SDA 1000-5100 Large Dehumidifying Dryers with AP0 Controls Part Number: 882.00292.00 Bulletin Number: DH1-605 Effective: 12/01/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement.
Shipping Info Unpacking and Inspection You should inspect the large dehumidifying 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.
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.
Table of Contents CHAPTER 1: SAFETY................................................................ 8 1-1 1-2 1-3 How to Use This Manual ............................................................................................. 8 Safety Symbols Used in this Manual .....................................................................8 Warnings and Precautions .......................................................................................... 9 Responsibility .......................................
Setting the Process Air Temperature ..................................................................29 Restoring the Process Air Temperature Controller (E5CN) to Factory Settings..29 Process Air Dew Point Display ............................................................................32 Setting the High Dew Point Alarm .......................................................................32 Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup ................
8-5 8-6 Dryer Identification (Serial Number) Tag................................................................... 58 Technical Assistance................................................................................................. 60 Parts Department ................................................................................................60 Service Department.............................................................................................60 Sales Department.........................
Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining the large 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 Tag Description Tag Read Operation & Installation Manual PE 1-2 Description High Voltage Inside Enclosure Hot! Lifting Point Protected Earth Ground 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.
; 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.
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. ; NEVER place your hands or any part of your body in any dangerous location.
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.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 600-3000 cfm Large Dehumidifying Dryers with AP0 control. These dryers are available with electric heaters or gas burners. Gas dryers are indicated with a “G” in the model number. 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.
moisture is stripped from the air by a desiccant bed. The dried process air is then re-heated and delivered back into the drying hopper to dry material again. This system is a "closed loop", because ambient (outside) air is never introduced into the process air. The closed loop system is used by the manufacturer because the process air is typically much drier than ambient air, even after carrying moisture out of the plastic resin.
AD600-AD1500 Dryer Flow Schematic Left Desiccant in Regeneration Regeneration Blower Regeneration Filter Dryer Valve Regeneration Heaters Process Heater Regeneration Exhaust Left Desiccant Insulated Drying Hopper Process Filter Right Desiccant Process Blower Sequence of Operation When the dryer is started, the main air valve rotates 360º and then moves to place the last successfully regenerated desiccant bed online.
2-3 Controller Description The AP0 control package uses a relay logic controller to control the operation of the dryer. See below for descriptions of each screen. Figure 2: Controller Screen Descriptions Regen Set Screen. Displays heating and cooling times for regeneration. Also used to change times if necessary. Material Miser OFF Screen. Used to enable material miser valve. Material Miser ON Screen. Used to disable material miser valve.
2-4 Standard Features Mechanical Features ; 180ºF – 250ºF Drying temperature range ; High regeneration temperature control safeties ; 13X desiccant (molecular sieve) ; Easy to access process and regeneration ; High pressure centrifugal blower ; Dew point +15º F to –40º F Electrical Features ; Electrically-actuated air valve ; NFPA79, UL & CUL machinery electrical standards (Electric Dryers) includes: • NEMA 12 controls, components & enclosure • Non-fused electrical disconnect • Solid state relays for
2-5 Options Closed-Loop Regeneration An optional regeneration closed-loop valve and heat exchanger can be used to close the regeneration loop during the cooling portion of the regeneration cycle. If this option is enabled on the dryer, air will be bled to the atmosphere until the heating portion of the regeneration cycle is finished.
Process Air Dust Collector The optional process air dust collector consists of a filter, dust can, pressure gauge, and optional pressure switch (see Figure 5). The gauge will let you know whether it is time to clean out your filters. The optional dirty filter alarm will be activated if the filter is dirty.
Figure 6: Material Miser/Air Balance Valve Temperature Probe Valve Proofing Switch Coupling Drying Hopper Mechanical Options ; Low temperature operation (120°F to 250°F) ; High temperature operation (180°F to 400°F) ; Precooler (Required for temperatures below 180°F, used with low temperature operation) ; Aftercooler (Required for temperatures above 250°F, used with high temperature operation) ; Plasticizer trap / Aftercooler w/filter ; Automatic airflow reduction valve 13X desiccant ; Closed loop coolin
2-6 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the large dehumidifying dryer. This manual is not intended to supersede or alter safety standards established by the user of this equipment. Instead, the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment.
In addition to the safety devices listed above, these dehumidifying dryers are equipped with a line cord plug. This allows the operator or maintenance personnel to unplug the system from its power source and tag it out. The plug can then be tagged with any number of approved electrical lockout tags available at most electrical supply stores. WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air) sources prior to servicing or cleaning the dehumidifying dryer.
Chapter 3: Mechanical Installation 3-1 Uncrating the Equipment The large 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.
; The power drop must include a ground wire. ; Make sure all electrical connections are tight. 3-4 Checking for Proper Blower Rotation After the electrical connections have been made, check the process and regeneration blowers for proper blower rotation. Check blower rotation before making process air connections between the dryer and hoppers, and before connecting cooling water (for the optional aftercooler). Blowers should rotate in a clockwise direction. See Figure 7.
3-5 Making Dryer/Drying Hopper Process Air Connections When making process air connections to your 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 (to the drying hopper) hose as short as possible to minimize heat loss. Insulated hose is recommended and available for maximum energy savings.
3-6 Connecting Aftercooler/Precooler Cooling Water (Optional) Support both sides of the fitting when making the cooling water connections to prevent damage to the aftercooler coil. See Figure 9. Connect 85°F water to the inlet closest to the exiting air side of the aftercooler coil. This will cool the process air about 100°F and raise the water-out temperature about 10°F. The table below lists available aftercooler models and their flow rates.
3-7 Using the Drying Hopper Air Trap Our exclusive air trap assembly in the top of the drying hopper prevents ambient air from contaminating the material being dried. To ensure that air does not enter the drying system, do the following (See Figure 10): ; Keep the material level above the bottom edge of the air trap for maximum efficiency. ; Use a hopper loader or vacuum conveying system to maintain the proper material level.
Chapter 4: Controls 4-1 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.) Indicator Lights Alarm Light.
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.
Identifying Temperature Controller Keys Indicator Name Description Mode Key Press the Mode key to shift the display to the next set of parameters. The menu screen displays. Down Key Press the Down arrow key to lower the process air set point temperature. During setup, it lets you decrease the value of the parameter displayed on the set point LED readout. Up Key Press the Up arrow key to raise the process air set point temperature.
Available E5CN Modes Operation Level Indicator Name Description Run/Stop Mode (r-S) When “RUN” is selected, the control is running. When “STOP” is selected, the control is stopped. When the control is stopped, the STOP display lights. The default is set to “RUN.” Alarm Value 1 Mode (AL-1) This setting is used to indicate how many degrees the process temperature will be allowed to exceed the set point temperature. An alarm output will deenergize the heaters.
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 2. Press parameter or turn 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 key for one (1) second. Level Display 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 3. Press the Up to move through the parameter prompts. or Down keys to change the parameter value. 4. Press the RESET Key at any time to return to the Home Page display. Figure 15: Setting List for Redundant Safety Controller (WATLOW), Part No.
Chapter 5: Operation 5-1 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. 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.
5-2 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.
5. If the Regen E5CN controller faults, a regen high heat fault is generated. “RH” is displayed on the relay screen. The alarm light is activated. The process heater, regen heater, and process/regen blower are turned off. Turn the OFF-ON-START switch to the START position to deactivate the alarm light and restart the dryer. If the fault condition still exists, the dryer will not restart. 6. If the process regen overload trips, a regen blower fault is generated. “RB” is displayed on the relay screen.
on the relay screen. Press ALARM RESET to deactivate the alarm until the next dew point fault occurs. 15. Use the right arrow key to display the REGEN SET screen (Screen 1). Use the up & down arrow keys to select the parameter to change. Use the + & - keys to change the parameter value. Press the OK key to accept and store the changed values. Press ESC to cancel changes. REGEN SET HEAT 45 COOL 20 Screen 1. 16. Use the right arrow key to display the Material Miser screen.
18. Turn selector switch to START position to start the dryer. The bed switch valve will cycle to a known good position. The process & regen blowers will start. Process & Regen heaters are enabled. A new regen heat/cool cycle is started. Blower alarms are enabled 5 seconds after startup. Dew Point alarm is enabled 5 minutes after startup. All other alarms are enabled with no delay. 19. Material Miser.
PF - PROCESS FILTER RF - REGEN FILTER CV - CLOSED LOOP VALVE BV - BED SWITCH VALVE PS - PROCESS TEMP SWITCH RS - REGEN TEMP SWITCH PH - PROCESS HI TEMP PL - PROCESS LOW TEMP RH - REGEN HI TEMP DP - DEWPOINT PR - REDUNDANT SAFETY 5-4 ALARMS : PB RB BV PS RS PH PL RH Screen 6. 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.
Chapter 6: Maintenance 6-1 Maintenance Schedule The checklist below contains a list of items that should be inspected and/or replaced to keep your Large Dehumidifying Dryer operating at peak efficiency. Perform each inspection at the regular intervals listed below.
6-2 Preventative Maintenance Cleaning or Replacing the Process Air Filters Regular filter cleaning will keep your dryer operating at peak efficiency. The process air filters protect the centrifugal blowers from plastic fines being drawn in from the drying hopper. Filters should be cleaned when airflow restriction trips the dirty filter alarm. Filters should be replaced at least once a year. Caution! Operating the dryer without the process air filters installed will void the warranty.
Use the following procedure to clean or replace the filter cartridges: 1. Turn off and/or lock out electrical power to the dryer. 2. Remove the hand knobs or clamps securing the filter access cover and remove the cover. 3. Remove the nut on the center-retaining rod to remove a filter cartridge. 4. Vacuum, blow out, or wash the filter. 5. Inspect the filter - a damaged filter should not be reused.
5. Remove the restricted filter cartridge from the housing again. The alarm light should stay off when the process blower operates if the switch is adjusted correctly. 6. Re-install the obstructed cartridge filter. The alarm light should go on again if the switch is adjusted correctly. 7. Fine tune the switch setting so it consistently warns of a blocked filter and does not falsely indicate a blockage of a clean filter. 8. Remove the restriction from the filter element and re-install the clean filter.
6-3 Corrective Maintenance Symptoms of Worn Out Desiccant The moisture adsorption capacity of the desiccant used in Large Dehumidifying Dryers degrades after an indefinite period of time. Useful life depends on variables such as material moisture content, plasticizer vapors in the return air and number of regeneration cycles. Your dryer may need new desiccant if it exhibits any of the following symptoms: • The plastic material is not being dried sufficiently (high scrap/reject rate).
6. Inspect the gaskets on each of the covers. Replace if necessary. 7. Re-install the covers. Figure 17: Desiccant Tower Assembly Regeneration Heater Cover. High Temperature Gaskets. Regeneration Heaters Heater Element Mounting Plate. Viewing Glass, for checking the status of the desiccant inside. Access cover can be removed in order to replace desiccant. High Temperature Gaskets.
1. Remove the bolts securing the process heater access cover. 2. Sketch the heater wiring configuration so the heaters may be re-wired properly. Heaters are mounted on a common plate of three or six for easy maintenance. 3. Remove the jumper bars and wires for the heater plate assembly(ies) being removed or replaced. 4. Remove the bolts securing the heater plate assembly and slide out the assembly. Avoid damaging the gaskets. 5.
1. 2. 3. 4. 5. 6. Access the desiccant canisters by removing the panels on the dryer. Remove the Regeneration Heater Cover. Unscrew the six (6) screws on the Heater Element Mounting Plate. Slide out the heater assembly, taking care to not damage the gaskets. Unscrew the heater loops that need to be replaced. Re-install the new heaters. Securely tighten all fasteners. Caution! 7. 8. 9. 10. The heater loops should not touch each other. This will create "hot spots" and lead to premature heater failure.
Chapter 7: Troubleshooting 7-1 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.
Problem Loss or reduction in drying capacity. Possible Cause Process heaters are faulty. Desiccant beds are contaminated. Material being dried differs from material specified at the time of purchase. Break in flex hose to/from drying hopper. Blower fins filled with dust or contaminants. Material in drying hopper cakes, or meltdown occurs. Process temperature set too high due to operator error. High temperature alarm not set properly. Process set point is out of acceptable range.
7-3 Alarms The Alarm Screen will pop up to show what alarm the dryer is having that moment. Look through the window on the door to see the screen. 7-4 Alarm Descriptions Alarm Code BV CV PS RS PH PL RH DP PB RB PF or RF PR Alarm Description The Main Air Valve did not maintain or find position. Possible Motor or Limit Switch Failure. The Closed Loop Cooling Valve did not find position. Possible Motor or Limit Switch Failure. The process supply air temperature switch opened. Possible thermocouple failure.
7-5 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 8: Appendix 8-1 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.
8-2 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. Allowable voltage fluctuation: +/- 10% 9.
8-3 Drawings and Diagrams Regeneration Blower Insulated Drying Hopper Regen. Filter Process Air Filter Process Heater Optional Regeneration Closed Loop Cooler Regen. Optional Regeneration Exhaust Closed Loop Valve Optional After-cooler Right Desiccants Left Desiccants Dryer Valve Process Blower Airflow Schematic: 2000-3000 cfm dryers (4 desiccant beds). Left desiccant beds are regenerating—closed loop regeneration is activated. Regeneration Blower Regen.
Filter Check Gage Differential Pressure Switch Thumb Screws PS Cartridge Filter Dust Shroud Filter Retainer F E Slide Gate Clamp Dust Level Indicator Dust Pan Optional dryer dust collector Large Dehumidifying Dryers Appendix 56
Large Dehumidifying Dryers 1000CFM 1000CFM 1000CFM 1250CFM 1250CFM 1250CFM 1250CFM 1250CFM 1500CFM 1500CFM 1500CFM 1500CFM 1500CFM 2000CFM 2000CFM 2000CFM 2500CFM 2500CFM 2500CFM 3000CFM 3000CFM 400V 50 HZ 3PH 460V 3PH 575V 60 HZ 3PH 208V 3PH 230V 3PH 400V 50 HZ 3PH 460V 3PH 575V 60 HZ 3PH 208V 3PH 230V 3PH 400V 50 HZ 3PH 460V 3PH 575V 60 HZ 3PH 400V 50 HZ 3PH 460V 3PH 575V 60 HZ 3PH 400V 50 HZ 3PH 460V 3PH 575V 60 HZ 3PH 400V 50 HZ 3PH 460V 3PH 3000CFM 1000CFM 2
LEVEL 3 ( Mechanical Components ) PART # SIZE Description A0542302 8" O.D. by 12 Ft Long Hi Temp Hose. A0571107 3" O.D. by 12 Ft Long Hi Temp Hose.
8-5 Dryer Identification (Serial Number) Tag (Located on back of Dryer) XXX Series Dryer Model Number XXX-15 Max Drying Capacity HR 460V Serial Number 060701R 1 Date of Manufacture 06/2003 4.5A Over-current Protection Device (s) 4.
Please note that our address and phone information has changed. Please reference this page for updated contact information. These manuals are obsolete and are provided only for their technical information, data and capacities. Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied upon.
8-6 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.
