for the regeneration sequence. Changes to these times can be made by the operator as follows: a. Press the up or down arrow until the cursor is positioned at the number to be changed.
Controller Operation (With Optional Alarm Horn & Reset Button) 1. Turn the disconnect on the control panel to the ON position. Power is applied to the voltage line fuses, line side of the control power switch and the temperature controller. 2. Turn the control power switch to the ON position. Power is applied to the programmable relay and dew point controller. The valve will move to the start position as follows: a. The valve motor rotates until the cam switch makes 2 transitions. b.
5. If the OMRON controller faults, the optional redundant high temperature safety device opens, or the process heater safety switch opens, a process heater fault is generated. “HIGH TEMP” is displayed on the relay screen. The alarm horn and light are activated. The process heater, regen heater, and process/regen blower are turned off. Pressing the ALARM RESET pushbutton will deactivate the alarm horn and light. Turn the Off-On-Start switch to the START position to restart the dryer.
Alarm Display Messages Note: The relay screen which contains the Alarm Display Messages is located inside the controller enclosure.
4-4 Auto-Tuning the Dryer 1. For Auto-tuning, press the beige button once. The AT screen will show with the setting OFF. 2. Press the UP arrow to change the setting to ON. 3. Press the beige button again to go back to the Temperature Screen. Your actual temperature will start to flash for about 10-20 minutes with the temperature fluctuating up and down during that period. After the flashing stops, it means autotuning has finished. 4-5 Shutting Down the Dryer 1.
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.
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. 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.
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.
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.
Figure 11: Desiccant Bed Location and Disassembly Undo (4) 10-32 Button Head Screws using 1/8 Allen Wrench Desiccant Cap 1" Wide x 1/8" Thick Silicon Strip and Stick Gasket 13X Molecular Sieve 8x12 Beads Regeneration Heater Regeneration Thermocouple 16 Mesh 0.028 Diameter Wire Stainless Steel Screen (2) 4-40 screws Hi Temperature Snap Switch 1" Wide x 1/8" Thick High Temperature Gasket Caution! You should properly dispose of any discarded desiccant.
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.
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 Material in drying hopper cakes, or meltdown occurs. Possible cause Corrective action 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. Process set point is out of acceptable range. Function set for degrees Celsius (ºC), set point at degrees Fahrenheit (ºF). Process thermocouple not in airflow.
Problem Possible cause Corrective action No setting change possible on temperature controller. The key protection switch is set to ON. Input polarity on thermo-couple is wrong or connection is wrong. Set the key protection switch to OFF. Input-type setting is incorrect. Properly set the input with the input-type selector rotary switch. No compensating lead wires used for extension of the thermocouple. Use proper compensating lead wires and terminals.
Chapter 7: Appendix 7-1 Warranty Unless otherwise specified, this product includes a Standard ONE YEAR PARTS WARRANTY. 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.
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.
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: 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.
Aftercooler Design Specifications Entering water temp.
LEVEL 2 ( Mechanical Components ) PART # SIZE Description A0548621 Ceramic Cap for the End of Heater Elements A0566478 750 Watts Heater element 208/220 Volts A0566479 750 Watts Heater element 230 Volts A0566480 750 Watts Heater element 400 Volts A0566481 750 Watts Heater element 460 Volts A0566482 750 Watts Heater element 575 Volts A0566483 1250 Watts Heater Element 208/220 Volts A0566484 1250 Watts Heater Element 230 Volts A0566485 1250 Watts Heater Element 400 Volts A0566486 1250 Watts Heater Element 460
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.
7-8 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.
7-9 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.
