5, 30, & 60 cfm Compact Dehumidifying Dryers Part Number: A0570882 Bulletin Number: SM1-690.1 Effective: 8/05/04 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.
Credit Returns Prior to the return of any material authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned. Reason for requesting the return must be given. ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00 minimum) restocking charge. ALL returns are to be shipped prepaid. The invoice number and date or purchase order number and date must be supplied.
Table of Contents CHAPTER 1: SAFETY.................................................................... 6 1-1 1-2 1-3 1-4 How to Use This Manual ............................................................................................ 6 Safety Symbols Used in this Manual.....................................................................6 Dryer Safety Tags ................................................................................................7 Warnings and Precautions ........................
4-3 4-4 4-5 Identifying Control Panel Indicator Lights and Switches for the Standard Controller ...........................................................................................................23 Process Air Temperature Controller....................................................................24 Setting the Process Air Temperature ..................................................................25 Restoring the Process Air Temperature Controller (E5CN) to Factory Settings....
Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your dehumidifying dryer. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer. The Functional Description section outlines models covered, standard features, and safety features.
Dryer Safety Tags Hot! Read Operation and Installation Manual High Voltage Earth Ground Inside Enclosure PE Lifting Point 1-2 Protected Earth Ground Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations.
˛ When welding or brazing in or around this equipment, make sure VENTILATION is ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with sheet metal. An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed. ˛ Do not restore power until you remove all tools, test equipment, etc., and the equipment and related components are fully reassembled. ˛ Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment.
Operator Responsibility The operator’s responsibility does not end with efficient production. The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations. Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or through a casual attitude toward machinery formed over a period of months or years. Your employer probably has established a set of safety rules in your workplace.
• Clean the dryer and surrounding area DAILY, and inspect the machine for loose, missing or broken parts. • Shut off power to the dryer when it is not in use. Turn the switch to the OFF position, or unplug it from the power source. Maintenance Responsibility Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety a priority to effectively repair and maintain equipment.
1-4 Technical Specifications Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equipment that could alter the CE compliance 2. Ambient temperature: 0 degrees Celsius – Maximum (104 degrees Fahrenheit) 3. Humidity range: 50% relative humidity 4. Altitude: Sea level 5. Environment: Clean, dust-free and non-explosive 6. Radiation: None 7. Vibration: Minimal, i.e. machine mounting 8.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 15, 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.
What is desiccant? Desiccant is a material that attracts and holds (absorbs) water from the air. The desiccant our dryers use is a synthetic crystalline metal aluminosilicate blended with a clay binder and formed into beads. Absorbed water is driven from saturated desiccant by heating it to a high temperature (reducing desiccant capacity to hold water) and forcing air through it. This moisture removal process is called regeneration. The Process/Regeneration Cycle Our dryers have two desiccant beds.
• Display of process temperature set point and actual settings 2-4 Options Options marked with “*” indicate options that can be factory installed or retrofitted in the field. • Process temperature up to 400ºF (or below 180ºF), including aftercooler on back of dryer and silicone insulated delivery hose. Note: For below 160°F, cooler needs to be outside, between dryer and drying hopper. • Machine mount adapter to accommodate a dryer and corresponding hopper. • Drawer magnet, stainless steel construction.
must be held closed with the device it is to protect. If the switch fails, it will go to the open condition, tripping out the safety circuit. At no time should the safety device fail and allow the operation to continue. For example, if a safety switch is guarding a motor, and the safety switch fails, the motor should not be able to run. Safety Device Lock-Outs Some safety devices disconnect electrical energy from a circuit.
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 Mounted Dryers 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 Existing hopper lifting bracket Drop forged steel eye nut Chain connector Vendor McMaster-Carr — McMaster-Carr McMaster-Carr Vendor p
Figure 4: Suggested Lift Rigging for Machine Mounted Dryers DEW POINT CONT ROL POWE R ON OFF PROCESS TEMPERATUR E ON POWER ON ALAR M OFF Caution! 3-3 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 electrical con
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.
Starting Up the Dryer 1. Turn on (energize) the disconnect switch in your power drop, then turn on the disconnect switch on the dryer (3 phase only). 2. Turn the system ON/OFF switch to ON to start the dryer. 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. Dryer performance is compromised if hopper is not full! 5.
Chapter 4: Operation 4-1 Start-up 1. Turn on (energize) the disconnect switch in your power drop, then turn on the disconnect switch on the dryer. 2. Turn the system ON/OFF switch to ON to energize the display panel. The process blower starts. 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.
4-2 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 can be energized without the dryer running.) 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. 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. 2. Press the Up Key and the Down Key to set the higher or lower the values of the 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 Level Display key for one (1) second. 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. Figure 8: Typical Dew Point Display Monitor – Part No.
4-3 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. The valve motor rotates until the cam switch makes 2 transitions. b.
4. If either the left or right bed safety temperature switch opens, a regen heater fault is generated. “HIGH TEMP” is displayed on the relay screen. The alarm light is activated. The process heater, regen heater, and process/regen blower are turned off. 5. 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.
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.
Vacuuming Try vacuum-cleaning a soiled filter first. Vacuuming removes most large particles and surface contaminants, and may suffice for the first time you clean a filter. Use a commercialduty (recommended) or household vacuum cleaner. Vacuum the filter from the air intake (dirty) side only. Cleaning with Compressed Air Blow clean, dry compressed air up and down the pleats, blowing out the filter from the inside out. Remove loose dirt from the filter with compressed air or vaccum from the outside.
5-3 Corrective Maintenance This section provides you with the information necessary to correct or repair any issues which might appear during the normal operation of your dehumidifying dryer. Although we have listed how to perform these procedures, it is recommended that you call the Service Department to have any in-depth maintenance performed. Symptoms of Worn Desiccant The moisture absorption capacity of the desiccant used in your dehumidifying dryer degrades after an indefinite period of time.
Replacing Worn Desiccant Caution! DESICCANT BEDS ARE HOT DURING OPERATION. To avoid burn hazard, make sure desiccant beds are sufficiently cool before replacing worn desiccant. To access the Desiccant Bed: 1. Disconnect electrical power to the dryer. 2. Using a 1/8” Allen wrench, remove the 10-24 button head screws holding the top, back and side panels to the frame and back of the dryer. 3. Disconnect the three (3) plugs for the valve motor, switch, and blower (15 cfm only) 4.
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.
Procedures 1. Disconnect electrical power to the dryer. 2. Using a 1/8” Allen wrench, remove the 10-24 button head screws holding the top, back and side panels to the dryer frame. 3. Disconnect the plug for the valve motor, valve switch, and blower (15 only). 4. Remove the four (4) nuts at each corner of the top casting. 5. Pickup and place the top casting in a safe place. 6. Pickup the desiccant can to reveal the heater. 7. Using a 1/8” Allen wrench, remove the four (4) 10-32 screws on the heater plate. 8.
Chapter 6: Troubleshooting 6-1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal trouble-shooting must be accomplished with the power off, line fuses removed, and with the machine tagged as out of service. The use of good quality test equipment cannot be over-emphasized when troubleshooting is indicated.
Problem Possible cause Process heaters are faulty. Loss or reduction of process air temperature. Solid-state temperature controller faulty. 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. Airflow valve sticking or failing to shift.
Problem Poor dew point performance. Nothing displays when the controller is turned on. Possible cause Burned out regeneration heater. Contaminated or worn out desiccant. Leaking process air hoses. Dryer operates beyond its capacity. Bad dew point sensor. Fouled dew point sensor manifold. Dirty filter. The internal mechanism is not inserted properly into the housing. The power supply is not connected. No power is supplied, or the supplied power is not within the specified range.
6-2 Determining Temperature Controller Errors or Sensor Errors Using a Thermocouple If the controller displays a temperature that is close to room temperature (70ºF/21ºC) when you short-circuit controller input terminals, the controller is normal and the sensor is probably broken, short-circuited, or incorrectly wired. Using a Platinum Resistance Thermometer If the controller displays a temperature of about 0.
Chapter 7: Appendix 7-1 Warranty The manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. The company’s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser, and which, in the company’s opinion, are defective. Any replacement part assumes the unused portion of this warranty.
7-2 Drawings and Diagrams Figure 14: Machine-Mount Dryer Dimensions Mounting flange PROCESSTEMPERATUREDEW POINTCONTROLPOWERONOFFALARMPOWER ONONOFF CBAD E G E G 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). Model Hopper Size 15 cfm 0.85 ft_/24 liters 30 cfm 1.7 ft_/48 liters 1.
Figure 15: Cart-Mount Dryer Dimensions A B C D E F ASD15 ASD30 PROCESS TEMPERATURE DEW POINT CONTROL POWER ON OFF ON OFF ALARM C D E F POWER ON B A A 15 cfm 30 cfm 60 cfm B C In. Cm. In. Cm. 27 _ 69.9 23 58.4 36 91.4 36 5/16 92.2 D E F In. Cm. In. Cm. In. Cm. 3 7/8 9.8 11 _ 29.2 22 58.9 In. Cm. 27 13/16 70.6 33 83.8 Aftercooler Design Specifications Entering water temp.
Figure 16: Electrical Drawing 15, 30, & 60 cfm Compact Dryers Chapter 7: Appendix 49 of 51
7-3 Spare Parts List LEVEL 2 ( Mechanical Components ) PART # SIZE Description A0568483 500 Watts Heater element 115 Volts A0568484 500 Watts Heater element 208/220 Volts A0568485 500 Watts Heater element 230 Volts A0568486 500 Watts Heater element 400 Volts A0568487 500 Watts Heater element 460 Volts A0568488 500 Watts Heater element 575 Volts A0570287 1000 Watts Heater element 115 Volts A0570288 1000 Watts Heater Element 208/220 Volts A0570289 1000 Watts Heater Element 230 Volts A0570290 1000 Watts Heat
7-4 Dryer Identification (Serial Number) Tag (Located on back of Dryer) Company Logo XXX Series Dryer Model Number XXX-15 Max Drying Capacity HR 460V Serial Number 060701R 1_ Date of Manufacture 06/2003 4.5A Over-current Protection Device (s) 4.
