Sterling Dehumidifier 8820029500 User Manual

SDA 1000-5100 Series  
Large Dehumidifying Dryer  
AP-1 Control  
Part Number: 882.00295.00  
Bulletin Number: DH1-615  
Effective: 12/01/05  
Write Down Your Serial Numbers Here For Future Reference:  
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_________________________  
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We are committed to a continuing program of product improvement.  
Specifications, appearance, and dimensions described in this manual are subject to change without notice.  
DCN No. ____________  
© Copyright 2005  
All rights reserved.  
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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.  
The invoice number and date or purchase order number and date must be supplied.  
No credit will be issued for material that is not within the manufacturer’s warranty period  
and/or in new and unused condition, suitable for resale.  
Warranty 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 returns are to be shipped prepaid.  
The invoice number and date or purchase order number and date must be supplied.  
After inspecting the material, a replacement or credit will be given, at the manufacturer’s  
discretion. If the item is found to be defective in materials or workmanship, and it was  
manufactured by our company, purchased components are covered under their specific  
warranty terms.  
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Table of Contents  
CHAPTER 1: SAFETY................................................................7  
1-1  
How to Use This Manual .............................................................................................7  
Safety Symbols Used in this Manual.....................................................................7  
Warnings and Precautions ..........................................................................................8  
Responsibility ..............................................................................................................9  
General Responsibility...........................................................................................9  
Operator Responsibility.........................................................................................9  
Maintenance Responsibility.................................................................................10  
Reporting a Safety Defect ...................................................................................11  
1-2  
1-3  
CHAPTER 2: FUNCTIONAL DESCRIPTION...........................12  
2-1  
2-2  
Models Covered in This Manual................................................................................12  
General Description...................................................................................................12  
Specifying a Drying System ................................................................................12  
What is Desiccant?..............................................................................................12  
The Closed Loop Drying System.........................................................................12  
The Process/Regeneration Cycle........................................................................13  
Sequence of Operation .......................................................................................13  
Standard Features.....................................................................................................14  
Auto Start Timer ..................................................................................................14  
Mechanical Features...........................................................................................14  
Electrical Features...............................................................................................14  
Options......................................................................................................................15  
Dewpoint Extend .................................................................................................15  
Closed-Loop Regeneration .................................................................................15  
Drawings and Diagrams............................................................................................16  
Process Aftercooler.............................................................................................18  
Aftercooler Design Specifications........................................................................18  
Process Air Dust Collector...................................................................................18  
Material Overdrying Protection............................................................................20  
Mechanical Options.............................................................................................21  
Electrical Options ................................................................................................21  
Controller Options ...............................................................................................21  
Safety Devices and Interlocks...................................................................................22  
2-3  
2-4  
2-5  
2-6  
Dimensions and Specifications  
......................................................................24  
Mechanical Options ......................................................................................24  
Electrical Features...............................................................................................25  
Electrical Options ................................................................................................25  
CHAPTER 3: MECHANICAL INSTALLATION ........................26  
3-1  
3-2  
3-3  
3-4  
3-5  
3-6  
Uncrating the Equipment...........................................................................................26  
Rigging and Placing Unit...........................................................................................26  
Making Electrical Connections ..................................................................................26  
Making Gas Line Connections (Gas-Fired Models Only)..........................................27  
Checking for Proper Blower Rotation........................................................................28  
Making Dryer/Drying Hopper Process Air Connections ............................................29  
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3-7  
3-8  
Connecting Aftercooler/Precooler Cooling Water (Optional).....................................32  
Using the Drying Hopper Air Trap .............................................................................33  
CHAPTER 4: CONTROLS........................................................34  
4-1  
4-2  
Controller Description................................................................................................34  
Identifying Control Panel Components for the AP-1 Optional Controller...................35  
Disconnect Switch...............................................................................................35  
Control Power Switch..........................................................................................35  
Touch Screen......................................................................................................35  
Alarm Horn & Light..............................................................................................35  
Process Air Temperature and Conveying Process Controller...................................35  
Identifying Controller Screens ...................................................................................36  
Redundant Safety Controller Display ........................................................................49  
Setting the Redundant Safety Controller...................................................................50  
4-3  
4-4  
4-5  
4-6  
CHAPTER 5: OPERATION.......................................................52  
5-1  
5-2  
5-3  
5-4  
5-5  
Start-up......................................................................................................................52  
Using the Dryer Status Screen..................................................................................53  
Alarms .......................................................................................................................54  
Alarm Descriptions ....................................................................................................54  
Shutdown ..................................................................................................................55  
CHAPTER 6: MAINTENANCE .................................................56  
6-1  
6-2  
Maintenance Schedule..............................................................................................56  
Preventative Maintenance.........................................................................................57  
Cleaning or Replacing the Process Air Filters.....................................................57  
Cleaning or Replacing the Regeneration Filter....................................................58  
Calibrating the Dirty Filter Alarm..........................................................................58  
Checking the Dewpoint Control System..............................................................59  
Corrective Maintenance ............................................................................................60  
Symptoms of Worn Out Desiccant ......................................................................60  
Replacing the Desiccant......................................................................................60  
Replacing the Process Heater (Electric Dryers)..................................................61  
Replacing the Regeneration Heater (Electric Dryers) .........................................62  
6-3  
CHAPTER 7: TROUBLESHOOTING .......................................64  
7-1  
7-2  
7-3  
Introduction................................................................................................................64  
Basic Troubleshooting...............................................................................................64  
Determining Temperature Controller Errors or Sensor Errors...................................66  
Using a Thermocouple ........................................................................................66  
Using a Platinum Resistance Thermometer........................................................66  
CHAPTER 8: APPENDIX..........................................................67  
8-1  
8-2  
Warranty....................................................................................................................67  
Technical Specifications............................................................................................68  
Annex B Information............................................................................................68  
Spare Parts List.........................................................................................................69  
Dryer Identification (Serial Number) Tag...................................................................70  
Technical Assistance.................................................................................................72  
8-3  
8-4  
8-5  
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Parts Department ................................................................................................72  
Service Department.............................................................................................72  
Sales Department................................................................................................72  
Contract Department...........................................................................................72  
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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. Additional sections within the manual provide instructions for installation, pre-  
operational procedures, operation, preventive maintenance, and corrective maintenance.  
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup  
of the large dehumidifying dryer. We can also provide the assistance of a factory-trained  
technician to help train your operator(s) for a nominal charge. This section includes  
instructions, checks, and adjustments that should be followed before commencing with  
operation of the dryer. These instructions are intended to supplement standard shop  
procedures performed at shift, daily, and weekly intervals.  
The Operation chapter includes a description of electrical and mechanical controls, in  
addition to information for operating the dryer safely and efficiently.  
The Maintenance chapter is intended to serve as a source of detailed assembly and  
disassembly instructions for those areas of the equipment requiring service. Preventive  
maintenance sections are included to ensure that the dehumidifying dryer provides excellent,  
long service.  
The Troubleshooting chapter serves as a guide for identification of most common problems.  
Potential problems are listed, along with possible causes and related solutions.  
The Appendix contains technical specifications, drawings, schematics, parts lists, and  
available options. A spare parts list with part numbers specific to your machine is provided  
with your shipping paperwork package. Refer to this section for a listing of spare parts for  
purchase. Have your serial number and model number ready when ordering.  
Safety Symbols Used in this Manual  
The following safety alert symbols are used to alert you to potential personal injury hazards.  
Obey all safety messages that follow these symbols to avoid possible injury or death.  
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,  
will result in death or serious injury.  
WARNING! WARNING indicates a potentially hazardous situation or practice that, if  
not avoided, could result in death or serious injury.  
Caution!  
CAUTION indicates a potentially hazardous situation or practice that, if  
not avoided, may result in minor or moderate injury or in property damage.  
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Dryer Safety Tags  
Tag Description  
Tag  
Description  
Read Operation &  
Installation Manual  
High Voltage Inside  
Enclosure  
Hot!  
Lifting Point  
Earth Ground  
Protected Earth  
Ground  
PE  
1-2 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.  
To avoid possible personal injury or equipment damage when installing, operating, or  
maintaining this equipment, use good judgment and follow these safe practices:  
; Read and follow these operation and installation instructions when installing,  
operating, and maintaining this equipment. If these instructions become  
damaged or unreadable, additional copies are available from the manufacturer.  
; Follow all SAFETY CODES.  
; Wear SAFETY GLASSES and WORK GLOVES.  
; Work only with approved tools and devices.  
; Disconnect and/or lock out power before servicing or maintaining the equipment.  
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this  
equipment.  
; Operate this equipment within design specifications.  
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.  
You should remove the fuses and carry them with you.  
; Make sure the equipment and components are properly GROUNDED before you  
switch on power.  
; 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 nearby 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.  
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; 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.  
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.  
All personnel engaged in the use of the machines should become familiar with their operation  
as described in this manual.  
Proper operation of the machine promotes safety for the operator and all workers in its  
vicinity.  
Each individual must take responsibility for observing the prescribed safety rules as outlined.  
All warning and danger signs must be observed and obeyed. All actual or potential danger  
areas must be reported to your immediate supervisor.  
General Responsibility  
No matter who you are, safety is important. Owners, operators and maintenance personnel  
must realize that every day, safety is a vital part of their jobs.  
If your main concern is loss of productivity, remember that production is always affected in a  
negative way following an accident. The following are some of the ways that accidents can  
affect your production:  
Loss of a skilled operator (temporarily or permanently)  
Breakdown of shop morale  
Costly damage to equipment  
Downtime  
An effective safety program is responsible and economically sound.  
Organize a safety committee or group, and hold regular meetings. Promote this group from  
the management level. Through this group, the safety program can be continually reviewed,  
maintained, and improved. Keep minutes or a record of the meetings.  
Hold daily equipment inspections in addition to regular maintenance checks. You will keep  
your equipment safe for production and exhibit your commitment to safety.  
Please read and use this manual as a guide to equipment safety. This manual contains safety  
warnings throughout, specific to each function and point of operation.  
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  
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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.  
;NEVER operate, service, or adjust the dryer without appropriate training and first  
reading and understanding this manual.  
;NEVER try to pull material out of the dryer with your hands while it is running!  
;Before you start the dehumidifying dryer, check the following:  
Remove all tools from the dryer;  
Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the  
area;  
;If your dryer has been inoperative or unattended, check all settings before starting.  
;At the beginning of your shift and after breaks, verify that the controls and other  
auxiliary equipment are functioning properly.  
;Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify,  
or remove safety guards. Such alteration is not only unsafe, but will void the  
warranty on your equipment.  
;When changing control settings to perform a different mode of operation, be sure  
selector switches are correctly positioned. Locking selector switches should only be  
adjusted by authorized personnel and the keys removed after setting.  
;Report the following occurrences IMMEDIATELY:  
unsafe operation or condition  
unusual dryer action  
leakage  
improper maintenance  
NEVER stand or sit where you could slip or stumble into the  
dehumidifying dryer while working on it.  
;DO NOT wear loose clothing or jewelry, which can be caught while working on the  
dryer. In addition, cover or tie back long hair.  
;Clean the dehumidifying 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.  
Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric  
supplies and all accessory equipment at the machine, and disconnect and lockout electrical  
and pneumatic power. Attach warning tags to the disconnect switch and air shutoff valve.  
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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. 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.  
Be sure that all non-current carrying parts are correctly connected to earth ground with an  
electrical conductor that complies with current codes. Install in accordance with national and  
local codes.  
When you have completed the repair or maintenance procedure, check your work and remove  
your tools, rigging, and handling equipment.  
Do not restore power to the dehumidifying dryer until all persons are clear of the area. DO  
NOT start and run the dryer until you are sure all parts are functioning correctly.  
BEFORE you turn the dehumidifying dryer over to the operator for production, verify all  
enclosure panels, guards and safety devices are in place and functioning properly.  
Reporting a Safety Defect  
If you believe that your equipment has a defect that could cause injury, you should  
immediately discontinue its use and inform the manufacturer.  
The principle factors that can result in injury are failure to follow proper operating procedures  
(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.  
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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 AP1 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.  
Our dehumidifying dryers are designed to generate heated, dehumidified air at carefully  
controlled temperatures for use in closed-loop plastic drying systems. Dehumidifying dryers  
are sized to meet the specific requirements stated by the Customer at the time of purchase.  
2-2 General Description  
Moisture removal from hygroscopic (moisture attracting) plastic pellets is an essential step in  
the manufacture of high-quality plastic products.  
Our Dehumidifying Dryers are used by the plastics industry to generate very low dewpoint  
air that is heated to a controlled temperature for drying plastic pellets and regrind.  
The drying system consists of a dry air source and drying hoppers with process heating  
controls. The dry air source controls two primary sub-systems, the process air and the  
regeneration circuit. Each dryer has a left and a right desiccant bed so that one bed can  
regenerate while the other is in use. 2000-3000 cfm dryers feature two sets of desiccant beds,  
for a total of four desiccant beds.  
The drying system can be configured for one drying hopper or for as many as 20 hoppers.  
The process air heater can be located on the dryer or on each individual drying hopper.  
Heaters that are located on the drying hoppers can be set up with their own independent  
controls or can be controlled centrally using the main dryer controller.  
Specifying a Drying System  
There were many variables considered in the selection of your drying system, including: type  
of materials, residence time, throughput of the extruder or injection molding machine,  
ambient air moisture and temperature, and the altitude at the processing site. Should your  
operating environment change, we can advise you on necessary equipment, process time and  
temperature modifications.  
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 that is blended with a clay binder  
and formed into beads.  
Absorbed water is driven from saturated desiccant by heating it to a high temperature  
(reducing the desiccant's capacity to hold water) and forcing air through it. This moisture  
removal process is called "regeneration".  
The Closed Loop Drying System  
These 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,  
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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.  
Recycling process air maintains drying efficiency at a consistently high level.  
The Process/Regeneration Cycle  
There are two desiccant beds in a dryer up to 1500 cfm. Larger dryers have four beds (two  
left and two right beds). While one desiccant bed is on-line in the process air loop, the other  
is off-line being regenerated (see Figure 1).  
When a desiccant bed is on-line, it absorbs moisture from the process air. The desiccant will  
become saturated with moisture and need to be regenerated. The dryer automatically redirects  
the process airflow to the second bed and starts regenerating the first bed.  
During regeneration, air is heated to approximately 550°F and forced through the saturated  
desiccant. The moisture driven off the desiccant is bled to the atmosphere. The regeneration  
heater is then turned off while the regeneration blower continues to blow air through the  
desiccant bed until it is cooled.  
Figure 1: Regeneration Cycle  
AD600-AD1500  
Dryer Flow Schematic  
Right Desiccant in  
Regeneration  
AD600-AD1500  
Dryer Flow Schematic  
Left Desiccant in  
Regeneration  
Regeneration  
Blower  
Regeneration  
Blower  
Regeneration  
Filter  
Dryer Valve  
Regeneration  
Filter  
Dryer Valve  
Insulated  
Drying  
Hopper  
Insulated  
Drying  
Hopper  
Regeneration  
Heaters  
Regeneration  
Heaters  
Process  
Heater  
Process  
Heater  
Regeneration  
Exhaust  
Process  
Filter  
Regeneration  
Exhaust  
Process  
Filter  
Left Desiccant  
Right Desiccant  
Left Desiccant  
Right Desiccant  
Process  
Blower  
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. If the dryer was powered off using the main  
power disconnect or E-stopped, then the regenerating bed is placed back into regeneration,  
and the regeneration cycle is started over. The main air valve is allowed a period of time to  
move from one position to the other. If the main air valve does not complete positioning  
within the allotted time, then a “Main Air Valve Fail” alarm is generated and the dryer stops  
the process air blower and disables the drying hoppers and regeneration circuit.  
If the closed loop regeneration option is enabled, the regeneration closed loop valve moves to  
the open loop position. The system always begins the cooling phase for a regeneration cycle  
using ambient (open loop) air. The closed loop regeneration valve is allowed a period of time  
to move from the closed to the open loop position and a “Closed Loop Valve” alarm is  
generated if the valve fails to reach the commanded position within this time. This alarm will  
disable the regeneration circuit but does not stop the process air system or drying hoppers.  
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Functional Description  
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Once the main air valve and closed loop regeneration valve are in place, the process air  
blower starts. The system monitors the process air blower’s overload, starter auxiliary contact  
feedback and air pressure. Loss of any of these items when the process air blower is running  
will cause the process air blower and the drying hopper’s process heaters to shut down.  
The process air heaters (or gas burners, on gas-fired dryers) will turn on after a delay to allow  
the process air blower to accelerate the operating speed.  
During normal operation, one set of desiccant beds is connected to the process air circuit  
while the other set is being regenerated. When the offline beds are done regenerating, they  
will be switched into the process air circuit and the other beds will be regenerated. The  
default bed switch setting is based on time. If the Dewpoint Switch option is enabled, the  
beds will switch when the process air dewpoint reaches the dewpoint switch point. The  
dewpoint option will automatically disable itself and an alarm will be generated if the  
dewpoint sensor or related electronics fail.  
2-3 Standard Features  
Auto Start Timer  
The autostart timer is used to automatically start and stop the dryer at the time you specify. It  
can be programmed for one start and/or stop event per day for a week. When the Auto Start  
Timer is enabled, the dryer will automatically start and stop at pre-programmed times. If the  
dryer is stopped due to the Auto Start Timer, the DRYER STATUS message will indicate  
that the Auto Start timer is active.  
Mechanical Features  
; 180ºF – 250ºF Drying temperature range  
; High regeneration temperature control safeties  
; 13X desiccant (molecular sieve)  
; Easy to access process, regeneration, and combustion air filters.  
; 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 heater control  
Branch fusing  
Lockable power disconnects  
Regeneration temperature control  
“Process high temp” indication light and audible alarm  
7 day timer  
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Functional Description  
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Sequence shutdown switch  
; NFPA86, UL, AGA & CGA machinery electrical standards (Gas Dryers)  
; Available supply voltages of 208, 230, 460, 575/3/60 and 400/3/60  
2-4 Options  
Dewpoint Extend  
The Dewpoint Extend option measures the temperature of the moist air as it is bled to the  
atmosphere after regeneration. After a period of time, the bleed temperature will rise. This  
condition, called "bed breakthrough" indicates that the bed is dry. At bed breakthrough, the  
bleed air temperature peaks between 350°F and 400°F.  
The regeneration heaters turn off automatically on bed breakthrough for additional energy  
savings. A 550°F regeneration temperature will dry the desiccant beds sufficiently to produce  
process air dewpoint of -40°F. In a properly sized system, this ultra-low humidity level will  
be more than adequate to dry plastics to as little as .003% moisture.  
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. Then, the regeneration closed loop valve will direct air through  
a water-cooled heat exchanger and back into the regeneration loop (see Figure 2).  
Figure 2: Closed Loop Regeneration  
Regeneration  
Blower  
Regeneration  
Blower  
AD600-AD1500  
Dryer Flow Schematic  
Regeneration Heating is  
Activated  
AD600-AD1500  
Dryer Flow Schematic Dryer Valve  
Regeneration Closed Loop  
Cooling is Activated  
Dryer Valve  
Regeneration  
Filter  
Regeneration  
Filter  
Optional  
Optional  
Regeneration  
Closed Loop  
Cooler  
Regeneration  
Closed Loop  
Regeneration  
Cooler  
Regeneration  
Heaters  
Heaters  
Regenerarion  
Exhaust  
Regeneration  
Exhaust  
Optional  
Regeneration  
Closed Loop  
Valve  
Optional  
Regeneration  
Closed Loop  
Valve  
Left Desiccant  
Left Desiccant  
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Functional Description  
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2-5 Drawings and Diagrams  
Regeneration  
Blower  
Insulated  
Drying  
Hopper  
Regen.  
Filter  
Process  
Air Filter  
Process  
Heater  
Optional  
Regeneration  
Closed Loop  
Cooler  
Regen.  
Exhaust  
Optional  
Regeneration  
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  
Insulated  
Drying  
Hopper  
Regen.  
Filter  
Process  
Air Filter  
Process  
Heater  
Optional  
Regeneration  
Closed Loop  
Cooler  
Regen.  
Exhaust  
Optional  
Regeneration  
Closed Loop  
Valve  
Optional  
After-cooler  
Right Desiccants  
Left Desiccants  
Dryer Valve  
Process  
Blower  
Airflow Schematic: 2000-3000 cfm dryers (4 desiccant bed). Left desiccant beds are  
regenerating in open-loop regeneration mode.  
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Filter Check  
Gage  
Differential  
Pressure  
Switch  
Thumb Screws  
PS  
Cartridge Filter  
Dust Shroud  
Filter Retainer  
Slide Gate  
Clamp  
Dust Pan  
Dust Level  
Indicator  
Optional dryer dust collector  
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Functional Description  
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Process Aftercooler  
The optional aftercooler cools the moist air returning to the dryer from the drying hopper.  
The aftercooler can cool the return air from 250ºF to about 150ºF. This maintains the dryer’s  
efficiency and condenses the unwanted plasticizer from the air stream. The aftercooler  
requires a cooling water connection (see Figure and page 25).  
Figure 3: Process Aftercooler  
Mounting  
Brackets  
Mounting Brackets  
High  
Temperature  
Gasket  
Cooling Coil  
Cooling Coil  
Pipe Gasket  
Stainless Steel Cooler  
Housing  
Stainless Steel  
Cooler Housing  
High  
Temperature  
Gasket  
Cooling Coil  
Cooling Coil  
Cover Plate  
Cooling Coil  
Cover Plate  
Cooling Coil  
Pipe Gasket  
Aftercooler Design Specifications  
Entering water temp.  
ºF  
ºC  
85ºF  
29ºC  
Process Air Dust Collector  
The optional process air dust collector consists of a filter, dust can, pressure gauge, and  
optional pressure switch (see Figure). 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.  
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Functional Description  
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Figure 4: Process Air Dust Collector  
Filter Check  
Gage  
Differential  
Pressure  
Switch  
Thumb Screws  
PS  
Cartridge Filter  
Dust Shroud  
Filter Retainer  
Slide Gate  
Clamp  
Dust Pan  
Dust Level  
Indicator  
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Functional Description  
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Material Overdrying Protection  
Material Overdrying Protection is an automatic system used to reduce the chance of over-  
drying, and possibly melting, the resin in the drying hopper. Material Overdrying Protection  
activates when the return temperature is above a set value, indicating that all the resin in the  
hopper is dry.  
The control system monitors the return air temperature and automatically changes the process  
air setpoint to the SET BACK SETPOINT value when the return air temperature rises above  
the set back temperature. The process air setpoint returns to normal when the return air  
temperature falls below the SETUP TEMPERATURE value. The target values for  
changing the process air setpoint can be adjusted on the Mat Protect screen.  
Recommended Temperature Settings  
Drying Temperature (ºF) 160 180 200 220 240 260 280 300 320 340 360  
Setpoint  
120 125 130 135 135 140 150 160 170 180 200  
Figure 5: Material Miser/Air Balance Valve  
Temperature  
Probe  
Valve  
Proofing  
Coupling  
Switch  
Drying  
Hopper  
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Mechanical Options  
; Low temperature operation (120°F to 250°F)  
; High temperature operation (250°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  
; Temperature Set Back  
; Automatic airflow reduction valve (not for gas dryers)  
; 13X desiccant  
; Closed loop cooling valve  
; Dew point +15°F to -80°F  
; Sound insulation for under 85 DBA noise level  
; Dust collector  
Electrical Options  
; Hopper mounting of the process heater box  
; Remote operator interface (with standard controller only)  
; Ethernet module for remote communication w/data logging  
; CSA approval  
; UL rating  
; 400/3/50 supply voltage (includes CE compliance)  
Controller Options  
; Dew point meter w/regeneration on demand  
; Phase detection  
; Airflow monitoring  
; Temperature setback  
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Functional Description  
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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.  
At the completion of this section, the operator and maintenance personnel will be able to do  
the following:  
Identify and locate specific safety devices.  
Understand the proper use of the safety devices provided.  
Describe the function of the safety device.  
Safety Circuit Standards  
Safety circuits used in industrial systems protect the operator and maintenance personnel  
from dangerous energy. They also provide a means of locking out or isolating the energy for  
servicing equipment.  
Various agencies have contributed to the establishment of safety standards that apply to the  
design and manufacture of automated equipment. The Occupational Safety and Health  
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the  
organizations that have joined with the plastics industry to develop safety standards.  
Every effort has been made to incorporate these standards into the design of the large  
dehumidifying dryer; however, it is the responsibility of the personnel operating and  
maintaining the equipment to familiarize themselves with the safety procedures and the  
proper use of any safety devices.  
Fail Safe Operation  
If a safety device or circuit should fail, the design must be such that the failure causes a  
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch  
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. The safety devices that are  
used on the large dehumidifying dryer are primarily concerned with electrical power  
disconnection and the disabling of moving parts that may need to be accessed during the  
normal operation of the machines.  
Some of the safety devices utilize a manual activator. This is the method of initiating the  
safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable  
handle, there may be a location for a padlock. Personnel servicing the equipment should  
place a padlock in the lockout handle.  
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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. Failure to do so may  
result in serious injury. No one but the person who installed the lockout may remove it.  
Large Dehumidifying Dryers  
Functional Description  
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Dimensions and Specifications  
9 Denotes availability  
CFM  
600 850 1000 1250 1500 2000 2500 3000  
(Electric Dryer w/ Basic Control)  
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
(Electric Dryer High Performance)  
(Gas Dryer option in lieu of Electric- 180°F to 250°F)  
Gas dryer 250°F -400°F temp. range, includes aftercooler,  
insulated drying hose, & high temp. return air hose  
Gas central dryer (no process gas heater)  
Dimension and Specifications  
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
(Gas & Electric Dryer)  
Air inlet/outlet: OD, in inches (mm)  
8(203)  
10(254)  
12(305)  
Gas Flow Requirement (Gas Dryers)  
Low Heat Gas Flow Rate (CFH)  
High Heat Gas Flow Rate (CFH)  
Exhaust Duct Sizes in inches (MM)  
Comb. Flue Air Flow (CFM)  
159 225 265 331 397 528 661 793  
227 322 378 473 568 756 945 1,134  
3(76)  
87 123 145 182 218 290 363 436  
Overall Dimensions (Electric Dryers)  
4(102)  
5(127)  
6(152)  
Dimensions (in inches)  
Height  
Depth  
Width  
67  
96  
63  
81  
118  
83  
150  
73  
Shipping Weight (in lbs.)  
Dimensions (in inches)  
2100 2200 2950 4350 4700 6500 7300 8450  
Overall Dimensions (Gas Dryers)  
Height  
Depth  
Width  
67  
96  
63  
83  
118  
85  
150  
73  
Shipping Weight (in lbs.)  
2950 3050 3800 5150 5800 8125 8875 9050  
Mechanical Options  
9 Denotes availability  
CFM  
Option Description  
600 850 1000 1250 1500 2000 2500 3000  
Low temp operation 120°F to 180o F. (Electric dryers only)  
High temp operation for the electrical dryers, 180°F to 400o F.  
High temp operation for the Gas dryers, 250°F to 400o F.  
Plasticizer trap/ After Cooler w/Filter  
Aftercooler  
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
Over Drying Protection  
Temperature Set Back  
Automatic airflow reduction valve. (Not for gas dryers)  
13X Desiccant  
9
9
9
9
STD  
Closed Loop Cooling Valve  
(Std. w/high performance)  
9
9
9
9
Dew Point +15°F to –40°F  
Dew Point + 15°F to -80°F  
9 (Not with high performance)  
9 (Standard with high performance)  
Sound Insulation Package for under 85 DBA Noise Level  
Dust Collector ADC  
Process Heater 180°F to 250°F  
Process Heater 180°F to 400°F  
Not Required  
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
Large Dehumidifying Dryers  
Functional Description  
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Electrical Features  
CFM  
Dryer AMP Draw  
600 850 1000 1250 1500 2000 2500 3000  
Full load Amps  
152 217 249 314 378  
Standard voltage Low Heat (Electric Dryers)  
208v/3/60Hz.  
230v/3/60Hz.  
N/A  
137 196 225 284 342  
400v/3/50Hz.  
79 113 129 163 197 270 339 424  
460v/3/60Hz.  
575v/3/60Hz.  
Standard voltage High Heat (Electric Dryers)  
208v/3/60Hz.  
230v/3/60Hz.  
69  
55  
98 112 142 171 234 294 370  
78  
90 114 137 188 236 295  
Full load Amps  
207 296 342 430  
187 267 309 389  
N/A  
400v/3/50Hz.  
108 154 178 224 269 366  
N/A  
460v/3/60Hz.  
575v/3/60Hz.  
Standard voltage (Gas Dryers)  
208v/3/60Hz.  
230v/3/60Hz.  
400v/3/50Hz.  
460v/3/60Hz.  
575v/3/60Hz.  
94 134 154 194 234 318 399 494  
75 107 123 156 187 254 319 395  
Full load Amps  
36  
33  
19  
16  
13  
47  
43  
48  
44  
61  
55  
32  
28  
22  
75 120 150 191  
67 109 136 173  
25  
22  
17  
39  
34  
27  
62  
54  
43  
78  
67  
54  
99  
87  
69  
Electrical Options  
9 Denotes availability  
CFM  
Option Description  
600 850 1000 1250 1500 2000 2500 3000  
AP1 control  
(Includes: 4”x2” touch screen and dew point monitoring, 7  
day timer, dirty filter indication, & temperature setback.)  
Hopper mounting of the process heater box  
Remote operator interface  
9
9
9
CF  
Redundant process temperature safety  
Ethernet module for remote communication w/ Data logging  
CSA approval  
9 (Standard w/High Performance)  
9
9
UL rating  
9
Supply voltages 400/3/50 (includes CE compliance)  
Audible & Visual Alarm  
9
9 (Standard w/High Performance)  
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Functional Description  
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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. Lift unit from sides, inserting forklift under the base. The forks must be equidistant  
from the centerline of the unit and the unit must be balanced on the forks. Lift slowly  
and only high enough to clear the skid. Use a pry bar if necessary to carefully remove  
the skid from the unit.  
4. Lower slowly.  
5. Remove the temporary hardware that has been installed to prevent the side panels  
from shifting in transit. Retain the crating material for reshipping the components in  
case hidden shipping damage is found.  
3-2 Rigging and Placing Unit  
As with all equipment installations, follow all applicable codes and regulations.  
Locate close to the process to reduce piping expense.  
Locate adjacent to drain and city water sources (If equipped with aftercooler).  
Consult a structural engineer to assure that the floor, mounting pad or structural steel  
support is of adequate strength.  
Allow for required service clearances necessary for maintenance and easy access to all  
components.  
3-3 Making Electrical Connections  
Refer to local electrical codes, the schematic, and connection diagrams supplied with this unit  
and the serial tag for wiring considerations. Run all wiring in conduit if codes require it.  
Label all wiring to make any future troubleshooting easier.  
When making electrical connections to your dryer, ensure that you take into consideration  
and make arrangements for the following:  
; A qualified electrician should make all electrical connections.  
; The serial tag lists voltage, phase, and amp draw information. Line voltage must be  
within plus or minus ten percent (±10%) of the voltage listed on the serial tag, or  
damage may occur. Phase imbalance must be less than two percent (2%).  
; Connect main power to the dryer at the disconnect or terminals in the upper right  
corner of the control enclosure.  
; Install a fused disconnect with a lockout feature in the power main leading to the  
dryer.  
; The power drop must include a ground wire.  
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Mechanical Installation  
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; Make sure all electrical connections are tight.  
3-4 Making Gas Line Connections (Gas-Fired Models Only)  
Connect a gas line to the dryer’s gas inlet. See Figure 6 for a detailed schematic of the gas  
system.  
Figure 6: Gas Flow Schematic  
Gas Dryers Air  
Fuel Train  
9
10  
7
24  
25  
6
8
5
PS  
PS  
11  
18  
4
C
B
19  
15  
PS  
4
12  
23  
13  
3
1
2
16  
15  
PS  
PS  
16  
14  
3
17  
16  
3
P
S
3
PS  
20  
20  
20  
20  
21  
21  
21  
21  
22  
22  
22  
22  
Fume  
Exhaust  
Item  
1
2
3
4
5
6
7
8
Description  
Manual gas shut off valve  
Gas regulator  
Gas pressure switch  
Process gas solenoid valve  
Manual adjustable butterfly valve  
Process gas proportionator  
Process air actuator  
Item  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
Description  
Regeneration gas regulator  
Regeneration air solenoid valve  
Regeneration gas solenoid valve  
Regeneration gas proportionator  
Regeneration butterfly orifice valve  
Regeneration air actuator  
Adjustable gas orifice  
Regeneration thermocouple  
Regeneration SER burner  
Air pressure switch  
9
Process ratiomatic burner  
Process gas heat exchanger  
Gas pressure switch  
Process combustion air blower  
Process combustion air filter  
10  
11  
12  
13  
Regeneration & combustion air filter  
Combustion air blower  
Air pressure switch  
DANGER! Natural gas burners are started, stopped, and monitored independently of  
the dryer controls using EclipseTM Bi-Flame burner controls. Read and  
follow the burner control manufacturer’s operating and safety instructions  
and applicable NFPA© (National Fire Protection Association) codes in  
addition to your local rules and regulations. The Eclipse Bi-Flame model  
6500 Dual Burner Monitoring System (instruction manual no. 826, 05/03)  
should be included with the dryer. It is also available online at  
Large Dehumidifying Dryers  
Mechanical Installation  
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3-5 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 opposite shaft end. See Figure.  
The blowers are rotating properly when air flows from the delivery outlet.  
Incorrect phasing of power leads will cause backward rotation of blower motors and  
contamination of the desiccant.  
If both blowers are rotating improperly, reverse any two wires at the fused disconnect outside  
the dryer or at the disconnect/terminal in the control enclosure. This assures that both blowers  
will be rotating in the proper direction.  
If just one blower is rotating incorrectly, reverse the wires at the motor starters.  
Figure 7: Checking Blower Rotation  
Process Blower  
Regeneration Blower  
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Mechanical Installation  
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3-6 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.  
; Do not use insulated hose on the return (from the drying hopper)  
; Do not shorten the return hose. The return air to the blower must be 150°F or below.  
; Make sure the hoses are not kinked.  
; Drying hopper air inlet and outlet locations vary, but always connect the hoses so the  
dry process air from the dryer enters the bottom of the drying hopper and flows out  
the top to return to the dryer inlet.  
Figure 8: Dryer/Drying Hopper Process Air Connections  
Return air  
thermocouple  
(Do not insulate)  
location  
Process Air Heater on Dryer  
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Return air  
thermocouple  
location  
Process Air Heater on Drying  
Hopper  
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Return air  
thermocouple  
location  
Drying System with Dust Collector  
and Process Air Heater on Dryer  
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3-7 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.  
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.  
Figure 9: Aftercooler Components & Flow Rates  
Mounting Brackets  
Cooling Coil  
Cooling Coil  
Pipe Gasket  
Stainless Steel Cooler  
Housing  
High  
Temperature  
Gasket  
Cooling Coil  
Cover Plate  
Mounting  
Brackets  
High  
Temperature  
Gasket  
After cooler  
Water Flow  
Model  
(GPM)  
600  
10  
850  
10  
1000  
1250  
15  
15  
20  
1500  
2000  
25  
Stainless Steel  
Cooler Housing  
2500  
30  
Cooling Coil  
3000  
35  
Cooling Coil  
Cover Plate  
Cooling Coil  
Pipe Gasket  
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3-8 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):  
; 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.  
Figure 10: Drying Hopper Air Trap  
Flapper Valve  
of the loader  
Suggested material level  
for the optimum  
efficiency.  
Return air from the  
drying hopper.  
Air Trap  
Insulation  
Delivery low dew point,  
heated air to the drying  
hopper.  
Recommended process  
temperature control  
thermocouple location.  
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Mechanical Installation  
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Chapter 4: Controls  
4-1 Controller Description  
The AP1 control package uses a PLC with a touch screen interface to control the operation of  
the dryer. See for descriptions of each screen.  
Figure 11: Controller Screen Descriptions  
Main Menu. The main navigational screen. Used to access status and set-up screens.  
Dryer Status Screen. Displays actual dryer temperature and temperature setpoint, as well as  
actual dewpoint.  
Dryer Menu. Navigational screen for dryer status, setup and other options  
Dryer Setup Screen. Used to set high and low temperature alarms. Also used to enable or  
disable closed-loop drying. Closed-loop drying is not available on single blower dryers.  
Over-Dry Protect Screen. Used to enable/disable and configure material overdrying  
protection. Also displays actual return temperature.  
Autotune Screen. Used to start and stop autotuning. Also displays PID settings.  
Dew Pt Setup Screen. Used to configure dewpoint alarms. Also used to enable/disable  
dewpoint switching.  
Autostart Screen. Used to configure the autostart timer.  
System Menu. Navigational screen for system settings.  
Setup Screen. Used to configure alarm duration and passwords.  
Set Clock Screen. Used to configure the system clocks.  
Hour Meter Screen. Used to view and reset the hour meters for the dryer, machine blower,  
and dryer blower.  
I/O Status Screen. Used to view the status of inputs and outputs used by the dryer’s  
controller.  
System Backup. This screen is used to save and restore the dryer settings.  
Service Menu. This screen is password protected and meant for the manufacturer’s service  
personnel use only.  
Alarm History Screen. Used to scroll through the alarm history.  
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Controls  
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4-2 Identifying Control Panel Components for the AP-1 Optional  
Controller  
Disconnect Switch  
The Disconnect Switch is located in the front upper right hand corner of the control  
enclosure. It allows the user to disconnect power to the dryer for emergency shutdown,  
service or long periods of inactivity.  
Control Power Switch  
The Control Power Switch is located on the front of the control enclosure below the touch  
screen. The switch energizes the control circuit (PLC, touch screen, relays, etc.) within the  
control enclosure.  
Touch Screen  
The Touch Screen is located in the center of the control enclosure. Once the disconnect is  
on and the control circuit is energized, the machine can be started and parameters can be  
adjusted through the touch screen.  
Alarm Horn & Light  
The Alarm Horn and the Alarm Light are located on the top of the enclosure. These  
devices give an audible and visual indication that there is a malfunction with the system.  
4-3 Process Air Temperature and Conveying Process Controller  
AEC dryers equipped with the “AP-1” control package use a PLC with a touch screen  
interface to control the operation of the dryer system. This section of the manual will address  
those parameters that allow the user to optimize the drying/conveying system for specific  
applications.  
(Dryer Status Screen)  
(Startup Screen)  
The screen shown above provides the operator with the following information:  
Dryer Model Number  
Temperature units (In Celsius or Fahrenheit)  
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PLC Version  
Display Version  
After approximately 10-12 seconds the controller will flash to the Dryer Status Screen shown  
on the previous page.  
4-4 Identifying Controller Screens  
Main Menu Screen  
(Main Menu Screen)  
The MAIN MENU provides information on the following system parameters:  
DRYER  
ALARMS  
HELP  
SYSTEM  
LOG OFF  
Press the DRYER MENU button to return to the next section of dryer functions.  
Typical Dryer Screens  
(Dryer Status Screen)  
(Shown at Controller Power Up)  
(Looking at the screen from Left to Right)  
The SETPOINT button allows the operator to set the process air  
temperature.  
The ACTUAL value will give you a reading of what the actual  
process air temperature is entering the drying hopper.  
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The DEW POINT value will give you a reading of what the actual  
process air dew point is.  
The area in the lower left portion of the touch screen conveys two  
lines of information relating to the overall operation of the dryer.  
The following is a list of typical machine/dryer summary status  
line text messages:  
1. Dryer Off  
2. Left Bed In Process  
3. Right Bed In Process  
4. Valve Changing Position  
5. Autostart Timer Enabled  
6. Autotune in Progress  
7. Over-dry Protect Active  
8. Left Bed Heat  
9. Left Bed Cool  
10. Left Bed Ready  
11. Left Bed Failure  
12. Left Bed Process Failure  
13. Right Bed Heat  
14. Right Bed Cool  
15. Right Bed Ready  
16. Right Bed Failure  
17. Right Bed Process Failure  
18. Dyer is Shutting Down  
19. Process Offline  
The START BUTTON allows the user to stop and start the dryer manually. When  
the start button is pressed, the dryer begins to operate. The text in the button will  
change from START to SHUTDOWN. The next time the button is pressed, the  
dryer will go into a sequence shutdown and the button text will change to  
RESTART. The process heater will shut off, the current bed regeneration will be  
completed and then the blower will stop. If sequence shutdown is not desired,  
turning the POWER SWITCH off will turn off all components of the dryer  
immediately and the optional conveying system will be turned off also.  
When the button shows ALARM, the process temperature is too hot to start the  
dryer. When the process air temperature falls below the setpoint, the button changes  
to either START or RESTART, you may begin dryer operation.  
SETTING VALUES  
By pressing and holding the numbers in the SETPOINT button, the following screen will be  
displayed:  
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Enter the values you would like to set in the screen by pressing the number keys. Press ENT  
(Enter) when you are finished to set the new values or CLR (Clear) to erase the current  
values and reenter new ones. To set the values in the next field, press ENT (Enter) to close  
the screen shown above. Then select the next number field to enter new values.  
For fields with a decimal point (X.X) enter the number assuming there is a decimal point  
present. For instance, to enter a 5.8 into an X.X field simply enter "58."  
DRYER MENU  
Pressing this button will take the user to another screen where more machine parameters can  
be viewed and adjusted.  
(Dryer Menu Screen)  
The screen shown above will allow the operator to set/review operating parameters for the  
following:  
DRYER STATUS  
DRYER SETUP  
OVER DRY PROTECT  
ALARMS  
AUTO TUNE  
DEW PT SETUP (Dew Point Setup)  
AUTO START  
MAIN MENU  
Pressing the DRYER STATUS button will take the operator back to the original status  
screen shown on page 35.  
Pressing MAIN MENU will return you back to the menu screen.  
Dryer Setup  
There are four (4) dryer setup pages. Use the MORE and BACK buttons to switch between  
the dryer setup screens.  
(Dryer Setup Screen - 1 of 4)  
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By pressing the LOW TEMP or HIGH TEMP alarm buttons, the operator can enter the  
desired values to enable the alarm to go off at a specific deviation from setpoint (on the high  
or low side).  
When these settings have been made, the operator now has a choice of returning to the  
DRYER MENU or entering the MAIN MENU screen.  
(Dryer Setup Screen – 2 of 4)  
The dryer temperature values can be switched between reading in Fahrenheit and  
reading in Celsius. The dryer will continue to run using the new temperature  
units if the dryer is running when the temperature units are changed. Check all  
temperature related values to ensure that they are correct after changing the  
temperature units.  
(Dryer Setup Screen – 3 of 4)  
The third dryer setup page contains process return and supply air temperature offset  
values. The values can be used to bring the dryers temperature readings into agreement  
with a reference source such as a calibrated lab thermometer. The user can adjust these  
values +/- 10 degrees (F or C). Any number other than zero is added to the supply/return  
temperature reading before it is used by the system. For instance, if the user enters an -8.0  
for a process temperature offset then the original temperature reading, 165°F, would be  
displayed as 157°F.  
(Dryer Setup Screen – 4 of 4)  
If CLOSED LOOP COOLING is ENABLED then after a pre-set amount of time has  
elapsed in open loop cooling, the dryer will close the optional closed loop cooling  
valve and finish the cooling portion of the regeneration cycle in closed loop. Closed  
loop cooling uses an air to water heat exchanger instead of ambient air to cool the  
regenerating bed.  
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OVERDRY PROTECTION  
(Overdry Protection Screen - 1 of 2)  
This feature is used to prevent the overdrying of the plastic resin in the drying hopper.  
RETURN TEMP provides the actual temperature of the process air leaving the drying  
hopper.  
Press the MORE button located in the top right corner of the Over-Dry Protection screen.  
By pressing the MATERIAL OVER-DRY OPTION button, the operator can enable or  
disable this feature.  
(Overdry Protection Screen - 2 of 2)  
The SET BACK SETPOINT is the lower process air temperature that will keep the  
material ready for processing but not damage it over an extended period of time.  
The SET BACK DELAY button prevents the control from going to the SET BACK  
SETPOINT until the subject time period has elapsed.  
When the return air temperature reading is above the SET BACK TEMPERATURE  
the SET BACK SETPOINT is used on the process air setpoint.  
When the return air temperature reading is below the SETUP TEMPERATURE, the  
process air setpoint returns to normal.  
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ALARMS  
(Alarm History Screen)  
This screen allows the operator to review the number and type of issues that the dryer has  
encountered during its operation.  
Problems can be viewed by Date, Hour, and Comment.  
Because of the size of the screen, only three (3) comments/alarms can be viewed at a  
time. Alarm history is not resetable. (Display holds up to 100 messages).  
To view alarms not visible on the screen, press the DOWN button.  
To return to a particular alarm, press the UP button to scroll upward in the alarm history.  
Pressing DRYER in this screen will take the operator to the DRYER STATUS of the  
system.  
Pressing MAIN will take you to the main screen.  
At this point, the operator can return back to the DRYER MENU or MAIN MENU by  
touching the appropriate button on the screen.  
AUTOTUNE  
(Process AutoTune Screen)  
This screen allows the operator to automatically tune the process air temperature control  
algorithm to a specific drying application. The autotune sequence should be initiated if the  
user feels there are unacceptable fluctuations in the process air temperature. The calculated  
P, I, and D variables are shown for reference purposes.  
The autotune feature can be activated by pressing the START/STOP button located  
in the center of the screen. After autotuning is done, it will automatically stop and  
give new P, I, and D variables.  
AUTOTUNE IN PROGRESS or PROCESS NOT ACTIVE will inform the operator of  
the current status of this feature.  
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DEW POINT SETUP  
(Dew Point Setup Screen)  
This screen allows the operator to set the dew point.  
The HIGH DEW PT ALARM is an audible/visual alarm that will sound when the process air  
dewpoint rises to this value. Values can be set between –40 through +30 degrees. The  
dewpoint sensor only reads to a maximum of +15. Set the high alarm value to +30 to disable  
high dewpoint alarms.  
Used to configure the dewpoint switch. Regeneration will switch sides when the dewpoint  
reaches the switch value. If this option is disabled, regeneration will switch sides after a set  
period of time.  
Used to switch regeneration at this time if dewpoint does not rise above bed switch point.  
Press this button to enable or disable the SWITCH ON DEW POINT feature.  
AUTO START  
(Autostart Timer Screen)  
This screen allows the operator to set the time and day that the dryer will start  
Automatically.  
Pressing PREV DAY allows the operator to scroll backward through the days of the  
week to select the day they desire the dryer to start.  
Pressing NEXT DAY allows the operator to scroll forward through the days of the week  
to select the day they desire the dryer to start.  
By touching the ON TIME and OFF TIME sections on the screen, the operator can  
enter the values for the time they wish the dryer to turn on and off. The time is on a 24  
hour schedule (1:00pm = 13:00). If you do not want to turn the dryer on or off, enter  
0:00.  
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This button enables and disables the AutoStart Timer.  
HELP MENU  
(Help Menu Screen)  
The DRYER ALARMS button shows Help menus for Dryer Alarms.  
MAIN MENU  
(Main Menu Screen)  
This screen allows you to jump to the different areas of the controller to set, monitor, and  
operate different features of the dryer.  
System Screens  
SYSTEM MENU  
(System Menu Screen)  
The screen shown above will allow the operator to set/review operating parameters for the  
following:  
SYSTEM SETUP  
SET CLOCK  
HOUR METERS  
ALARM HISTORY  
I/O STATUS  
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SYSTEM BACKUP  
SERVICE MENU  
MAIN MENU  
SYSTEM SETUP  
(System Setup Screen)  
This screen allows the operator to set alarm and password features.  
ALARM OFF DUR is the amount of time (0-99 minutes) that the alarm and horn will stay  
off after the alarm silence button is pushed. (When this function is set to 0, this feature will  
never turn off. When it is set to 99, it will stay off until another alarm occurs.)  
OPER PW is the four (4) digit number that allows access to the station and pump status  
screen and the station operator screen. (When this feature is set to 0000 these screens are  
not password protected.)  
OPER PW DUR is the amount of time (5-99 minutes) the password will allow access to  
the associated screens. The screen changes to the station status screen when the time  
expires.  
SETUP PW is the four (4) digit number that allows access to the setup screens. (When  
this is set to 0000 there is no password protection).  
Note: Factory default is Supervisor security enabled. Supervisor password is 1234.  
SETUP PW DUR is the amount of time (5-99) the password will allow access to the  
associated screens. When the time expires, the screen changes to the station status screen.  
LOW LEVEL DETECTION SETUP  
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The AP1 control system can detect and alarm a low material level condition in up to three (3)  
material hoppers. The material hopper assignments on the display are “Machine Hopper 1,”  
“Machine Hopper 2,” and “Drying Hopper.” Although your naming conventions may vary,  
the low material level detection capability of the AP1 can still be exploited. Refer to the  
provided electrical diagram for the proper wiring of the required level detection hardware.  
Low material level detection will not be performed for this hopper.  
Low material level detection will be performed on this hopper provided that the dryer is  
running.  
SET CLOCK  
(Clock Menu Screen)  
This menu allows the operator to set the AUTOSTART CLOCK and the ALARM CLOCK.  
The Autostart clock controls the 7-day timer, which can be programmed to start or stop the  
dryer automatically. An internal battery backup holds the settings in memory when the dryer  
is de-energized. From the Clock Menu screen, press the SET AUTOSTART button to  
access the Autostart clock.  
Use the following procedure to set the Autostart clock:  
1. Press the Month field on the Set Clock screen and use the keypad to enter in the  
current month. Pres the ENTER button to save the value.  
2. Press the Date field on the Set Clock screen and use the keypad to enter in the current  
date. Press the ENTER button to save the value.  
3. Press the Year field on the Set Clock screen and use the keypad to enter in the current  
year. Press the ENTER button to save the value.  
4. Press the Hour field on the Set Clock screen and use the keypad to enter in the  
current hour. Press the ENTER button to save the value.  
5. Press the Minutes on the Set Clock screen and use the keypad to enter in the current  
minutes. Press the ENTER button to save the value.  
6. Press the SET TIME button to save the information.  
(Autostart Clock Screen)  
In this screen the user can set the variables that are used to time and date stamp alarms. This  
feature works in conjunction with the ALARM screen (see Page 43 ) to notify the user of  
issues that the dryer had encountered during its operation.  
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Press the SYSTEM MENU button to return back to the system menu screen and the next set  
of programmable features.  
HOUR METERS  
(Hour Meter Screen)  
This screen monitors the number of hours that the dryer has operated.  
In addition to monitoring the total number of hours of equipment operation, it also has a  
resetable field that allows the operator to set the counter back to zero. This is useful for  
monitoring hours between equipment maintenance periods.  
Press the DRYER button to reset the counters.  
INPUT STATUS  
(Input Status Screen)  
This screen allows the operator to view the status of the variables contributing to the input of  
material into the drying system. It also is useful in troubleshooting system issues (i.e. a dirty  
filter or low material level in a hopper).  
Press the OUTPUTS button to see the outputs of the dryer.  
OUTPUT STATUS  
(Output Status)  
This screen allows the operator to view the status of the dryer.  
Press the INPUTS button to see the inputs of the dryer.  
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(System Backup Screen)  
ACS Dryer control version 2.000 introduces a system backup feature.  
Pressing SAVE SETTINGS will save the system variables for later recall.  
Pressing RESTORE SETTINGS will restore previously saved values.  
Pressing RESTORE FACTORY DEFAULTS will return the dryer to its factory default  
state, namely:  
CONVEYING:  
NO CONVEYING UNITS AVAILABLE - CONVEYING DISABLED  
DRYER OPTIONS:  
TEMPERATURE IN FAHRENHEIT  
STANDARD HEAT  
OVERDRY PROTECTION DISABLED  
AUTO START TIMER DISABLED  
DRYER VALUES:  
ALARM SILENCE DURATION  
PASSWORD - OPERATOR  
99 MIN  
0000  
PASSWORD SUPERVISOR  
1234  
PASSWORD OPERATOR DURATION  
PASSWORD SUPERVISOR DURATION  
DEWPOINT HIGH LIMIT ALARM VALUE  
10 MIN  
10 MIN  
30 DEGF  
(ALARM DISABLED)  
OVERDRY SET BACK TEMPERATURE  
OVERDRY SET BACK SETPOINT  
OVERDRY SET UP TEMPERATURE  
PROCESS AIR TEMP. SETPOINT  
PROCESS AIR HI DEVIATION VALUE  
PROCESS AIR LO DEVIATION VALUE  
REGENERATION AIR SETPOINT  
PROCESS ACTUAL VALUE OFFSET  
REGEN ACTUAL VALUE OFFSET  
170 DEGF  
100 DEGF  
90 DEGF  
180 DEGF  
35 DEGF  
-35 DEGF  
450 DEGF  
0.0 DEGF  
0.0 DEGF  
SERVICE  
(Service Menu Screen)  
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This service menu screen is PASSWORD PROTECTED and meant for ACS personnel use  
only.  
Press the RETURN key to go back to the SYSTEM MENU.  
Touching the MAIN MENU button in the SYSTEM MENU screen, will return the operator  
back to the overall menu screen. In this screen, the operator will be able to select the button  
that displays the ALARMS screen.  
Alarm Screens  
ALARMS  
(Alarm History Screen)  
This screen allows the operator to review the number and type of issues that the dryer has  
encountered during its operation.  
Problems can be viewed by Date, Hour, and Comment. Because of the size of the screen,  
only three (3) comments/alarms can be viewed at a time.  
To view alarms not visible on the screen, press the DOWN button.  
To return to a particular alarm, press the UP button to scroll upward in the alarm  
history.  
At this point the operator can return back to the DRYER MENU or MAIN  
MENU by touching the appropriate button on the screen.  
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Alarm Screen Example  
This is an example of what a typical Alarm screen looks like. The user will see the message  
causing the alarm in the top half of the display with an ALARM SILENCE button in the  
lower half.  
To turn off the alarm, the user must press the ALARM SILENCE button. This will cancel  
the alarm.  
See Section 7-4: Alarms on p. 57 for alarm descriptions.  
4-5 Redundant Safety Controller Display  
Optional  
The Redundant Safety Controller limits the process air temperature from exceeding specific  
temperatures in case of a catastrophic failure of the primary PLC process air temperature  
control system. 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 is necessary.  
Figure 12: Typical Redundant Safety Controller Display  
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4-6  
Setting the Redundant Safety Controller  
The Redundant Safety Controller alarm setting is changed by pressing the up and down keys  
to input the alarm value. The upper display reading indicates the Process Value, while the  
lower display indicates the High Point Setting alarm value. The factory setting for the High  
Point Alarm Value is 150°F (-23°C).  
Always put your set point to 30°F above set point.  
To set the redundant safety controller:  
1. Press the P button.  
2. The controller will ask for a password. Press the Up  
get to 10.  
button until you  
3. Press the Up  
button until you get to your desired temperature.  
4. Press P again until you get to Run.  
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Chapter 5: Operation  
5-1 Start-up  
There are two possible methods of starting the dryer system: manually, by pressing the Start  
button on the Dryer Status screens, and automatically through use of the Auto Start Timer  
built into the dryer control system.  
Before operating the dryer, make sure all electrical connections are tight and that the  
blowers rotate in the right direction.  
Use the following procedure to start the dryer manually:  
1. Close the slide gate at the bottom of the drying hopper.  
2. Turn on the disconnect switch in your power drop, then turn on the one on the dryer.  
3. Turn the system ON/OFF switch to ON to energize the display panel.  
4. On the Dryer Status screen, press the START button to start the dryer. The process  
blower starts.  
5. If the dryer has an aftercooler, make sure there is proper flow of cooling water  
through the coil and bleed any trapped air from the system.  
6. On the Dryer Status screen, press the SETPOINT button, and use the keypad to enter  
the process set point value. Press the ENTER button to save the value.  
7. After the proper pre-drying time for the initial hopper fill has elapsed, fully open the  
drying hopper slide gate.  
Note: To allow proper residence time during continuous processing, the material level in  
the hopper should be maintained at a full level.  
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5-2 Using the Dryer Status Screen  
From the Main Menu screen, press the DRYER button to access the Dryer Status screen.  
The Dryer Status screen displays the set point and actual process temperature as well as the  
actual dewpoint.  
(Dryer Status Screen)  
The area in the lower left portion of the screen displays two lines of information relating to  
the overall operation of the dryer. Typical messages include the following:  
Dryer Off  
Left Bed In Process  
Right Bed In Process  
Valve Changing Position  
Autostart Timer Enabled  
Autotune in Progress  
Over-dry Protect Active  
Left Bed Heat  
Left Bed Cool  
Left Bed Ready  
Left Bed Failure  
Left Bed Process Failure  
Right Bed Heat  
Right Bed Cool  
Right Bed Ready  
Right Bed Failure  
Right Bed Process Failure  
Dyer is Shutting Down  
Process Offline  
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5-3 Alarms  
Use the Alarm History screen to monitor system alarms. From the Main Menu screen, press  
the Alarms button to access the Alarm History screen. The three most recent alarms appear at  
the top of the Alarm History screen. Use the DOWN and UP buttons to scroll through the  
alarms.  
(Alarm History Screen)  
5-4 Alarm Descriptions  
Alarm  
Comment  
Alarm  
Description  
Alarm  
Effect  
The Main Air Valve did not maintain  
position.  
Possible Motor or Limit Switch Failure.  
The Main Air Valve did not find  
position.  
Possible Motor or Limit Switch Failure.  
The Main Air Valves expected and actual  
positions do not match.  
VALVE  
POSITION  
Immediate  
Shut Down  
VALVE  
MTR  
OVERRIDE  
Immediate  
Shut Down  
VALVE  
MOTOR FAIL  
Immediate  
Shut Down  
Possible Motor or Limit Switch Failure.  
The process supply air temperature  
thermocouple is out of range.  
Possible thermocouple failure.  
The regeneration air temperature  
thermocouple is out of range.  
Possible thermocouple failure.  
Process air temperature deviation is  
above high limit value.  
PROCESS  
SENSOR FAIL  
Process  
Shut Down  
REGEN  
SENSOR FAIL  
Regeneration  
Shut Down  
PROCESS  
HIGH TEMP  
Process  
Shut Down  
Possible solid state relay failure.  
Process air temperature deviation is  
below low limit value.  
PROCESS  
LOW TEMP  
Alert Only  
Possible heater failure.  
Process air temperature control loop is  
unable to maintain the process air  
temperature set point.  
Possible Missing thermocouple, Failed  
heater, Failed solid state relay.  
PROCESS  
LOOP BREAK  
Process  
Shut Down  
REGEN  
HIGH TEMP  
Regeneration air temperature deviation is Regeneration  
above high limit value. Shut Down  
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Alarm  
Comment  
Alarm  
Description  
Alarm  
Effect  
Regeneration air temperature deviation is  
below low limit value.  
Possible heater failure.  
REGEN  
LOW TEMP  
Alert Only  
The dew point sensor is out of range.  
Possible transducer or electronics  
failure.  
Disables  
Switch on  
Dew Point  
DEWPOINT  
SENSOR  
The dew point value is above the high  
limit value. Faulty sensor or PC board.  
Possible ambient air contamination or  
failed regeneration cycle.  
Process blower is not running.  
HIGH  
DEWPOINT  
Alert Only  
PROCESS  
Process  
BLOWER FAIL Possible overload fault, contactor fault.  
Shut Down  
Process heaters are not active.  
PROCESS  
Process Shut  
Down  
Possible surface switch trip, redundant  
HEATER FAIL  
temperature safety trip.  
REGEN  
Regeneration blower is not running.  
Regeneration  
Shut Down  
Immediate  
Shut Down  
Alert Only  
Disables  
BLOWER FAIL Possible overload fault, contactor fault.  
REGEN  
HEATER FAIL  
DIRTY FILTER Monitored filter(s) require cleaning.  
Regeneration heaters are not active.  
Possible surface switch trip.  
The process return air temperature  
P RETURN  
thermocouple is out of range.  
SENSOR FAIL  
Over dry  
Protection  
Possible thermocouple failure.  
5-5 Shutdown  
To prolong the life of the process air heaters and desiccant beds, the following procedure  
should always be used to shut down the dryer. In an emergency situation, turning off the main  
power disconnect will have the immediate effect of stopping all of the dryer’s systems, but  
this is not the preferred method for shutting down the system.  
1. On the Dryer Status screen, press the SHUT DOWN button to shut down the dryer.  
The process heater will shut off. The process blower will shut off after ??? minutes  
and the regeneration blower will shut down. The bed regeneration process will be  
completed. When the dryer is re-started, the process air will be directed through the  
bed that was regenerated last.  
2. When processing is complete, close the hopper slide gate and shut down any in-line  
companion equipment, such as aftercoolers.  
3. Empty the drying hopper, if desired.  
If the dryer is turned off manually (by turning off the dryer without using the above shut-  
down procedure), the dryer will stop immediately. When the dryer is re-started, the process  
air will be directed through the last bed that was being used when the dryer control switch  
was turned off. If a bed was being regenerated when the dryer control switch was turned off,  
the regeneration process will start over on the same bed. This may cause the dewpoint to  
become bad for that desiccant tank.  
Large Dehumidifying Dryers  
Operation  
55  
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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.  
Dryer Model #  
Serial #  
Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/  
EVERY WEEK  
By  
By  
By  
By  
By  
By  
By  
By  
By  
By  
By  
By  
By  
Inspect all filters for wear,  
replace/clean if dirty or  
worn  
EVERY MONTH Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec  
Lock out electrical power  
and inspect electrical  
wiring for integrity  
Lock out electrical power  
and check heater  
elements for continuity  
using an ohmmeter  
Check Dew point and  
temperature tracking with  
an external dew point  
monitor and pyrometer  
Visually inspect the  
shifting of the airflow  
valve during one cycle  
Next Scheduled  
Inspection  
Actual Inspection  
Date/By  
Next Scheduled  
Inspection  
Actual Inspection  
Date/By  
EVERY YEAR  
Inspect desiccant. Replace  
if brown or broken  
- Photocopy this page for your maintenance records -  
Large Dehumidifying Dryers  
Maintenance  
56  
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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.  
On 600-1500 cfm dryers, there is a single high-temperature (up to 350ºF) filter mounted  
above the process blower on the rear of the dryer. On 2000-3000 cfm dryers, there are two  
high-temperature (up to 350ºF) filters located in the housing under the blower platform on the  
left rear corner of the dryer.  
Vacuuming. Vacuum cleaning is the preferred method for cleaning the process air filters  
because compressed air or high-pressure washing can damage the filter. Vacuuming removes  
most large particles and surface contaminant. Use a commercial duty vacuum cleaner and  
vacuum the filter from the air intake (dirty) side only.  
Compressed Air Cleaning. Blow clean, dry compressed air up and down the pleats, blowing  
out the filter from the clean side. Do not shoot the air in a criss-cross motion against the grain  
of the pleats—this won’t clean the filter, and it may damage it. Compressed air should be less  
than 100 psi—use a 1/8 diameter nozzle at least 2 inches away from the filter.  
Figure 13: Process Filter Housing  
High  
Temeprature  
Gasket  
Stainless Steel  
Filter Housing  
High  
Temperature  
Cartridge Filter  
High  
Temperature  
Cartridge Filter  
Stainless Steel  
Filter Housing  
Stainless Steel  
Filter Housing  
Cover  
Filter Housing  
Cover Latches  
Filter Housing  
Cover Latches  
High  
Temeprature  
Gasket  
High  
Temeprature  
Gasket  
Stainless Steel  
Filter Housing  
Cover  
600-1500 cfm dryers  
2000-3000 cfm dryers  
Large Dehumidifying Dryers  
Maintenance  
57  
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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. Check the following:  
Hold a light bulb behind the filter element to find holes,  
tears, fatigued paper or residual dirt.  
Inspect the end plates—damage here could allow air to  
bypass the filter.  
Look for rust on the end plates and metal core—rust  
particles could flake off and contaminate the dryer and resin.  
Check the gasket for damage—a damaged gasket will allow  
contaminants into the process. Replace if needed.  
6. Return the filter cartridge to its original position and tighten the nut on the center  
retaining rod to secure the filter cartridge.  
7. Secure the filter access cover with the hand knobs or threaded fasteners.  
Cleaning or Replacing the Regeneration Filter  
Large dryers are equipped with a filter in the regeneration air loop located at the back of the  
dryer. Regular filter cleaning will keep your dryer operating at peak efficiency.  
Caution!  
Operating the dryer without the regeneration air filters installed will void  
the warranty.  
1. Turn off and/or lock out electrical power to the dryer.  
2. Remove the knob securing the filter.  
3. Remove the filter from the post..  
4. Vacuum or carefully blow out the filter with compressed air. If the filter is worn or  
can't be cleaned, replace it.  
5. Slide the filter back onto its post and tighten knob back on the filter.  
Calibrating the Dirty Filter Alarm  
Your dryer may be equipped with a Dirty Filter alarm. When the alarm sounds, it is time to  
clean or change the filter. The Dirty Filter alarm is tested and calibrated at the factory, but it  
can be adjusted in the field. Be sure that your filter is clean, and use the following procedure  
to calibrate the alarm.  
1. Remove the process air return filter element from its housing.  
2. Block off approximately 50% of the filter’s surface area to simulate a dirty filter.  
3. Reinstall the cartridge and secure the cover.  
4. While the process blower is operating, adjust the trim screw on the differential  
pressure switch until the alarm light just comes on.  
Large Dehumidifying Dryers  
Maintenance  
58  
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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. The  
alarm light should remain off.  
Checking the Dewpoint Control System  
The Dewpoint Switch option on dryers depends on the proper operation of the dewpoint  
sensor and its control board. The dewpoint sensor is in the process air stream and is therefore  
susceptible to contamination.  
Dewpoint sensor life is dependent 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.  
The dryer operator should monitor the initial dewpoint sensor readings and establish a  
periodic replacement schedule as needed.  
Caution! Do not attempt to check the continuity or resistance of a dewpoint sensor. The  
sensor will be destroyed.  
If you suspect that the dewpoint readings on the dewpoint meter are incorrect, a dewpoint  
simulation calibrator is available from the manufacturer. This device simulates various  
dewpoint outputs. It can confirm proper operation of the dewpoint sensor and dewpoint  
system control board.  
Use the following procedure to check the dewpoint sensor and dewpoint control board:  
1. Remove the sensor cable from the sensor hex nut adapter.  
2. Connect the cable to the plug on the rear of the simulator.  
3. Turn the rotary knob on the simulator to each position and note the readings on the  
dewpoint meter on the dryer's control panel. The readings should correspond within a  
degree or two across the entire range.  
4. If the readings agree, the control board is OK. Dewpoint sensor replacement is  
recommended. If the readings do not agree, replace the control board and run the test  
again to rule out the possibility of a bad sensor.  
Note: Do not attempt to make any adjustments to the components on the dewpoint  
control board.  
5. When testing is finished, re-connect the control cable to the sensor adapter.  
Large Dehumidifying Dryers  
Maintenance  
59  
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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).  
The air temperature at the top of the regenerating desiccant bed rapidly climbs to  
350°F or more shortly after the start of regeneration, even though a saturated bed has  
just started heating.  
The process air dewpoint, measured with a portable dewpoint monitor, is higher than  
-10°F throughout the process drying cycle.  
Smoke or dust is being blown out of the process air outlet.  
Noticeable amounts of desiccant in the beds is a medium-brown color, or darker.  
If any of these signs are noticed, the desiccant in the desiccant beds should be replaced.  
Desiccant replacement kits are available from the Parts Department. If you wish, the  
desiccant beds can be repacked at your site by a service technician.  
WARNING! DESICCANT MATERIAL CAUSES EYE IRRITATION  
BREATHING MAY BE HARMFUL/MAY CAUSE SKIN IRRITATION!  
Do not get in eyes.  
Avoid prolonged contact with skin.  
Use with adequate ventilation.  
Wash thoroughly after handling.  
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.  
Replacing the Desiccant  
Follow the procedure below to change the desiccant. See Figure 14 below for desiccant  
tower components.  
1. Disconnect electrical power to the dryer.  
2. Remove the bolts and nuts securing the covers of each desiccant canister. Remove  
the covers and set them aside.  
3. With a shop vacuum that has a 4 micron HEPA filter, carefully remove all desiccant  
from each tower.  
4. Inspect all screens for tears or burn-through spots.  
5. Fill each canister with 13X, 8 x 12 bead desiccant.  
Large Dehumidifying Dryers  
Maintenance  
60  
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6. Inspect the gaskets on each of the covers. Replace if necessary.  
7. Re-install the covers.  
Figure 14: Desiccant Tower Assembly  
High  
Temperature  
Gaskets.  
Regeneration  
Heater Cover.  
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.  
Stainless Steel  
Hollow Core  
Desiccant Tank  
Desiccant Tank  
Mounting  
Platform  
Figure 15: Desiccant Replacement Amounts  
Dryer  
CFM  
Desiccant Required per Tower  
“13 X”, 8 x 12 Bead  
Total  
350  
600  
850  
175  
175  
300  
300  
300  
300  
300  
300  
350  
600  
600  
600  
1000  
1250  
1500  
2000  
2500  
3000  
1200  
1200  
1200  
Replacing the Process Heater (Electric Dryers)  
Large Dryers have a number of single phase Calrod-type heater elements wired in a delta  
formation. They are mounted on top of the dryer or to the drying hopper. The number and  
wattage of the heaters varies with model, voltage, temperature range, etc., but the  
replacement procedure is the same.  
DANGER! Disconnect and lock out power before heater replacement.  
Large Dehumidifying Dryers  
Maintenance  
61  
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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. Remove individual heaters for replacement by removing the large brass nuts and  
washers.  
6. Re-install the heaters and heater plate assemblies in reverse order, replacing gaskets  
if necessary.  
Caution!  
Heater loops should not touch each other. "Hot spots" will lead to  
premature heater failure.  
7. Re-install the jumper wires and bars according to the sketch made earlier.  
8. Re-secure the process heater access cover.  
Stainless Steel  
Heater Housing  
Figure 16: Process Heater Box Assembly  
Cover  
High  
Temperature  
Gasket  
Heater Elements  
Double Wall  
Stainless Steel  
Heater  
Housing  
Heater Elements  
High  
Temperature  
Gasket  
Heater Element  
Mounting Plate  
Heater Element  
Mounting Plate  
Double Wall  
Stainless Steel  
Heater  
Housing  
High  
Temperature  
Gasket  
Heater Assembly  
Gude Bars  
Heater Assembly  
Gude Bars  
Stainless Steel  
Heater Housing  
Cover  
Hex Nut For  
Securing the Heater  
Wire  
Heater Element  
Mounting Hex Nut  
Heater Element  
High Temperature  
Washer / Gasket  
Washer  
Heater Wire with  
Crimped on Closed  
Loop Connector  
Heater Assembly  
Guide Bar  
Heater Element  
Bulkhead Fitting  
Heater Mounting  
Plate  
Replacing the Regeneration Heater (Electric Dryers)  
The regeneration heaters are wired in the delta formation, mounted in the core of the  
desiccant tanks.  
DANGER! Disconnect and lock out power before heater replacement.  
Large Dehumidifying Dryers  
Maintenance  
62  
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1. Access the desiccant canisters by removing the panels on the dryer.  
2. Remove the Regeneration Heater Cover.  
3. Unscrew the six (6) screws on the Heater Element Mounting Plate.  
4. Slide out the heater assembly, taking care to not damage the gaskets.  
5. Unscrew the heater loops that need to be replaced.  
6. Re-install the new heaters. Securely tighten all fasteners.  
Caution!  
The heater loops should not touch each other. This will create "hot spots"  
and lead to premature heater failure.  
7. Insert the heater assembly back into the desiccant canister.  
8. Fasten the six (6) screws on the Heater Element Mounting Plate.  
9. Re-secure the Regeneration Heater Cover.  
10. Re-install the dryer panels.  
Figure 17: Regeneration Heater Box Assembly  
High  
Temperature  
Gaskets.  
Regeneration  
Heater Cover.  
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.  
Stainless Steel  
Hollow Core  
Desiccant Tank  
Desiccant Tank  
Mounting  
Platform  
Large Dehumidifying Dryers  
Maintenance  
63  
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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.  
Before making haphazard substitutions and repairs when defective electrical components are  
malfunctioning, we recommend that you check the associated circuitry and assemblies for  
other defective devices. It is common to replace the obviously damaged component without  
actually locating the real cause of the trouble. Such hasty substitutions will only destroy the  
new component. Refer to wiring diagrams and schematics.  
7-2 Basic Troubleshooting  
Problem  
Little or no air  
coming from  
process delivery  
tube.  
Possible Cause  
Dirty Filters  
Desiccant beds contaminated by  
material or plasticizer leaking  
into the system. See Sec. 6-6.  
Corrective Action  
Clean or replace filters.  
Replace desiccant  
Blower fuse(s) blown.  
Overload tripped.  
Fix problem and Replace fuse(s).  
Fix problem and reset the  
overload.  
Wrong motor rotation.  
Turn off power. Reverse  
incoming power.  
Blower fins filled with dust or  
contaminants.  
Remove blower side plate, clean  
baffles, replace.  
Suction in delivery  
tube, pressure from  
the return tube.  
Phase is reversed on power drop  
coming into the dryer.  
Stop the Dryer.  
If the dryer was connected to the  
drying hopper, check to see if the  
desiccant and process air heater  
has been contaminated with resin.  
If so, replace the desiccant and  
remove any resin carry-over.  
Otherwise, change the phase of  
two legs of the three-phase power  
drop. Never change the phase at  
the motor starters unless only one  
of the two blowers is rotating  
improperly.  
Loss or reduction of Process heaters are faulty.  
process air  
temperature.  
Check for open or shorted heaters.  
Replace if required. Check the  
fuses.  
Solid-state temperature controller Replace.  
faulty.  
Process temperature was adjusted  
in error by plant personnel.  
Make sure that plant personnel are  
aware of the proper temperature  
set point. A sign posted next to the  
control would be helpful.  
Large Dehumidifying Dryers  
Troubleshooting  
64  
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Problem  
Possible Cause  
Corrective Action  
Replace.  
Desiccant beds are contaminated. Replace desiccant.  
Loss or reduction in Process heaters are faulty.  
drying capacity.  
Material being dried differs from  
material specified at the time of  
purchase.  
Drying systems are designed for  
the material that was originally  
specified. Different materials may  
need a longer residence time or  
different drying temperature.  
Inspect for air leaks; replace if  
necessary.  
Break in flex hose to/from drying  
hopper.  
Blower fins filled with dust or  
contaminants.  
Remove blower side plate, clean  
baffles, replace. Replace filter  
elements.  
Material in drying  
hopper cakes, or  
meltdown occurs.  
Process temperature set too high  
due to operator error.  
Check resin manufacturer's data  
sheet for proper drying  
temperature. Make sure plant  
personnel are aware of the correct  
process temperature Set Point.  
See Section “Temperature Screen  
Setup” on page 34.  
High temperature alarm not set  
properly.  
Process set point is out of  
acceptable range.  
Restore temperature controller to  
factory pre-sets. Auto-Tune if  
necessary.  
Poor Dew Point  
Performance.  
Burned out regeneration heater.  
Contaminated or worn out  
desiccant.  
Repair or replace.  
Replace.  
Leaking process air hoses.  
Repair or replace.  
Dryer is being operated beyond its Check dryer and drying hopper  
capacity.  
sizing.  
Bad dew point sensor.  
Replace.  
Fouled dew point sensor manifold. Clear obstruction. Air should flow  
freely through sensor.  
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Troubleshooting  
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7-3 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 0.0°C (32ºF) when you insert a 100-ohm  
resistor between terminals A and –B of the controller, and you short-circuit controller  
terminals +B and –B, the controller is normal and the sensor is probably broken, short-  
circuited, or incorrectly wired.  
Other service problems or questions can be answered by contacting the Service  
Department.  
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Troubleshooting  
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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.  
This parts warranty does not cover any labor charges for replacement of parts,  
adjustment repairs, or any other work. This warranty does not apply to any equipment  
which, in the company’s opinion, has been subjected to misuse, negligence, or operation  
in excess of recommended limits, including freezing or which has been repaired or  
altered without the company’s express authorization. If the serial number has been  
defaced or removed from the component, the warranty on that component is void.  
Defective parts become the property of the warrantor and are to be returned.  
The company is not liable for any incidental, consequential, or special damages or expenses.  
The company’s obligation for parts not furnished, as components of its manufactured  
equipment is limited to the warranty of the manufacturers of said parts.  
Any sales, use, excise, or other tax incident to the replacement of parts under this warranty is  
the responsibility of the purchaser.  
The company neither assumes nor authorizes any other persons to assume for it any liability  
in connection with the sale of its equipment not expressed in this warranty.  
Many types of the manufacturer’s equipment carry an additional one-year service policy.  
Consult your sales representative for specific details.  
Large Dehumidifying Dryers  
Appendix  
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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:  
3. Humidity range:  
4. Altitude:  
0 degrees Celsius – Maximum (104 degrees Fahrenheit)  
50% relative humidity  
Sea level  
5. Environment:  
6. Radiation:  
Clean and non-explosive  
None  
7. Vibration:  
Minimal, i.e. machine mounting  
8. Allowable voltage fluctuation:  
9. Allowable frequency fluctuation:  
+/- 10%  
Continuous  
Intermittent  
+/- 1%  
+/- 2%  
10. Nominal supply voltage:  
460/3/60 (Verify on serial number tag)  
11. Earth ground type: TN (system has one point directly earthed through a protective  
conductor)  
12. Power supply should include a ground connection.  
13. Over-current protection is supplied in the dryer, but additional protection should be  
supplied by the user.  
14. The door-mounted disconnect serves as the electrical disconnect device.  
15. Dryer is not equipped with local lighting.  
16. Functional identification  
17. Dryer is equipped with a CE mark  
18. Dryer is supplied with an operating manual in the language of the destination  
country.  
19. Cable support may be required for power cord, depending on final installation.  
20. No one is required to be in the interior of the electrical enclosure during the normal  
operation of the unit. Only skilled electricians should be inside the enclosure for  
maintenance.  
21. Doors can be opened with a screwdriver, but no keys are required.  
22. Two-hand control is not required or provided.  
23. All dryers should be moved around and set in a place with a lift truck or equivalent.  
24. There are no frequent repetitive cycles that require manual controlrepetitive  
functions are automatic while the dryer is operating.  
25. An inspection report detailing the functional test is included with the dryer.  
26. The machine is not equipped with cableless controls.  
27. Color-coded (harmonized) power cord is sufficient for proper installation.  
Large Dehumidifying Dryers  
Appendix  
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8-3 Spare Parts List  
LARGE DRYER SPARE PARTS LIST 600,850,1000,  
1250,1500,2000,2500, AND 3000  
LEVEL 1 ( Electrical Components )  
PART #  
SIZE Description  
A0536474  
A0536471  
A0534846  
A0545343  
A0538001  
A0538017  
A0538005  
A0534842  
A0540997  
A0540995  
A0542207  
50  
35  
20  
Fuse, Process Heater Elements  
Fuse, Regen Heater Elements  
Fuse, Process Blower  
3
3
3
3
2
1
2
1
1
2
1
3.5 Fuse, Regen Blower  
3.2 Transformer, Control Primary  
6
5
10  
1
Transformer, Control Secondary  
Transformer, Valve Motor Primary  
Transformer, Valve Motor Secondary  
Fuse, Control, PLC  
0.75 Fuse, Control, Output/Power Supply  
Fuse, Control, Power Supply Out  
3
LEVEL 1 ( Mechanical Components )  
PART #  
SIZE Description  
Dew Point Sensor Insert  
W00015435  
A0548556  
A0568271  
A0566467  
A0570595  
A0568062  
A0566531  
A0572408  
W00018051  
W00013983  
A0566564  
A0572479  
A0566676  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Dew Point Sensor  
Dew Point Sensor Cable  
Valve switch  
Process Air Filter 600-850 CFM  
Process Air Filter 1000-3000 CFM  
Regeneration Air Filter 600-850 CFM  
Regeneration Air Filter 1000-3000 CFM  
13X molecular Sieve Desiccant ( 8 X 12 Beads )  
High Temperature Gasket (15 Ft Roll)  
Desiccant Tank Sight Glass  
1
1
1
2
2
2
1
1
1
1
1
1
1
1
350 Lbs.  
350 Lbs.  
600 Lbs.  
600 Lbs.  
600 Lbs.  
1200 Lbs.  
1200 Lbs.  
1200 Lbs.  
2.25 Rolls  
2.25 Rolls  
2.75 Rolls  
3.0 Rolls  
3.0 Rolls  
4.5 Rolls  
4.5 Rolls  
4.5 Rolls  
2
2
3
2
2
3
2
2
3
2
2
3
2
2
3
4
4
5
4
4
5
4
4
5
Desiccant Tank Sight Glass Gasket  
High Temperature Snap Switch.  
LARGE DRYER SPARE PARTS LIST 600,850,1000,1250,  
1500,2000,2500, AND 3000  
LEVEL 2 ( Electrical Components )  
PART #  
SIZE Description  
A0558000  
A0558002  
A0558004  
A0558040  
A0558079  
A0569887  
A0569895  
A0505417  
A0567058  
A0554555  
A0548556  
9A Contactor, IEC  
16A Contactor, IEC  
32A Contactor, IEC  
1
1
1
1
1
1
1
1
1
1
1
Overload, IEC, 12-32A  
Overload, IEC, 1 - 2.9A  
Overload, IEC, 5 - 15A  
48A Relay, Solid State  
Relay, 4PDT, Regeneration T'Couple  
Relay, SPDT  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
*
*
Circuit Board, Dew Point  
Sensor, Dew Point  
LEVEL 2 ( Mechanical Components )  
PART #  
SIZE  
Description  
3500 Watts Heater Element 208/220 Volts  
3500 Watts Heater Element 230 Volts  
3500 Watts Heater Element 400 Volts  
3500 Watts Heater Element 460 Volts  
3500 Watts Heater Element 575 Volts  
Heater Element Gasket  
A0566544  
A0566547  
A0566549  
A0566549  
A0566549  
A0566415  
A0566682  
21  
30  
39  
39  
45  
21  
30  
39  
39  
45  
21  
42  
30  
60  
39  
78  
39  
78  
45  
90  
66  
78  
90  
21  
30  
39  
39  
45  
66  
78  
90  
21  
30  
39  
39  
45  
66  
78  
90  
120  
158  
180  
1/4" OD Teflon Tube.  
18 Feet  
18 Feet  
18 Feet  
18 Feet  
18 Feet  
18 Feet  
18 Feet  
18 Feet  
Large Dehumidifying Dryers  
Appendix  
69  
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LARGE DRYER SPARE PARTS LIST 600,850,1000,1250,  
1500,2000,2500, AND 3000  
LEVEL 3 ( Electrical Components )  
PART #  
SIZE  
Description  
A0567930  
A0567932  
A0569896  
A0567933  
A0563932  
A0568961  
PLC, Controller  
PLC, Temperature Control Module  
PLC, Analog Input Module  
PLC, Touch Screen  
Power Supply, 24VDC  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Redundant Temperature Safety Controller  
LEVEL 3 ( Mechanical Components )  
PART #  
SIZE  
Description  
8" O.D. by 12 Ft Long Hi Temp Hose.  
3" O.D. by 12 Ft Long Hi Temp Hose.  
Return Air Cooling Coil 600-850 CFM  
Return Air Cooling Coil 1000-1500 CFM  
Return Air Cooling Coil 2000-3000 CFM  
Closed Loop Cooling Coil  
A0542302  
A0571107  
A0570519  
A0566849  
A0568147  
A0568233  
A0546119  
A0562555  
A0565900  
A0572510  
A0572509  
A0572511  
A0559792  
A0559903  
A0559998  
A0553766  
A0572513  
A0572512  
A0572514  
A0572516  
A0572515  
A0572517  
A0559815  
A0568211  
A0560003  
W00015335  
A0548558  
W00015436  
A0572502  
A0566879  
A0565249  
A0565250  
A0566466  
A0547006  
A0537908  
A0568205  
A0542231  
A0571107  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
208-230/460 Volt Blower, 600 CFM  
575 Volt Blower, 600 CFM  
208-230/460 Volt Blower, 850 CFM  
380 Volt Blower, 1000 CFM  
230/460 Volt Blower, 1000 CFM  
575 Volt Blower, 1000 CFM  
380 Volt Blower, 1250 CFM  
230/460 Volt Blower, 1250 CFM  
575 Volt Blower, 1250 CFM  
230/460 Volt Blower, 1500 CFM  
380 Volt Blower, 2000 CFM  
230/460 Volt Blower, 2000 CFM  
575 Volt Blower, 2000 CFM  
380 Volt Blower, 2500 CFM  
230/460 Volt Blower, 2500 CFM  
575 Volt Blower, 2500 CFM  
380 Volt Blower, 3000 CFM  
230/460 Volt Blower, 3000 CFM  
575 Volt Blower, 3000 CFM  
Dew Point Sensor Manifold  
Gasket for the Dew Point Sensor  
Plastic Nut for the Dew Point Sensor  
O-Ring for Main Valve  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3.2 Feet  
3.2 Feet  
3.2 Feet  
3.2 Feet  
3.2 Feet  
3.2 Feet  
3.2 Feet  
3.2 Feet  
Main Valve Motor  
Filter housing Latch  
Filter Housing Strike  
Closed Loop Cooling Valve Motor  
Knob for the Regeneration Filter  
Handle for Panels.  
Latch for Panels  
8" Hose Clamp  
1
4
1
4
1
4
1
4
1
4
1
4
1
4
1
4
4
4
4
4
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
8
12  
36  
16  
6
12  
36  
16  
6
12  
36  
16  
6
16  
48  
32  
6
16  
48  
32  
6
16  
48  
32  
6
24  
16  
6
24  
16  
6
3" Hose Clamp  
Large Dehumidifying Dryers  
Appendix  
70  
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8-5  
Dryer Identification (Serial Number) Tag  
(Located on back of Dryer)  
XXX Series Dryer  
Model Number XXX-15  
Max Drying Capacity HR  
460V  
1
Serial Number 060701R  
Date of Manufacture 06/2003  
4.5A  
Over-current Protection Device (s) 4.5A Total  
Frequency 50/60Hz  
Compressed air supply None  
Dryer Mass 400 lbs/(180 KG)  
Electrical Diagrams &  
Pneumatic Diagram  
Street Address  
City, State Zip Code  
Telephone Number  
Large Dehumidifying Dryers  
Appendix  
71  
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8-5 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. A customer replacement parts list is included in this manual  
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing  
excellent customer service.  
Service Department  
[
]
[
]
Call toll-free 8am–5pm CST 800 233-4819 or call 630 595-1060  
[
]
Emergencies after 5pm CST, call 847 439-5655  
We have a qualified service department ready to help. Service contracts are available for most  
products.  
Sales Department  
[
]
Call 630 595-1060 Monday–Friday, 8am–5pm CST  
Our products are sold by a worldwide network of independent sales representatives. Contact our Sales  
Department for the name of the sales representative nearest you.  
Contract Department  
[
]
Call 630 595-1060 Monday–Friday, 8am–5pm CST  
Let us install your system. The Contract Department offers any or all of these services: project planning;  
system packages including drawings; equipment, labor, and construction materials; and union or non-  
union installations.  
Large Dehumidifying Dryers  
Appendix  
72  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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