Operating Instructions 64.
CTT 40 / CTT 70 Colortronic GmbH Otto-Hahn-Straße 10-14 61381 Friedrichsdorf USA Colortronic North America Inc. 155 E. 9th Avenue Runnemede, NJ 08078 Telephone (0 61 75) 7 92-0 Telefax (0 61 75) 7 92-1 79 Email info@colortronic.de Http://www.colortronic.com Telephone (856) 312-9600 Telefax (856) 312-9696 Email ctusa@colortronic.com Technical service: Service department Telephone: (0 61 75) 7 92-2 22 Telefax: (0 61 75) 7 92-1 19 Email service.d@colortronic.
CTT 40 / CTT 70 64.10-0214GB11 07/03 Colortronic GmbH retains all rights to change the information in these operating instructions at any time without notice. We assume no liability for any errors or direct or indirect damage resulting in context with these operating instructions. Copying, translation or publication in any form except for personal use of purchaser requires approval from Colortronic GmbH. All rights reserved.
CTT 40 / CTT 70 Table of contents 1. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1. 1.2. 1.3. 1.4. 1.5. Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Explanations and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Legal basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTT 40 / CTT 70 7. Transport, Assembly and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1. Tansport and Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.3. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTT 40 / CTT 70 1. General Information These operating instructions must be used by every person charged with work on the unit. 64.10-0214GB11 07/03 » These operating instructions are addressed to all users of the device.
CTT 40 / CTT 70 1.1. Warnings and symbols The following warnings and symbols are used in these operating instructions: » This symbol indicates danger to life! Fatal or serious injury is possible if the corresponding instructions, regulations or warnings are not observed. This symbol indicates that serious injury is possible if the corresponding instructions, regulations or warnings are not observed.
CTT 40 / CTT 70 When disposing of drying agents / batteries / oil, observe all official rules. Caution: High noise pollution ! For all work on the equipment, hearing protection should be worn. Avoids impairment of hearing! Caution: Danger of crushing ! Disconnect the equipment from mains supply before starting mainenance procedures. All compressed air pipes on the equipment should be depressurised before starting maintenance work.
CTT 40 / CTT 70 1.2. Explanations and information Various terms and designations are used in these operating instructions to ensure clarity. Therefore please note that the terms used in the text stand for the corresponding explanations listed below. • Equipment ”Equipment” can mean an individual unit, a machine or an installation. • Operating personnel The ”operating personnel” are persons operating the equipment on their own responsibility or according to instructions.
CTT 40 / CTT 70 2. Safety instructions » These safety instructions apply to all persons within the range of action of the equipment. Please inform all persons within the range of action of the equipment of the direct and indirect hazards connected with the equipment. These operating instructions are to be used by all persons assigned activities connected with the equipment. Knowledge of the English language is prerequisite. 64.
CTT 40 / CTT 70 2.1. For your safety General The operating personnel of this equipment must be at least 16 years old. Please read these operating instructions carefully before taking into operation for the first time. Contact us should questions arise. This avoids injury and damage to equipment! These operating instructions must be kept available at all times at the place of operation of the equipment.
CTT 40 / CTT 70 Assembly Compare the connected loads with those of the mains supply. Danger of injury through electrical shock! When using lifting gear, please observe the pertaining regulations. Caution: Danger of accidents! Do not modify, add other equipment or change the design of the equipment without the approval of the manufacturer. Caution: Danger of accidents! Attachments not supplied by Colortronic must be manufactured in accordance with safety regulation EN 294.
CTT 40 / CTT 70 When drying plastics which emit gases dangerous for human health, take care that the regeneration exhaust air is disposed of without polluting the environment. This will prevent danger to people and material! Maintenance Before starting maintenance work, appoint a supervisor. Inform the responsible personnel before maintenance work on the system is started.
CTT 40 / CTT 70 2.2. For the safety of the devices Never change settings without carefully assessing the consequences. Use only original Colortronic spare parts. Observe the maintenance instructions. Keep a record of all maintenance works and repairs. Please note that electronic components can be damaged by static discharge. Before initial operation and in regular intervals, make sure that no electrical connections are loose. Never readjust sensors without exactly knowing their functions.
CTT 40 / CTT 70 3. Start up » This chapter is addressed to the operators of the machine. This chapter assumes general skills with drying equipment. This chapter assumes that the functional description has been read and understood. It must be ensured that the operators have the required experience. F Make sure that the main switch is at “0" position. Check the drying hopper for cleanliness. Check to see whether the adhesive film on the drying hopper has be removed.
CTT 40 / CTT 70 3.1. Initial Operation Check whether the inlet of the drying hopper is closed by a blind lid, or whether a conveyor unit (optional) is installed. If not, manufacture a suitable blind lid and install it on the inlet of the drying hopper or install the conveyor unit (optional). F Attachments which are not supplied by Colortronic must be manufactured according to the safety regulation European Standard 294.
CTT 40 / CTT 70 Turn the release switches “Hopper” (TT1, TT2) at “I” position. Turn the thermo regulator to +80 °C (176 °F) for the drying temperature. Press the “PGM” key. Set by means of the arrow keys the drying temperature to “80" (176). After 2 seconds the display flashes and the value is stored. Press the “EXIT” key (the setpoint value and the actual value of the drying temperature are displayed). EXIT After 2 hours turn the release switches “Hopper” (TT1, TT2) at “0” position.
CTT 40 / CTT 70 3.2. Continuous Operation F Fill at least half of the drying hopper with material. 3.2.1. Switching the Dryer on Switch on the main switch of the dryer. & The signal lamp “power” goes on. For operation with timer clock (optional): Turn the release switch “Timer” at position: For operation without timer clock: Turn the release switch “Timer” at position: The blower is running. 64.
CTT 40 / CTT 70 3.2.2. Setting the Drying Temperature Turn the release switches “Hopper” (TT1, TT2) at “I” position. For each drying hopper, set the required drying temperature (= desired value) by means of the respective thermo regulator. Check whether the set drying temperature is appropriate for the materials which have been filled in. Observe the instructions of the material manufacturer. After the first filling, process the material only after the retention period is over.
CTT 40 / CTT 70 Optimizing the thermo regulator Press the “EXIT” key for at least 2 seconds. “tunE” flashes. The optimization can take several minutes. EXIT 60 tunE PGM If “tunE” stops flashing, the optimization is finished. EXIT 60 tunE PGM K1 K2 K3 K1 K2 K3 EXIT Press the “EXIT” key. 64.
CTT 40 / CTT 70 3.3. Switching the Dryer off Set the release switch “Timer” at position: L Wait until the blower has stopped. The run on time of the blower is 10 minutes. If there is a return air cooler installed, switch off its coolant circuit. Switch off the main switch of the dryer. The signal lamp “power” goes off. 64.
CTT 40 / CTT 70 4. Error and error correction » This chapter is directed at the operators of the equipment. This chapter assumes general skills in dealing with drying systems. This chapter assumes that the “start-up” description has been read and understood. It should be ensured in each and every case that the operators have the relevant skills. F & Faults must be eliminated before the control system can again start operating. An alarm is indicated by steady light of the signal lamp “trouble”. 64.
CTT 40 / CTT 70 The following errors can lead to an alarm: Blower The pressure of the blower is too low. Check the blower. Vacuum sensor defective. Regeneration heater 1 The safety temperature limiter of the regeneration heater 1 has been activated. Check the safety temperature limiter. Colortronic Service. Regeneration heater 2 The safety temperature limiter of the regeneration heater 2 has been activated. Check the safety temperature limiter. Colortronic Service. 64.
CTT 40 / CTT 70 5. Maintenance » This chapter is intended for persons with skills in electrical and mechanical areas due to their training, experience and received instructions. Personnel using the instructions in this chapter must be instructed of the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation. Ensure in each case that the personnel are informed. For maintenance work taking place at theights of over approx.
CTT 40 / CTT 70 F Please observe the maintenance schedule. Before starting maintenance work, clean the equipment of oil, fuel or lubricant. Ensure that materials and incidentals required for operation as well as spare parts are disposed of properly and in an environmentally sound manner. Use only original Colortronic spare parts. 64.10-0214GB11 07/03 Keep record of all maintenance and repair procedures.
CTT 40 / CTT 70 5.1.
CTT 40 / CTT 70 5.2. Cleaning or Replacing the Air Filter Set the release switch “Timer” at position: L Wait until the blower has stopped. The run on time of the blower is 10 minutes. If there is a return air cooler installed, switch off its coolant circuit. L Switch off the main switch of the dryer (the signal lamp “power” goes off). Interrupt the mains supply so that the device cannot be switched on unintentionally.
CTT 40 / CTT 70 5.2.1. Cleaning or Replacing the Return Air Filter CTT 40 / CTT 70 Detach the screw on the housing of the return air filter and remove the housing cover. Return Air Filter Remove the nut of the filter cartridge. Remove the filter cartridge. Clean the inside of the return air filter housing. Use non-fibrous cleaning cloths or an industrial type vacuum cleaner. Blow compressed air from the inside out through the clogged filter cartridge or replace the filter cartridge.
CTT 40 / CTT 70 5.3. Disposing of Drying Agents Please note that drying cells are replaced or refilled by Colortronic only if they are empty. When disposing of drying agents, observe all official rules. Since used drying agents may contain impurities from the dried materials, treat them as special waste. It is not possible for Colortronic to take back the used drying agent or drying cells with used drying agents. 64.
CTT 40 / CTT 70 5.4. Cleaning the Drying Hopper Set the release switch “Timer” at position: L Wait until the blower has stopped. The run on time of the blower is 10 minutes. If there is a return air cooler installed, switch off its coolant circuit. L Switch off the main switch of the dryer (the signal lamp “power” goes off). Interrupt the mains supply so that the device cannot be switched on unintentionally. F Clean the drying hopper each time you are changing the materials.
CTT 40 / CTT 70 TT 25 Open the toggle-type fasteners (A) at the hopper lid and fold the hopper lid upwards (if in use: remove before the single conveyor). A Clean the drying hopper. Close the hopper lid and close the toggle-type fasteners (A) (if in use: re-mount the single conveyor). TT 25 F Remove any granules remaining in the cleaning opening. TT 60 - 100 Open the cleaning opening of the drying hopper: Lift and turn the handle (A) to open the lock (if in use: remove before the single conveyor).
CTT 40 / CTT 70 6. Functional description » This functional description is addressed to the operators of the equipment. This functional description assumes general familiarity with drying equipment. 64.10-0214GB10 04/02 It should be verified that the operators do indeed have the appropriate skills.
CTT 40 / CTT 70 6.1. General Information The dehumidified air dryers were developed for drying plastic granules. Due to their compact construction, they can be employed next to the processing machine (drying hopper on the processing machine) or with one or more drying hoppers as a movable facility (compact facility). The dryers work according to the dehumidified air principle, i.e., the air is not only heated but also dehumidified before it flows through the drying hopper.
CTT 40 / CTT 70 All function sequences are fully automatic. The dryer is equipped with two drying cells. One drying cell is part of the drying cycle; the other drying cell is regenerated simultaneously. 64.10-0214GB10 04/02 Part of the dehumidified air is used for regenerating the moist drying cell. At the beginning of regeneration, it is heated by the regeneration heater. After the end of the heating period, the drying cell is cooled off by means of dehumidified air.
CTT 40 / CTT 70 A digital display of the current dew point temperature can be supplied as additional equipment. As an option, a timer clock can be supplied which switches the dryer on or off at preselected times. F Read the operating manual of the timer clock. 1 2 8 64.
CTT 40 / CTT 70 6.2. Drying Hopper (Optional) The material is dried in the drying hopper. The dehumidified air is conducted through the material in the drying hopper and takes up moisture. Drying hoppers must have the appropriate dimensions for their specific use so that the desired final moisture content is reached. When refilling a drying hopper, the material must first be dried completely before material can be taken out for the first time.
CTT 40 / CTT 70 6.2.1. Hopper Heater Each drying hopper has its own hopper heater. The temperature of the dehumidified air is adjusted by means of the thermo regulator. The setting range is from +60 - +180 °C (+140 - +356 °F). The current temperature can be read off the digital display (= actual value). F The thermo regulator is factory-programmed. Nevertheless, you have to set specific values which are dependent on the processed material.
CTT 40 / CTT 70 6.3. Connection to a Pneumatic Conveying System (Optional) Your drying facility works best in combination with a pneumatic conveying system. In this way, your drying hopper will always be supplied with sufficient material. The facility will only take as much material as is required by the processing machines. Therefore, the drying result will always be the same. Colortronic drying hoppers are equipped with a suitable flange for adding a Colortronic pneumatic conveyor.
CTT 40 / CTT 70 7. Transport, Assembly and Storage » This chapter is intended for all operating personnel of the equipment. Personnel using these instructions must be instructed in the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation. Ensure in each case that the operating personnel are sufficiently informed.
CTT 40 / CTT 70 7.1. Tansport and Packing » F Please ensure adequate carrying capacity of the lifting equipment. Note that the dryer system is top-heavy. Risc of toppling! The machine must not be tilted or laid on its side. The equipment pass a rigorous operating test in the factory and are packed carefully to avoid transport damage. Please check packing on delivery for transport damage. The inlet and discharge flanges are sealed with plugs, so that no dirt can enter during transport.
CTT 40 / CTT 70 7.2. Assembly » Please ensure adequate carrying capacity of the lifting equipment. Check the carrying capacity of the point of installation, particularly if installed on a platform. The place selected for installation should be as free of vibrations as possible. The main switch must be freely accessible. Ground the equipment against electrostatic charging. F The machine must not be tilted or laid on its side.
CTT 40 / CTT 70 8. Assembly instructions » These installation instructions are intended for persons with skills in electrical and mechanical areas due to their training, experience and received instructions. Personnel using these installation instructions must be instructed in the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation. Ensure in each case that the personnel are informed.
CTT 40 / CTT 70 8.1. Installation of the exhauster fan for regeneration of exhaust air When plastics are being dried that release harmful gases during the drying process, care must be taken that the regeneration exhaust air is disposed of in an environmentally sound way. At the same time the throughput of the regeneration blower must not be altered. It should be noted when assembling a disposal system (e.g. an exhauster system) that the regeneration exhaust air is very humid.
CTT 40 / CTT 70 8.3. Electrical Connection » Observe the rules of the local electricity board. Check that the supply voltage and the power frequency are in accordance with the data on the name plate of the device. The electrical connection may only be carried through or assigned by Colortronic service staff or by qualified staff authorized by Colortronic. Other persons are not permitted to carry through the electrical connection. The main switch must be freely accessible.
CTT 40 / CTT 70 8.4. Connection of Return Air Cooler (Optional) F A return air cooler must be employed if the return air temperature is higher than +65 °C (149 °F). You can connect the return air cooler to a coolant circuit or to the water mains network. The water flow rate in the water mains network* is for: CTT 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 0.2 m3/h (7.16cf/h), CTT 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTT 40 / CTT 70 9.
CTT 40 / CTT 70 Performance • Air drying capacity CTT 40: 40 m3/hr (1,412.69 cf/h) CTT 70: 70 m3/hr (2,472.03 cf/h) • Operating voltage CTT 40: 230 V +/-10%, AC, 50 Hz (Europe); 230 V/AC/60 Hz (U.S.). CTT 70: 400 V +/-10%, 3AC, 50 Hz (Europe), 460 V/3 AC/60 Hz (U.S.) • Connected load CTT 40: 1.3 kW +max. 1.5 kW hopper heaters CTT 70: 2.0 kW +max. 3.0 kW hopper heaters • Average dewpoint temperature of -50° C (- 76 °F) • Weight CTT 40: approx. 68 kg (149.9 lbs.) CTT 70: approx. 103 kg (227.17 lbs.
CTT 40 / CTT 70 10. Spare parts list Other persons are not permitted to modify or repair the equipment. 64.10-0214GB11 07/03 » This spare parts list is intended to be used only by trained personnel.
CTT 40 / CTT 70 CTT 40 2 1 9 8 3 7 6 4 64.
CTT 40 / CTT 70 Pos. ID-number Description 31940 31938 36212 84130 valve stem shaft housing disc with bush disc flywheel DU 1 2 83957 filter cartridge, when operating without return air cooler 83956 filter cartridge, when operating with return air cooler 3 84129 blower CTT 40 4 85819 guide roll with fixing device 5 85820 guide roll 6 94233 sealing 93298 hose clamp 85690 sealing 85691 tension ring 8 96196 desiccant (6 kg / 13.23 lbs.
CTT 40 / CTT 70 CTT 70 2 1 9 8 7 3 6 5 64.
CTT 40 / CTT 70 Pos. ID-number Description 31940 31938 36212 84130 valve stem shaft housing disc with bush disc flywheel DU 1 2 83957 filter cartridge, when operating without return air cooler 83956 filter cartridge, when operating with return air cooler 3 85677 blower CTT 70 4 85819 guide roll with fixing device 5 85820 guide roll 6 94233 sealing ring 97677 tension ring 23917 sealing ring 97677 tension ring 23533 sieve 8 96196 desiccant (13 kg / 28.76 lbs.
CTT 40 / CTT 70 Operating unit 5 4 6 7 3 ID-number Description 1 82368 main switch 2 82394 82393 82495 LED element, green cap fixing adapter 3 82494 82392 82495 LED element, white cap fixing adapter 4 26207 dew point display (optional) 5 82395 82490 selector switch actuator contact element 6 87454 thermo regulator TT1, TT2 7 85241 83646 timer clock (optional) sealing 1 64.10-0214GB11 07/03 Pos.
CTT 40 / CTT 70 Control unit CTT 40 85280 motor 84131 radiator 0.7 kW 83339 pull-button 87440 contact element 83411 controller 82516 temperature limiter 88440 contactor 85941 terminal 85940 fuse 99102 fuse 88806 relay holder 88816 relay 84510 thermal breaker Hopper heater radiator 1,5 kW safety temperature limiter 64.
CTT 40 / CTT 70 Control unit CTT 70 85279 motor 85676 radiator 1.2 kW 95816 pull-button 87440 contact element 83329 controller 85275 temperature limiter 88914 contactor 85254 power supply 88907 terminal 99815 fuse 88806 relay holder 88849 relay 83624 terminal 84512 thermal breaker 84159 control switch Hopper heater radiator 1,5 kW thermal breaker safety temperature limiter (= STB) 85338 84510 85652 radiator 3 kW thermal breaker STB 64.
CTT 40 / CTT 70 11. Electrical manual » This electrical manual is intended to be used only by Colortronic service personnel and trained personnel authorized by Colortronic. Other persons are not permitted to modify or repair the equipment. o Connection diagram no.: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 64.
CTT 40 / CTT 70 12. Accessories o Basic setting thermo regulator o Digital timer o Spare parts list Drying Hoppers TT 25 - TT 6400 o ___________________________ 64.
CTT 40 / CTT 70 Basic setting thermo regulator CTT 40 » This information is intended to be used only by Colortronic service personnel and trained personnel authorized by Colortronic. Other persons are not permitted to modify or repair the equipment.
CTT 40 / CTT 70 Basic setting thermo regulator CTT 70 » This information is intended to be used only by Colortronic service personnel and trained personnel authorized by Colortronic. Other persons are not permitted to modify or repair the equipment.
Accessories GB02 07/03 Spare parts list Drying Hoppers TT 25 - TT 6400 Colortronic GmbH
TT 25 - TT 6400 Colortronic GmbH Otto-Hahn-Straße 10-14 61381 Friedrichsdorf USA Colortronic North America Inc. 155 E. 9th Avenue Runnemede, NJ 08078 Telephone (0 61 75) 7 92-0 Telefax (0 61 75) 7 92-1 79 Email info@colortronic.de Http://www.colortronic.com Telephone (856) 312-9600 Telefax (856) 312-9696 Email ctusa@colortronic.com Technical service: Service department Telephone: (0 61 75) 7 92-2 22 Telefax: (0 61 75) 7 92-1 19 Email service.d@colortronic.
TT 25 - TT 6400 Colortronic GmbH retains all rights to change the information in these operating instructions at any time without notice. GB02 07/03 We assume no liability for any errors or direct or indirect damage resulting in context with these operating instructions. Copying, translation or publication in any form except for personal use of purchaser requires approval from Colortronic GmbH. All rights reserved.
TT 25 - TT 6400 1 2 3 4 5 6, 7 16 PT 100 8 17 PT 100 13 14 9 10 11 18 GB02 07/03 12 4
TT 25 - TT 6400 Pos. ID-number Description 85343 85338 85363 85651 95828 87094 Radiator hopper heater 1.5 kW 3.0 kW 6.0 kW 9.0 kW 18.0 kW, 27.0 kW, 36.0 kW, 63.0 kW 27.0 kW, 48.0 kW, 63.
TT 25 - TT 6400 Pos.
