SDA Series 25-100 (15, 30, & 60 cfm) Compact Dehumidifying Dryers Part Number: 882.00291.00 Bulletin Number: DH1-635.3 Effective: 05-15-07 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement.
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................................................................ 5 1-1 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in this Manual .....................................................................................5 1-2 Safety Tag Information ................................................................................................... 6 Dryer Safety Tags...................
Identifying Control Panel Indicator Lights and Switches for the Standard Controller ..........20 Process Air Temperature Controller ....................................................................................21 Setting the Process Air Temperature...................................................................................23 Restoring the Process Air Temperature Controller (E5CN) to Factory Settings..................23 Process Air Dew Point Display ..............................................
Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your drying system. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer. The Functional Description section outlines models covered, standard features, and safety features.
1-2 Safety Tag Information Dryer Safety Tags Hot! Read Operation and Installation Manual High Voltage Earth Ground Inside Enclosure PE Lifting Point Protected Earth Ground 1-3 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations.
; 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.
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.
• 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. Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric supplies and all accessory equipment at the machine, and disconnect and lockout electrical power.
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.
Figure 1: Typical Dryer Air Flow Schematic Regeneration Make Up Moisture Exhaust Filter High Pressure Peripheral Drying Hopper Thermocouple location 2-3 Standard Features Mechanical Features • Dual desiccant beds • Electrically-actuated air valve • 13X Molecular Sieve • Single regenerative process blower • Drying temperature range of 180ºF to 230ºF (82ºC to 110ºC). • 2.5” hose connections Electrical Features • Process thermocouple to be connected to drying hopper air inlet.
• Mercury process heater contactor • Process high temperature alarm light • Process/regeneration heater box • High temperature safety system (Process/Regeneration) 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.
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.
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 2: Suggested Lift Rigging for Cart Mount Dryers Caution! Do not use a hoist to move or rig your Drying/Conveying System when it is mounted on a cart! Moving the unit with a hoist will cause it to become unstable and may cause damage to the equipment and/or injury to personnel! Figure 3: Suggested Lift Rigging for Floor Mounted Dryers DEW POINT CONTROL POWER ON DEW POINT CONTROL POWER ON ON OFF PROCESS TEMPERATURE PROCESS TEMPERATURE OFF ON OFF POWER ON ALARM OFF POWER ON ALARM Note:
Figure 4: Suggested Lift Rigging for Machine Mounted Dryers Mounting flange E DEW POINT CONT ROL POWE R E ON OFF PROCESS TEMPERATUR E ON POWER ON ALAR M OFF 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. 3.0 cu. ft. (80 liter) hoppers and larger are not supplied with a cast flange (as shown).
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 15 and 30 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.
trapped air from the system. Make sure the aftercooler has the proper supply water temperature. 6. Set the process set point on the temperature controller. 7. After the proper pre-drying time for the initial hopper fill has elapsed, fully open the drying hopper slide gate. Note: To allow proper residence time during continuous processing, maintain the material level in the hopper at the midpoint of the air trap assembly. Auto-Tuning the Dryer 1. For Auto-tuning, press the Level Key once.
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.
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. Power is applied to the voltage line fuses, line side of the control power switch. 2. Turn the control power switch to the ON position. Power is applied to the temperature control, programmable relay and dew point controller. The valve will move to the start position as follows: 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. 5. If the process temperature controller faults or the process heater safety switch opens, a 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. (Requires turning the dryer OFF). 6.
The following is a list of Alarm Display Messages which can be found on the relay screen: Temperature Controller Alarm and/or Regen Heater Temp Switch and/or HIGH TEMP Process Heater Temp Switch and/or Redundant Temp Safety and/or the blower pressure switch is not detecting pressure.
Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule The checklist below contains a list of items which should be inspected and/or replaced to keep your Portable Drying/Conveying System operating at peak efficiency. Perform each inspection at the regular intervals listed below.
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 vacuum from the outside. Caution! DO NOT clean/wash filter with water! After each cleaning: • Inspect the filter element. Briefly hold a light bulb behind the element and look for any fatigued paper or residual dirt. Inspect for holes and tears by looking though the filter toward a bright light.
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 10: Desiccant Bed Location and Disassembly Valve & Air Manifold Casting Hollow Desiccant Tank Desiccant Assembly Rod Gasket Regeneration Heater Wire Conduit Assembly Caution! Lower Air Manifold Casting You should properly dispose of any discarded desiccant. Consult local disposal regulations for more information. 11. Inspect each desiccant screen for tears or holes where desiccant burned-through. Replace desiccant can if needed. 12.
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. Although the replacement procedure is the same for each heater, the wattage varies by model, voltage, temperature range, etc. WARNING! Hazardous electrical current present.
5. Disconnect heater thermostat safety. 6. Pickup and place the top casting in a safe place. 7. Pickup the desiccant can to reveal the heater. 8. Using a 1/8” Allen wrench, remove the four (4) 10-32 screws on the heater plate. 9. Remove the wires to the heater plate assembly being removed or replaced. 10. Remove the two (2) 4-40 screws for the temperature switch. 11. Inspect temperature switch with voltmeter. (Normally closed, ohms). Replace if faulty. 12.
5. Visually inspect the coil for leaks, dirt, and ant sign of volatiles. 6. Blow the dust out, or if the coil is covered with plasticizer, steam clean it. 7. Place the coil back in its housing. Make sure the gasket is OK, replace if necessary. 8. Inset the four 10-32 bolts back in place. 9. Turn the water to the cooling coil back on.
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.
Alarm Message HIGH TEMP Cause The process temperature has exceeded the alarm set point. The high temperature snap switch of the process heater box has tripped. The high temperature snap switch on of the regeneration heater boxes has tripped Process blower pressure switch is not detecting pressure. PROC BLWR The process blower pressure switch did not detect enough pressure. Process blower overload has tripped. Process blower motor has failed.
Alarm Message Cause Corrective Action Dryer Status VALVE MTR The limit switch on the valve may not have been wired correctly. The valve has made enough rotations and the correct position of the valve was not detected. Limit switch may be out of position. Re-adjust the switch to make sure it trips when it is at the high position, and it does not touch the cam when it is at the low position. The switch is indicating the incorrect desiccant tank is in regeneration.
Chapter 7: Appendix 7-1 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.
Figure 15: High Heat Model (180°F to 400°F) Air Flow Schematic After-Cooler Regeneration Make Up Air Moisture Exhaust Filter High Pressure Peripheral Blower Process Heater Drying Hopper Figure 16: Low Heat Model (120°F to 250°F) Air Flow Regeneration Make Up Air Moisture Exhaust Filter High Pressure Peripheral Blower Cooler 15, 30, & 60 cfm Compact Dryers Drying Hopper 42
7-3 Spare Parts List 500 Watts Heater element 115 Volts 500 Watts Heater element 208/220 Volts 500 Watts Heater element 230 Volts 500 Watts Heater element 400 Volts 500 Watts Heater element 460 Volts 500 Watts Heater element 575 Volts 1000 Watts Heater element 115 Volts 1000 Watts Heater Element 208/220 Volts 1000 Watts Heater Element 230 Volts 1000 Watts Heater Element 400 Volts 1000 Watts Heater Element 460 Volts 1000 Watts Heater Element 575 Volts 1500 Watts Heater Element 208/220 Volts 1500 Watts Heat
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 725.00761.00 120 VAC 1 GRAPHIC, ASD CONTROL, 1∅ COMMON PARTS, 120VAC CONTROL FUSE BLOCK, 2P 30A CC FUSE, PROC BLOWER, LP-CC-6 25 26 27 28 1 1 1 1 A0566840 A0571673 A0534258 725.00758.
33 3 A0534047 33 3 A0534048 33 3 A0534043 33 3 A0534044 33 3 A0534042 33 3 A0534043 33 3 A0534041 33 3 A0534041 FUSE, HEATERS, KTK-R-12 230VAC 3∅ HIGH HEAT FUSE, HEATERS, KTK-R-15 400VAC 3∅ LOW HEAT FUSE, HEATERS, KTK-R-7 400VAC 3∅ HIGH HEAT FUSE, HEATERS, KTK-R-8 460VAC 3∅ LOW HEAT FUSE, HEATERS, KTK-R-6 460VAC 3∅ HIGH HEAT FUSE, HEATERS, KTK-R-7 575VAC 3∅ LOW HEAT FUSE, HEATERS, KTK-R-5 575VAC 3∅ HIGH HEAT FUSE, HEATERS, KTK-R-5 30 CFM Item Qty.
40 41 1 1 A0558000 A0558078 CONTACTOR, IEC, 9A, 120VAC COIL RELAY, OVERLOAD, IEC, .32-1A 33 1 A0534051 FUSE, HEATERS, KTK-R-30 33 1 725.00860.00 33 1 A0568936 33 3 725.00860.00 33 3 A0568936 33 3 725.00860.00 33 3 A0568936 33 3 725.00860.00 33 3 A0568936 33 3 A0534048 33 3 A0534046 33 3 A0534047 33 3 A0568935 33 3 A0568935 33 3 A0534043 Item 20 Qty.
40 41 1 1 A0558000 A0558079 CONTACTOR, IEC, 9A, 120VAC COIL RELAY, OVERLOAD, IEC, 1-2.9A 24 28 31 32 40 41 1 1 1 2 1 1 A0571675 A0568940 A0558192 A0536886 A0558000 A0558079 575VAC 3∅ COMMON PARTS, 3∅ POWER FUSE, XFMR SECONDARY, FNM-1.25 TRANSFORMER, 575X120 PSF FUSE, XFMR, PRIMARY, FNQ-R-0.25 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.
7-5 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.
7-7 Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 783-7835 or call [262] 641-8600, Fax [262] 641-8653 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.