Operation and Installation Manual SDA 150-380 (90-225 CFM) Cabinet Series Dehumidifying Dryers Important! Read Carefully Before Attempting to Install or Operate B A A B B A A A0534806 Part No: 882.00282.
Performance figures stated in this manual are based on a standard atmosphere of 59°F (15°C) at 29.92” Hg (1,014 millibars) at sea level, using 60 hz power. Altitude is an important consideration when specifying drying and conveying systems. The manufacturer can advise you on proper selection and sizing of systems for your operating environment. We are committed to a continuing program of product improvement.
Table of Contents CHAPTER 1: SAFETY……………………………………………...6 1-1 1-2 1-3 How to Use This Manual. ............................................................................................ 6 Safety Symbols Used in this Manual .....................................................................6 Warnings and Precautions .......................................................................................... 7 Responsibility ....................................................................................
-6 4-7 Setting the Process Air Temperature ........................................................................ 22 PLC Controller........................................................................................................... 22 PLC LED Indicators .............................................................................................23 Output LED Indicators .........................................................................................24 Status LED Indicators................
Charts and Figures 1 2 3 4 5 6 7 8 9 Dryer Air Flow Diagram 12 Typical Dryer Interface Panel 18 Typical Dryer Temperature Controller 20 Display Readout for Mode Settings and Available Security Levels 22 Typical Subpanel Layout 25 Typical Cabinet Dryer Electrical Schematic, Drawings 1 and 2 26-27 Required Desiccant Amounts Per Bed Setting List for Process Temperature Controller, Part No. A0548565 41 Setting List for Dew Point Controller, Part No.
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 General Information section outlines models covered, standard features, and safety features.
Dryer Safety Tags Tag Description PE 1-2 Tag Description Read Operation & Installation Manual 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.
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. 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.
NEVER place your hands or any part of your body in any dangerous location. NEVER operate, service, or adjust the dryer without appropriate training and first reading and understanding this manual.
If you need to repair a large component, use appropriate handling equipment. Before you use handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes) be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable. Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using them to lift a load.
Chapter 2: General Information 2-1 Models Covered This manual provides instructions for installing and operating 90, 100, 150, and 225 CFM cabinet-style dehumidifying dryers. 2-2 Equipment Function Our dehumidifying dryers are designed to generate heated, dehumidified air at carefully controlled temperatures for use in closed-loop plastic drying systems. Moisture removal from hygroscopic (moisture attracting) plastic pellets is an essential step in the manufacture of highquality plastic products.
; Audible/visual critical alarm. ; Fusing for blowers and heaters. ; Dirty Filter indicator for each individual blower. 2-6 The Closed Loop Drying System Dehumidifying dryers force hot, dry air through the resin in the drying hopper where the air picks up moisture from the material and is drawn back to the dryer. In the dryer, a desiccant bed strips moisture from the air. The dryer then re-heats dried process air, and sends it back into the drying hopper to dry material again.
2-7 What is Desiccant? Desiccant is a material which attracts and holds (absorbs) water from the air. Our dehumidifying dryers use a synthetic crystalline metal aluminosilicate desiccant blended with a clay binder and formed 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.
Chapter 3: Installation 3-1 Positioning Your Dryer The dehumidifying dryer system was designed to be wheeled into place. The entire assembly is mounted on a rugged, compact frame and is equipped with sturdy, 4” (10 cm) heavy-duty casters, two locking and two swivel. Caution! 3-2 Use caution and observe safety rules when placing your dryer! Making Electrical Connections ; Fulfill all national, state, and local safety and electrical code requirements.
3-5 Process Air Connections Between the Dryer and Drying Hopper ; Remove the cap plugs from the inlet, discharge and bleed tubes before operation. ; Use high-temperature flexible dryer hose to connect the dryer to the drying hopper. ; Keep the delivery hose as short as possible to minimize heat loss. Insulated dryer hose is available for maximum energy savings. ; Do not shorten the return hose. ; Make sure the hoses are not kinked.
Chapter 4: Controls 4-1 Control Panel Indicator Lights and Switches Rocker Switches System ON/OFF Rocker Switch Used to de-energize control power to the indicator panel, allowing separate control of the dryer and conveying systems. Dryer ON/Sequence Shutdown Rocker Switch Used to start the dryer. Move this switch to the Sequence Shutdown position to turn off the process heaters, finish the regeneration cycle and then turn off the dryer.
Indicator Name Description compressed air, the pressure switch opens and sends a signal to the PLC controller to shut down dryer operation. Dryer operation automatically resumes when 80 psi (551 kPa/ 5.51 bars) air is restored. High Temp Process Air Light The High Temp Process Air alarm indicator lights when the temperature at the process air thermocouple is above the high alarm set value. Upon high temperature alarm condition the process heaters turn off, the process blower remain on.
Figure 2-Typical Dyer Interface Panel Cabinet Series Dehumidifying Dryer 17
4-2 Process Air Dew Point Display The Dew Point display indicates the current process air delivery moisture content. The display uses a microprocessor-based controller for reading dew point air temperature. The controller is a modular, self-contained removable unit in the mounting housing. All parameters are factory-set and adjusted; no field adjustment to the internal controls is necessary. The high dew point alarm is also factory adjusted.
4-5 Identifying Temperature Controller Buttons Display Button This button shifts the display to the next set of parameters. Then, the menu screen displays. Down Arrow Button The Down Arrow button lets you 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 Arrow Button The Up Arrow button lets you raise the process air set point temperature.
E5CK Operating Parameters The E5CK has several mode selections. Within each mode are numerous parameters that can be set. The setting is different for the temperature control unit and the dew point display. Before you can access the several modes of operating parameters, you must change the security lock-out of the controller. The factory sets the security level to protect the parameters from being accidentally changed.
Figure 4: Display Readout for Mode Settings PV Menu display SV SV SV SV SV SV SV 4-6 Level 0 mode Level 1 mode Level 2 mode Setup mode Expansion mode Option mode Calibration mode Setting the Process Air Temperature To change the process air temperature set point with the dryer running: Press the Up Arrow button to increase the set point to the temperature you want. Press the Down Arrow button to lower the set point to the temperature you want.
PLC LED Indicators The following indicators are located inside the dryer cabinet. See Figures 5, 6, and 7. Name Description System Start/Sequence Shutdown (I/0) When ON, activates the operation of the dryer portion. Compressed Air Input (I/1) Process Blower Enable (I/2) When ON, confirms that compressed air is present. Bed Switch Set Point Input (I/4) When ON, indicates that dewpoint is above bed switching set point.
Output LED Indicators Name Description Blower On (O/0) The Blower On indicator lights when the blower energizes. Process Heater Enable (O/2) The Process Heater Enable activates the process heater. The indicator lights when the process heater is energized. This condition occurs when no blower failures or high temperature conditions exist.
Figure 5: Typical Subpanel Layout Cabinet Series Dehumidifying Dryer 24
Figure 6: Typical Cabinet Dryer Electrical Schematic, Drawing 1 \ Cabinet Series Dehumidifying Dryer 25
Figure 6: Typical Cabinet Dryer Electrical Schematic, Drawing 2 222 Cabinet Series Dehumidifying Dryer 26
4-8 Setting the Shift on Dew Point Our dehumidifying dryers shift air flow from the on-line desiccant bed to the regenerated desiccant bed, based on actual dew point demand, not fixed time cycles. After the off-line bed regenerates, the PLC controller waits for a high dew point signal from the process air dew point controller before switching beds. The PLC controller has a four (4) -hour timer override if it does not receive a signal from the dew point control.
5. Use the Up and Down Arrow buttons to set the higher or lower value for the high dew point alarm. Hold the Display button to save the value and return to Level One. 6. Press the Down Arrow button until the controller displays Level 0. 7. Press and hold the Display button to return to Operating mode. Note: The E5CK controller has several levels of securities to lock out access to parameters and menu settings.
No. 1 2 3, 4 5 6 7 8 9 10 11 12 13 14 15 16 Function Shifts the cursor (∇) specifying a day to the right. Sets or cancels (reset) a specified day. Sets a time or ON/OFF time width. (hours, minutes) Monitors the parameters set for an operation during an operation. Sets parameters. (Write) Sets a time adjustment mode. Specifies a cyclic operation, or sets a pulse width. (Not used) Specifies a day substitution operation. (Copy) Cancels the parameters set for each circuit, or a day substitution operation.
8. Press the WRITE key (#6) to store the correct time. 9. The time and day can be adjusted or changed while the timer is operating. Daily Timer Operation Daily time is typically set to operate from 8:00 AM and to stop at 5:00 PM from Monday through Friday. 1. Set the MODE switch (#11) to P1. 2. Press the SHIFT key (#1) to move the cursor to the desired day of the week. Or select several days at once by using the SHIFT (#1) and SET keys (#2). The bar mark will turn on under the chosen days. 3.
1. Hold the COPY key (#9) for one (1) second or longer. Make sure that the mode selector switch is in RUN mode. 2. Select the day(s) you want with the SHIFT (#1) and SET keys (#2). If a previous override had been set, this will show up when you first hold the COPY key. To clear a previous override, press the CLR key (#10). 3. Press the WRITE key (#6). 4. Select Sunday (or another shutdown day) with the SHIFT (#1) and SET keys (#2). 5. Press the WRITE key (#6).
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Chapter 5: Operation 5-1 Pre-Startup Checks 1. Verify that the drying hopper is clean of rust-prohibitive oil or any foreign objects. 2. Verify that process and return hose connections are tight. 3. If your dryer has a water-cooled aftercooler, make sure that sufficient cooling water flows properly through the coil and that you have bled any trapped air from the system. Make sure that the aftercooler has the proper supply water temperature. 4.
twenty minutes to cool down the process. The regeneration cycle of the off-line bed completes the cycle before the dryer shuts down completely. 4. To override the sequence shutdown turn the system ON/OFF switch to OFF. 5. To completely shut off the unit after sequence shutdown has completed, turn the system ON/OFF switch to OFF. 6. If needed, empty the drying hopper. 7. For maintenance or a long term shutdown, open (de-energize) the electrical disconnects at the dryer and at the power drop.
Chapter 6: Maintenance 6-1 Work Rules The installation, operation, and maintenance of this equipment is to be conducted in accordance with all applicable work and safety codes for the installation location. This may include, but is not limited to, OSHA, NEC, CSA, and any other local, national, and international regulations. In addition, you must observe the following specific work rules: ; Keep these operating instructions on hand and follow them when installing, operating, or maintaining your dryer.
Recommendations for Cleaning and Replacing Filters • Turn off and/or lock out electrical power to the dryer. • Remove the threaded fastener securing the filter access cover, and then remove the cover. • Remove the nut on the center retaining rod to remove the filter cartridge. 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.
Preventative Maintenance Checklist Dehumidifying Dryer Systems 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 Nov Dec Inspect all filters for wear, replace/clean if dirty or worn. Check air regulator to make sure pressure is 60-80 psi (413.7 to 551.6 kPa /4.1 to 5.5 bars).
6-3 Servicing the Dew Point Monitor The accuracy of the dew point monitor on dehumidifying dryer systems depends on proper operation of the dew point sensor and the control board. The dew point sensor is in the process air stream and is therefore susceptible to contamination. 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.
First Aid: In case of eye contact, immediately flush eyes with plenty of water for at least 15 minutes. If irritation persists, see a physician. 6-5 Replacing Worn Desiccant Caution! Make sure desiccant beds are sufficiently cool before replacing worn desiccant. 1. Disconnect the electrical and compressed air supply. 2. Remove the rear and side shrouds to expose the desiccant beds. 3. Free the bed covers by removing the hex nuts on the retaining rods and remove the upper screens from both beds. 4.
Figure 7: Required Desiccant Amounts per Bed; Type 4X Desiccant (2 beds per unit) Dryer CFM 90 100 150 225 Large bead (Type 4X) Part no. lbs. Kg 3.0 1.362 3.0 1.362 W00000892 9.0 4.086 9.0 4.086 Small bead (Type 4X) Part no. lbs. Kg 21.0 9.534 21.0 9.534 W00000893 30.0 13.620 30.0 13.620 Total per bed lbs. Kg 24.0 10.896 24.0 10.896 39.0 17.706 39.0 17.706 Type 13X Desiccant Dryer CFM 90 100 150 225 6-6 Large bead (Type 13X) Part no. lbs. Kg 3.0 1.362 3.0 1.362 W00018050 9.0 4.086 9.0 4.
6-7 Replacing the Regeneration Heater The dehumidifying dryers use heater elements located below each desiccant bed. WARNING! Disconnect and lock out power before you replace heater elements! 1. Remove the cover plate secured by bolts. 2. Sketch the heater wiring configuration so you can properly re-assemble the heaters. 3. Remove the wiring for the heater being removed or replaced. 4. Remove the bolts securing each heater mounting plate. Slide out the heater. 5.
2. Make sure jumper setting for input type is set for thermocouple TC-PT, middle jumper. 3. Return controller to housing. 4. Press the Display button for one (1) second to enter Menu Display. 5. Press the Up Arrow button to get to Setup mode. 6. To switch parameters within Setup mode, press the Display button. Figure 8: Setting List for Process Temperature Controller, Part No.
Level 1 Level 1 Level 1 Level 1 Level 1 Level 1 Level 1 Level 1 Level 1 Level 1 Level 1 Level 1 Mode AL-2 Alarm Value 2 AL-3 Alarm Value 3 P Proportional Band I Integral Time d Derivative Timer C-SC Cooling Coefficient C-db Dead Band 6F-r Manual Reset Value HYS Hysteresis (Heat) CHYS Hysteresis (Cool) CP Control Period (Heat) C-CP Control Period (Cool) -1999 to 9999 EU -1999 to 9999 EU 0.1 to 999.9% FS 0 to 3999 SEC 0 to 3999 SEC 0.01 to 99.99 0 0 10.0 233 40 1.00 25.0 Default 4.4 84 13 Default -19.
Setup Setup Setup Setup Setup Setup Setup Setup Setup Setup Initialize 6UE1 Control Output 1 Assignment 6UE2 Control Output 2 Assignment Sub 1 Auxiliary Output 1 Assignment ALE1 Alarm 1 Type AL1n Alarm 1 open in alarm ALE2 Alarm 2 Type AL2n Alarm 2 open in alarm ALE3 Alarm Type AL3n Alarm 3 open in alarm 6rEu Direct/Reverse Operation Mode Expansion Expansion Expansion Expansion Expansion Expansion Expansion Expansion Expansion Expansion Expansion Heat/Cool/Alarm 1/Alarm 2/Alarm 3/ LBA Heat/Cool/Alarm 1/A
Option Type Board Number RE232C E53-CK01 RS-485 E53-CK03 Mode Parameter Option Option Option Option Option Option Option Option Option Option Eu-A Multi-SP Function Eu-1 Event Input Assign 1 SbCE Communication Stop Bit Len Comm. Data Length PrEY Commication Parity 6PS Comm. Baud Rate U-n6 Comm. Unit No. Er-E Transfer Output Type Er-H Xfer Output Upper Limit Er-L Xfer Output Lower Limit Event Input E53-CKB Setting range 0/1 STOP/MAN ½ BITS 7/8 BITS None/Even/Odd 1.2/2.4/4.8/9.6/19.
Level 2 Cn5L input shift lower limit Mode Setup Setup Setup Setup Setup Setup Setup SetUp Setup Setup Setup Setup Setup Expansion Expansion Expansion Expansion Expansion 6-8 Parameter Cn-t Input Type -999.9 to 999.9°C Setting range 0 to 21 Scaling Lower Limit +1 to Cn-H Scaling Upper Limit 9999 EU -1999 to SP Setting Upper Cn-L Scaling Lower Limit Limit –0.
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Chapter 7: Troubleshooting Problem Little or no air coming from the process delivery tube. Possible cause Dirty filter. Desiccant beds are contaminated by material or plasticizer leaking into the system. Blower overload has tripped. Blower fins filled with dust or contaminants. Suction in delivery tube, pressure from the return tube. Phase is reversed on power drop coming into the dryer. Process heaters are faulty. Loss or reduction of process air temperature.
Problem Loss or reduction in drying capacity. (Cont’d.) PLC Regeneration Bed LED indicators both off. Possible cause Airflow valve sticking or failing to shift. Blower fins filled with dust or contaminants. Insufficient power to PLC (Power LED is off). Faulty PLC (PLC Power light is on, Run light is off, and/or Error light is on). Regenerating bed cool down. Blower Input indicator is off. PLC Regeneration Heater Left/Right output indicators both off. Process air in hightemperature condition.
Problem Nothing displays when the controller is turned on. Possible cause The internal mechanism is not inserted properly into the housing. The power supply is not connected to its terminals properly. No power is supplied, or the supplied power is not within the specified range. Disconnect switch or Control Power switch not set to ON. Control Power fuse blown. Input polarity on thermocouple is wrong or connection is wrong. No compensating lead wires used for extension of the thermocouple.
