Sterling Dehumidifier 90 225 CFM User Manual
Operation and Installation Manual  
SDA 150-380 (90-225 CFM)  
Cabinet Series  
Dehumidifying Dryers  
Important! Read Carefully Before Attempting to Install or Operate  
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A0534806  
Part No: 882.00282.00 Effective: 12/01/05 Bulletin No: DH1-630  
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Table of Contents  
CHAPTER 1: SAFETY……………………………………………...6  
1-1  
How to Use This Manual. ............................................................................................6  
Safety Symbols Used in this Manual.....................................................................6  
Warnings and Precautions ..........................................................................................7  
Responsibility ..............................................................................................................8  
General Responsibility ..........................................................................................8  
Operator Responsibility.........................................................................................8  
Maintenance Responsibility...................................................................................9  
Reporting a Safety Defect ...................................................................................10  
1-2  
1-3  
CHAPTER 2: GENERAL INFORMATION ...............................11  
2-1  
2-2  
2-3  
2-4  
2-5  
2-6  
2-7  
2-8  
2-9  
Models Covered…………………………………………………………………………….11  
Equipment Function ..................................................................................................11  
Necessary Documents ..............................................................................................11  
Standard Features.....................................................................................................11  
Options......................................................................................................................11  
The Closed Loop Drying System...............................................................................12  
What is Desiccant?....................................................................................................13  
The Process/Regeneration Cycle..............................................................................13  
Specifying a Drying/Conveying System ....................................................................13  
CHAPTER 3: INSTALLATION…………….………...…………...14  
3-1  
3-2  
3-3  
3-4  
Positioning Your Dryer ..............................................................................................14  
Making Electrical Connections ..................................................................................14  
Connecting Compressed Air .....................................................................................14  
Checking for Proper Blower Rotation........................................................................14  
Three Phase Models…..……………………………………………………………...14  
Process Air Connections Between the Dryer and the Drying Hopper.......................15  
Connecting Cooling Water to the Optional Aftercooler..............................................15  
Installing Water Lines…………………………………………………………………15  
Drying Hopper ...........................................................................................................15  
Removing the Rust Inhibitor................................................................................15  
Air Trap Considerations.......................................................................................15  
3-5  
3-6  
3-7  
CHAPTER 4: CONTROLS………………………………………..16  
4-1  
Control Panel Indicator Lights and Switches.............................................................16  
Rocker Switches..................................................................................................16  
Indicating Lights ..................................................................................................16  
Process Air Dew Point Display..................................................................................19  
Process Air Temperature Controller..........................................................................19  
Identifying Temperature Controller LED Indicators ...................................................19  
Identifying Temperature Controller Buttons...............................................................20  
E5CK Operating Parameters...............................................................................21  
Available E5CK Modes........................................................................................21  
4-2  
4-3  
4-4  
4-5  
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4-6  
4-7  
Setting the Process Air Temperature ........................................................................22  
PLC Controller...........................................................................................................22  
PLC LED Indicators.............................................................................................23  
Output LED Indicators.........................................................................................24  
Status LED Indicators..........................................................................................24  
Setting the Shift on Dew Point...................................................................................28  
Entering Operating Parameters to Select Modes......................................................28  
4-8  
4-9  
4-10 Setting the High Dew Point Alarm.............................................................................28  
4-11 Optional Seven-Day Timer........................................................................................29  
Programming the Optional Times........................................................................30  
Checking the Set Time ........................................................................................31  
Day Override .......................................................................................................32  
Canceling the Settings ........................................................................................32  
CHAPTER 5: OPERATION………………………………………..34  
5-1  
5-2  
5-3  
Pre-Startup Checks...................................................................................................34  
Startup.......................................................................................................................34  
Shutdown ..................................................................................................................34  
CHAPTER 6: MAINTENANCE…………………………………...36  
6-1  
Work Rules................................................................................................................36  
6-2 Servicing Process Air Filters .....................................................................................36  
Recommendations for Cleaning and Replacing Filters .......................................37  
6-3  
6-4  
6-5  
6-6  
6-7  
Servicing the Dew Point Monitor ...............................................................................39  
Symptoms of Worn Desiccant...................................................................................39  
Replacing Worn Desiccant........................................................................................40  
Replacing the Process Heater...................................................................................41  
Replacing the Regeneration Heater..........................................................................42  
Changing the Controller Security Level...............................................................42  
Restoring Factory Defaults on the Process Temperature Controller...................42  
Restoring Factory Defaults on the Dew Point Controller....................................46  
Restoring the E5CK Temperature Controller and Dew Point Meter to Factory Setup 47  
6-8  
CHAPTER 7: TROUBLESHOOTING…………………………….48  
CHAPTER 8: APPENDIX………………………………………….52  
8-1  
8-2  
Contact Information...................................................................................................52  
Technical Specifications............................................................................................52  
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Charts and Figures  
1
2
Dryer Air Flow Diagram  
12  
18  
Typical Dryer Interface Panel  
3
Typical Dryer Temperature Controller  
20  
4
Display Readout for Mode Settings and Available Security Levels  
22  
5
Typical Subpanel Layout  
25  
6
7
8
Typical Cabinet Dryer Electrical Schematic, Drawings 1 and 2  
26-27  
41  
Required Desiccant Amounts Per Bed  
Setting List for Process Temperature Controller,  
Part No. A0548565  
43  
9
Setting List for Dew Point Controller, Part No. A0548565  
46  
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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 General Information 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 Controls and Operations chapters include 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  
Tag  
Description  
Description  
Read Operation  
& Installation  
Manual  
High Voltage Inside  
Enclosure  
Hot!  
Lifting Point  
Protected Earth  
Ground  
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.  
; Only PROPERLY TRAINED personnel familiar with the information in this  
manual should work on this equipment.  
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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 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.  
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„ 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.  
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.  
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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: General Information  
2-1 Models Covered  
This manual provides instructions for installing and operating 90, 100, 150, and 225 CFM  
cabinet-style dehumidifying dryers.  
2-2 Equipment Function  
Our dehumidifying dryers are designed to generate heated, dehumidified air at carefully  
controlled temperatures for use in closed-loop plastic drying systems. Moisture removal from  
hygroscopic (moisture attracting) plastic pellets is an essential step in the manufacture of high-  
quality plastic products. Our dehumidifying dryers are used to generate very low dew point air  
heated to a controlled temperature for drying plastic pellets and regrind.  
2-3 Necessary Documents  
The documents listed below are necessary for the operation, installation, and maintenance of  
Cabinet Series dehumidifying dryers. You can obtain additional copies from the manufacturer.  
Make sure that the appropriate personnel are familiar with these documents:  
; This manual.  
; The schematic and assembly drawings included in the customer information packet.  
; The Customer Parts List included in the information packet.  
; Operation and installation manuals for any optional controls or auxiliary equipment in the  
drying system.  
2-4 Standard Features  
; Rugged compact frame with handle and sturdy 4” (10 cm) casters.  
; Dual blower dryer with dual desiccant beds and 4-way compressed air operated valves.  
; Up to 400ºF (204ºC) drying temperature range.  
; Cartridge type (two stage) air filters for all blowers.  
; Integral Control Center for dryer options.  
; Electrical disconnect with all wiring to a common terminal point.  
; PLC microprocessor control of the drying and conveying stations.  
; Digital Dew Point monitor indicates dryer efficiency.  
; Sequence shutdown of the dryer.  
2-5 Options  
Options can tailor your dehumidifying dryer system to meet the exact requirements of the drying  
task being performed.  
; 13X desiccant.  
; Aftercoolers for high and low temperature applications.  
; Seven-day timer to allow programmable dryer startup.  
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; Audible/visual critical alarm.  
; Fusing for blowers and heaters.  
; Dirty Filter indicator for each individual blower.  
2-6 The Closed Loop Drying System  
Dehumidifying dryers force hot, dry air through the resin in the drying hopper where the air picks  
up moisture from the material and is drawn back to the dryer.  
In the dryer, a desiccant bed strips moisture from the air. The dryer then re-heats dried process  
air, and sends it back into the drying hopper to dry material again.  
This system is a closed loop, because ambient (outside) air is never introduced into the process  
air. See Figure 2. Our dehumidifying dryers use the closed loop system, 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.  
Figure 1-Dryer Air Flow Diagram  
From  
drying hopper  
Ambient  
Regen  
filter  
Process  
filter  
Process air  
heater  
Regen  
bleed  
To drying  
hopper  
Upper valve  
Desiccant  
Desiccant  
beds  
beds  
Regen heater  
Regen heater  
Lower valve  
Regen blower  
Process blower  
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2-7 What is Desiccant?  
Desiccant is a material which attracts and holds (absorbs) water from the air. Our dehumidifying  
dryers use a synthetic crystalline metal aluminosilicate desiccant blended with a clay binder and  
formed beads.  
Absorbed water is driven from saturated desiccant by heating it to a high temperature (reducing  
desiccant capacity to hold water) and forcing air through it. This moisture removal process is  
called regeneration.  
2-8 The Process/Regeneration Cycle  
Our dehumidifying dryers have two desiccant beds. While one bed is on-line in the process air  
loop, the other is off-line being regenerated.  
When a desiccant bed is on-line, it absorbs moisture from the process air. In time, the bed  
becomes saturated with moisture and needs to be regenerated. The dryer automatically redirects  
the process airflow to the second bed and starts the regeneration cycle on the first bed.  
During regeneration, the dryer heats air to over 500°F (260ºC) and forces it through the desiccant  
bed. Moisture driven off the bed bleeds to the atmosphere.  
If you measure the temperature of the air bled to the atmosphere (bleed temperature), you should  
observe a rise after a period of time. This condition, bed breakthrough, indicates that the bed is  
dry. At bed breakthrough, the bleed air temperature peaks between 350°F (176ºC) and 400°F  
(204ºC).  
The Dew Point meter measures the dew point of the process air. A properly regenerated bed  
produces process air dew point of -40°F (-40ºC). This ultra-low humidity level is more than  
adequate to dry plastics to as little as .003% moisture, depending on the process and material.  
2-9 Specifying a Drying/Conveying System  
Many variables were 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. If your operating environment  
changes, the manufacturer can advise you on necessary equipment and process time and  
temperature modifications required for your system.  
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Chapter 3: Installation  
3-1 Positioning Your Dryer  
The dehumidifying dryer system was designed to be wheeled into place. The entire assembly is  
mounted on a rugged, compact frame and is equipped with sturdy, 4” (10 cm) heavy-duty casters,  
two locking and two swivel.  
Caution!  
Use caution and observe safety rules when placing your dryer!  
3-2 Making Electrical Connections  
; Fulfill all national, state, and local safety and electrical code requirements.  
; Connections should be made by a qualified electrician.  
; Make sure all electrical connections are tight.  
; 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.  
WARNING! Proper grounding of the main power line is critical!  
3-3 Connecting Compressed Air  
Connect compressed air to the dryer before operation.  
Caution!  
Excessive air pressure damages the neoprene components of the  
air distribution valve.  
Connect the air supply, using a ¼” NPT fitting, to a clean, dry, lightly lubricated source of 80 psi  
(551 kPa/5.51 bars) compressed air. A pressure gauge and regulator are recommended  
components of your plant air supply.  
The compressed air indicator switch prevents the dryer from starting without an 80 psi (551  
kPa/5.51 bars) air supply. If the air supply drops to below 60 psi (413 kPa/ 4.13bars) during  
operation, the dryer shuts down until at least 80 psi (551 kPa/5.51 bars) is restored.  
3-4 Checking for Proper Blower Rotation  
Three-Phase Models  
The blower rotates properly when air flows from the delivery outlet and a vacuum is felt on the  
blower inlet.  
Caution!  
In three-phase models, incorrect phasing of power leads can cause  
backward rotation of blower motors and CONTAMINATION OF  
THE DESICCANT! Always check blower rotation before putting  
material in the drying hopper!  
If the three-phase blower rotates improperly, reverse any two wires at the fused disconnect  
outside the dryer or at the disconnect/terminal in the control enclosure. This assures that the  
blower rotates in the proper direction.  
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3-5 Process Air Connections Between the Dryer and Drying Hopper  
; Remove the cap plugs from the inlet, discharge and bleed tubes before operation.  
; Use high-temperature flexible dryer hose to connect the dryer to the drying hopper.  
; Keep the delivery hose as short as possible to minimize heat loss. Insulated dryer hose is  
available for maximum energy savings.  
; Do not shorten the return hose.  
; Make sure the hoses are not kinked.  
; Drying hopper air inlet and outlet locations vary from one drying hopper model to  
another, 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.  
3-6 Connecting Cooling Water to the Optional Aftercooler  
High temperature applications (300°F to 400°F / 148°C to 204°C) require aftercoolers to cool  
moist air returning to the dryer from the drying hopper. An aftercooler cools the return air by  
100°F (38°C); this maintains dryer efficiency and condenses unwanted plasticizers from the  
airstream. Aftercoolers are also required in extremely low temperature applications.  
Installing Water Lines  
•
Use the ½” (about 13 mm) brass pipe nipples for water line connections. Inlet  
and outlet line positions do not matter.  
•
Make sure you grip the nipple tightly when attaching a fitting. Doing so prevents  
damage to the soft copper coils. You should make connections with flexible hose  
to allow removing the coil assembly for cleaning.  
•
The aftercooler is designed to utilize either tower or city water as warm as 85ºF  
(29ºC). Recommended flow rate is one to three (1 to 3) gallons per minute (4 to  
11 liters per minute).  
3-7 Drying Hopper  
Removing the Rust Inhibitor  
Rust preventative has been applied to internal unfinished surfaces. Remove rust inhibitor before  
using the drying hopper.  
Using a non-water based degreasing agent, clean all inside surfaces of the drying hopper. Allow  
components to dry thoroughly.  
Inspect the inside of the drying hopper for loose connections, foreign objects, or a blocked  
diffuser.  
Air Trap Considerations  
The air trap assembly in the top of the drying hopper prevents ambient air from contaminating the  
material being dried.  
; Keep the material level at the mid point of the air trap for maximum efficiency.  
; Use a hopper loader or vacuum conveying system to maintain the proper material level.  
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Chapter 4: Controls  
4-1 Control Panel Indicator Lights and Switches  
Rocker Switches  
System ON/OFF Rocker Switch  
Used to de-energize control power to the indicator panel, allowing separate control of the dryer  
and conveying systems.  
Dryer ON/Sequence Shutdown Rocker Switch  
Used to start the dryer. Move this switch to the Sequence Shutdown position to turn off the  
process heaters, finish the regeneration cycle and then turn off the dryer.  
Optional Alarm Silence Rocker Switch  
Press the Alarm Silence switch to silence the horn when a high temperature alarm activates.  
The alarm repeats every five minutes until the problem causing the alarm condition is cleared.  
Indicating Lights  
Indicator  
Name  
Description  
Regen Blower  
On Light  
The Regen Blower On indicator lights when the  
regeneration blower energizes.  
G
Left Bed In  
Regen Light  
The Left Bed In Regen LED lights when the left bed  
is in regeneration.  
G
Left Bed Heater  
Light  
The Left Bed Heater indicator lights when the left  
bed regenerates and is in the heat-up portion of the  
regeneration cycle.  
G
Right Bed In  
Regen Light  
The Right Bed In Regen LED lights when the right  
bed is in regeneration.  
G
Right Bed Heater The Right Bed Heater indicator lights when the right  
Light  
bed regenerates and is in the heat-up portion of the  
regeneration cycle.  
G
Process Blower  
On Light  
The Process Blower On indicator lights when the  
process blower energizes.  
G
Process Heater  
On Light  
The Process Heater On indicator lights when the  
process air heater is energized.  
G
Low Compressed The Low Compressed Air alarm indicator lights  
Air Light  
when the dryer compressed air supply drops below  
60 psi (413kPa/ 4.13 bars). Upon loss of  
R
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Indicator  
Name  
Description  
compressed air, the pressure switch opens and sends  
a signal to the PLC controller to shut down dryer  
operation. Dryer operation automatically resumes  
when 80 psi (551 kPa/ 5.51 bars) air is restored.  
High Temp  
The High Temp Process Air alarm indicator lights  
Process Air Light when the temperature at the process air  
thermocouple is above the high alarm set value.  
Upon high temperature alarm condition the process  
heaters turn off, the process blower remain on.  
The alarm mode and value are factory-set to track  
25º above the process set point. The alarm value is  
an upper-limit deviation above the process set point.  
When the temperature at the process thermocouple  
returns to within the acceptable range, the alarm  
output de-energizes and all heaters turn on again  
automatically.  
R
High Temp  
Regen Air Light  
The High Temperature Regen Air alarm indicator  
lights when the thermostat above the regeneration  
heater assembly senses an abnormally high  
temperature.  
The regeneration heaters shut down until the  
temperature falls below the alarm point. The  
regeneration blower continues to run for cooling the  
heaters and desiccant bed. The alarm condition  
clears when the temperature drops below the  
thermostat setpoint. The heaters re-energize  
automatically.  
R
High Dew Point  
Light  
The High Dew Point alarm indicator lights when the  
process air delivery dew point exceeds a dew point  
of -10°F (-23°C).  
A
Material Loading The Material Loading indicator lights when material  
G
Light  
is being conveyed.  
Optional Dirty  
Filter Light  
If installed, the Dirty Filter alarm indicator lights  
when the pressure differential across the process,  
regeneration and conveying air return filter exceeds  
the pressure switch setting. Service the filter when  
this indicator lights. The indicator and the alarm  
condition clears after you service and reinstall the  
filter.  
A
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Figure 2-Typical Dyer Interface Panel  
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4-2 Process Air Dew Point Display  
The Dew Point display indicates the current process air delivery moisture content. The display  
uses a microprocessor-based controller for reading dew point air temperature. The controller is a  
modular, self-contained removable unit in the mounting housing. All parameters are factory-set  
and adjusted; no field adjustment to the internal controls is necessary. The high dew point alarm  
is also factory adjusted.  
4-3 Process Air Temperature Controller  
Our dehumidifying dryers use a microprocessor-based PID temperature controller for maintaining  
process air temperature. The controller is a modular, self-contained unit you can remove from the  
mounting housing. All parameters except for the process air set point is factory set and adjusted;  
no field adjustment to the internal controls is necessary.  
4-4 Identifying Temperature Controller LED Indicators  
LED  
Description  
Indicator  
Process Value  
Numerical  
LED  
During normal operation, the process value (PV)  
numeric LED indicator displays the process  
temperature at the To Process thermocouple. It  
also lists parameters during setup and error  
messages if any errors occur.  
Set Value  
Numeric LED  
During normal operation, the set value (SV)  
numeric LED indicator displays the process set  
point you selected for the dryer. The dryer then  
maintains this set point temperature. This LED  
indicator also displays parameter and pre-set  
function values during setup.  
Lit when control output 1 turns on. The Out  
indicator lights when the controller signals the  
process heaters to be energized.  
OUT1  
Lit when control output 2 turns on. Not used in  
this application.  
OUT2  
Lit when the manual operation mode is being  
used.  
MANU  
Lit when control operation has been stopped. Not  
used in this application.  
STOP  
RMT  
Lit during remote operation. Not used in this  
application.  
Flashes during auto-tuning.  
AT  
Lit when the output function assigned to auxiliary  
output 1 turns on.  
SUB1  
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4-5 Identifying Temperature Controller Buttons  
Display Button  
This button shifts the display to the next set of parameters. Then, the menu screen displays.  
Down Arrow Button  
The Down Arrow button lets you lower the process air set point temperature. During setup, it lets  
you decrease the value of the parameter displayed on the set point LED readout.  
Up Arrow Button  
The Up Arrow button lets you raise the process air set point temperature. During setup, it lets you  
increase the value of the parameter displayed on the set point LED readout.  
AT  
Auto-Tune Button  
Hold down for two seconds to initiate auto-tune. Repeat to cancel.  
Figure 3:  
Typical Dryer Temperature Controller  
PV  
SV  
OUT1  
OUT2 MANU STOP RMT AT  
SUB1  
AT  
E5CK  
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E5CK Operating Parameters  
The E5CK has several mode selections. Within each mode are numerous parameters that can be  
set. The setting is different for the temperature control unit and the dew point display.  
Before you can access the several modes of operating parameters, you must change the security  
lock-out of the controller. The factory sets the security level to protect the parameters from being  
accidentally changed. Below is an explanation of the operating modes, how to change out the  
security level and the factory default settings.  
Available E5CK Modes  
Menu Display  
Level 0 Mode  
For normal operation. Execute AT auto-tuning, change to manual mode.  
Level 1 Mode  
For adjusting primary control parameters. Execute: Set alarm values; set the control period; set  
PID parameters.  
Level 2 Mode  
For adjusting secondary control parameters. The dehumidifying dryer uses E5CK default settings.  
Setup Mode  
For setting the basic specifications. Set parameters for input type, scaling, output assignments and  
direct/reverse operation.  
Expansion Mode  
For setting expanded functions. Set: ST (self-tuning), SP setting limiter. Select: advance PID or  
ON/OFF control.  
Option Mode  
This mode is only accessible when and option board is installed.  
Calibration Mode  
For calibrating communication unit E53-CKF. Not used.  
Manual Mode  
Sets the controller to manual operation mode. Not used on dehumidifying dryers.  
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Figure 4:  
Display Readout for Mode Settings  
PV  
Menu display  
SV  
Level 0 mode  
SV  
SV  
SV  
SV  
SV  
Level 1 mode  
Level 2 mode  
Setup mode  
Expansion mode  
Option mode  
SV  
Calibration mode  
4-6 Setting the Process Air Temperature  
To change the process air temperature set point with the dryer running:  
„ Press the Up Arrow button to increase the set point to the temperature you want.  
„ Press the Down Arrow button to lower the set point to the temperature you want.  
„ Press the Auto-tune button to initiate auto-tuning.  
4-7 PLC Controller  
The PLC controller uses an Allen-Bradley programmable logic controller (PLC). This “brick”-  
type controller has 32 I/O points: twenty (20) inputs and twelve (12) outputs, all inputs and  
outputs are 115 VAC.  
All programming and logic is factory-installed on an EEPROM chip and cannot be modified. A  
battery backup retains programming if power fails. Battery life is five (5) years at room  
temperature.  
If the alarm indicator blinks intermittently, replace the battery within one week.  
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PLC LED Indicators  
The following indicators are located inside the dryer cabinet. See Figures 5, 6, and 7.  
Name  
Description  
System  
Start/Sequence  
Shutdown (I/0)  
When ON, activates the operation of the dryer  
portion.  
Compressed Air  
Input (I/1)  
Process Blower  
When ON, confirms that compressed air is present.  
When ON, Confirms the operation of the process  
blower.  
Enable (I/2)  
Bed Switch Set  
Point Input (I/4)  
When ON, indicates that dewpoint is above bed  
switching set point.  
High Regen  
Temp Alarm,  
Right Bed (I/5)  
When OFF, indicates a situation of a temperature  
exceeding the set level in the right regen bed.  
When OFF, indicates a situation of a temperature  
exceeding the set level in the right regen bed.  
High Regen  
Temp Alarm,  
Left Bed (I/6)  
Compressed Air  
Alarm Input (I/7)  
When ON, it indicates loss of compressed air.  
When ON, sends the information to the PLC to be  
High Process  
Temp Alarm (I/8) used later in forming alarm procedure.  
Push To Silence  
(I/9) (Optional)  
When the existing rocker switch is pressed, the  
audible horn will be silenced and flashing strobe  
will be turned off. Also, it serves as an alarm  
acknowledgment.  
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Output LED Indicators  
Name  
Description  
Blower On (O/0) The Blower On indicator lights when the blower  
energizes.  
Process Heater  
Enable (O/2)  
The Process Heater Enable activates the process  
heater. The indicator lights when the process heater  
is energized. This condition occurs when no blower  
failures or high temperature conditions exist.  
Left/Right Regen The Regen Heater Output indicator lights when the  
Heater Output  
(O/3, O/4)  
indicated bed regeneration heater energizes.  
Right Bed  
Regeneration  
Output (O/5)  
The right Bed Regeneration Output activates the  
right bed regeneration indicator lights when the  
right bed regenerates. When this indicator is off, the  
left bed is energized.  
High Regen  
Temp Alarm  
(O/6)  
When ON, indicates a high regen temp condition in  
either the left or right bed.  
Alarm Horn  
Output (O/7)  
Optional  
The Alarm Horn Strobe Output indicates a high  
process temperature condition and optional critical  
low level at the drying hopper.  
Status LED Indicators  
Name  
Description  
Power  
The Power indicator lights when the PLC receives  
115V control power.  
Run  
The Run indicator lights when the PLC executes the  
program in normal conditions.  
Fault  
Force  
The Fault indicator lights when the PLC program  
has a problem or failure condition.  
The Force indicator is not used.  
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Figure 5:  
Typical Subpanel Layout  
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Figure 6:  
Typical Cabinet Dryer Electrical Schematic, Drawing 1  
\
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Figure 6:  
Typical Cabinet Dryer Electrical Schematic, Drawing 2  
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4-8 Setting the Shift on Dew Point  
Our dehumidifying dryers shift air flow from the on-line desiccant bed to the regenerated  
desiccant bed, based on actual dew point demand, not fixed time cycles. After the off-line bed  
regenerates, the PLC controller waits for a high dew point signal from the process air dew point  
controller before switching beds. The PLC controller has a four (4) -hour timer override if it does  
not receive a signal from the dew point control.  
„ Set the shift on dew point set point to the highest process air moisture content you  
want to allow before the dryer shifts air flow to the regenerated desiccant bed. The  
dew point controller is set at the factory for -20ºF (-29ºC).  
„ To change the dew point setting, press the Up Arrow and Down Arrow buttons to the  
shift point you want.  
4-9 Entering Operating Parameters to Select Modes  
To enter the menu display:  
1. Press the Display button for one second (keep the pressure on the button for about 1.5 to 2  
seconds).  
The screen displays  
.
2. Press the Up Arrow button to toggle through the different modes.  
The SV readout displays the mode you selected.  
3. To switch parameters within a mode, press the Display button once more for about one and a half  
to two (1.5 to 2) seconds.  
The PV readout displays the different parameters within each mode.  
4. Use short presses on the Display button to display each parameter within a mode.  
The SV readout displays the different values for the parameter within a mode.  
5. Press Up Arrow and Down Arrow buttons to set the higher or lower the values of a parameter.  
6. Press Display button for about one and a half to two (1.5 to 2) seconds to move up a level back  
into the different modes.  
7. Press Down Arrow button until Level 0 displays. Press the Display button for about one to one  
and a half (1 to 1.5) seconds to go to Operating mode.  
4-10 Setting the High Dew Point Alarm  
The high dew point alarm is factory set for -10ºF (-23ºC). The high dew point alarm will energize  
the “High Dew Point” light. Entering the Level 1 operating parameter changes the high dew point  
alarm setting. Use the following procedure to set the high dew point alarm:  
1. Press and hold the Display button to access Level 0. The controller displays Level 0.  
2. Press Up Arrow button to display Level 1. Lu-1 displays.  
3. Press the Display button to select Level 1.  
4. Press the Display button until the controller displays AL-1.  
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5. Use the Up and Down Arrow buttons to set the higher or lower value for the high dew point  
alarm. Hold the Display button to save the value and return to Level One.  
6. Press the Down Arrow button until the controller displays Level 0.  
7. Press and hold the Display button to return to Operating mode.  
Note: The E5CK controller has several levels of securities to lock out access to parameters and menu  
settings. If the controller will not allow you to change settings, see Section 6-8 on Page 60 to  
set the E5CK security to access the function you need.  
4-11 Optional Seven Day Timer  
The seven-day timer can be programmed for daily or weekly (over midnight) on/off operation.  
An internal battery back up holds the settings in memory when the dryer is de-energized.  
Timer  
SUN MON TUE WED THU FRI SAT  
SHIFT  
(16) Timing chart display  
DAY  
(1) SHIFT key  
SET/RESET  
(2) SET/RESET key  
PM  
h
(15) Output indicator  
(3) h key  
1
1
AM  
m
PM  
OUT  
PROG  
(4) m key  
(5) CHECK key  
(12) OUT switch  
1
OUT  
ON  
AUTO  
OFF  
2
CHECK  
WRITE  
(6) WRITE key  
P1  
P2  
(11) MODE switch  
(7) TIME ADJ key  
TIME ADJ  
RUN  
TIMER 1 2 MAN  
MODE  
CYCLE/PULSE COPY  
CLR  
BOOT  
(10) CLR key  
PULSE 1 2 AUTO  
(9) COPY key  
(8) CYCLE/PULSE key  
(14) MAN/AUTO RESET switch  
(13) TIMER/PULSE switch  
Display  
Cursor  
SUN MON TUE WED THU FRI SAT  
Day indicator  
Main display  
Time adjustment  
mode indicator  
AM  
PM  
S
m
Pulse width indicator  
Indicator for number  
of remaining steps  
Set circuit  
Power failure indicator  
Output circuit indicator  
1
2
1
2
AM  
PM  
AM  
PM  
S
m
Timing chart display  
number indicator  
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No. Function  
1
2
Shifts the cursor (∇) specifying a day to the right.  
Sets or cancels (reset) a specified day.  
3, 4 Sets a time or ON/OFF time width. (hours, minutes)  
5
6
Monitors the parameters set for an operation during an operation.  
Sets parameters. (Write)  
7
Sets a time adjustment mode.  
8
9
Specifies a cyclic operation, or sets a pulse width. (Not used)  
Specifies a day substitution operation. (Copy)  
10  
Cancels the parameters set for each circuit, or a day substitution operation.  
P1:  
P2:  
Run:  
Circuit 1 programming mode.  
Circuit 2 programming mode.  
Run mode.  
11  
ON:  
Turns on the output regardless of the program  
12  
13  
AUTO: Executes according to the program.  
OFF: Turns off the output regardless of the program.  
TIMER: Executes an ordinary timer or cyclic operation.  
PULSE: Executes a pulse-output operation.  
14  
15  
16  
Specifies automatic or manual operation following a power failure.  
The Output indicator will light when the timer output is energized. (Dryer On)  
Displays the time at which the next operation will be preformed.  
Note: For timer operation, the System Power rocker switch must be in the ON position and the  
Dryer/on Sequence Shutdown rocker switch must be in the SEQUENCE SHUTDOWN  
position.  
•
•
The OUT switch (#12) should be set to AUTO.  
The P1-P2 RUN mode switch (#11) should be set to RUN for normal 7-day timer operation, set to  
P1 for changing times; P2 is not used. Open the front cover; the MODE switch (#13) must have  
Mode 1 set to TIMER (up); 2 is not used, BOOT (#14) is set to AUTO (down).  
•
Program 1 is operational; Program 2 is not used.  
Note: To bypass the 7-day timer operation, turn the 7-day timer OUT switch (#12) to off. Turn the  
Dryer/On Sequence Shutdown rocker switch located on the dryer control panel to DRYER  
ON.  
Programming the Optional Timer  
Setting the Current Day of the Week, Hour, and Minute  
1. Apply main power to the dryer.  
2. The 7-Day timer MODE selector switch (#11) should be in the RUN position.  
3. Hold the TIME ADJ key (#7) for 1 second or longer.  
4. Press the SHIFT key (#1) to move the cursor (∇) to the desired day position. Holding down this  
key advances the day.  
5. Press the SET key (#2). The bar mark will turn on under the chosen day.  
6. Press the h key (#3) to adjust the hours. Holding the key will rapidly advance the hour.  
7. Press the m key (#4) to adjust the minutes.  
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8. Press the WRITE key (#6) to store the correct time.  
9. The time and day can be adjusted or changed while the timer is operating.  
Daily Timer Operation  
Daily time is typically set to operate from 8:00 AM and to stop at 5:00 PM from Monday through Friday.  
1. Set the MODE switch (#11) to P1.  
2. Press the SHIFT key (#1) to move the cursor to the desired day of the week. Or select several  
days at once by using the SHIFT (#1) and SET keys (#2). The bar mark will turn on under the  
chosen days.  
3. Press the SET key (#2).  
4. Set the desired start time by pressing the h key (#3) to adjust the hour. Holding this key will  
rapidly advance the hour.  
5. Press the m key (#4) to adjust the minutes.  
6. Press the WRITE key (#6) to store the start time in the timer memory.  
7. Next, set the stop time by using the h and m keys, then press WRITE.  
8. Turn the MODE switch (#11) to run.  
Multiple-Day Operation  
Multiple day operation will start the dryer on one day and run continuously for several days before  
stopping the dryer.  
1. Turn the MODE switch (#11) to P1.  
2. Select the desired start day with the SHIFT (#1) and SET keys (#2).  
3. Set the start time with the h and m keys.  
4. Press the WRITE key (#6) to store the dryer startup hour in the timer memory.  
5. Next cancel the day that was just set by using the RESET key (#2).  
6. Now select the stop day by using the SHIFT (#1) and SET key (#2).  
7. Set the stop time with the h and m keys.  
8. Press the WRITE key (#6).  
9. Turn the MODE switch (#11) to RUN.  
Checking the Set Time  
The set times can be checked in the sequence the timer is to operate.  
1. Press the CHECK key (#5). Each time the key is pressed the operation schedule is displayed in  
the time sequence.  
2. If the time switch is left untouched for 20 seconds during check, the display automatically returns  
to RUN mode.  
If a holiday occurs during the weekly operation, the off time for Sunday can be executed for the holidays.  
The override will execute for one week only, then the timer will automatically go back to the previous  
program.  
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1. Hold the COPY key (#9) for one (1) second or longer. Make sure that the mode selector switch  
is in RUN mode.  
2. Select the day(s) you want with the SHIFT (#1) and SET keys (#2). If a previous override had  
been set, this will show up when you first hold the COPY key. To clear a previous override,  
press the CLR key (#10).  
3. Press the WRITE key (#6).  
4. Select Sunday (or another shutdown day) with the SHIFT (#1) and SET keys (#2).  
5. Press the WRITE key (#6).  
Day Override  
If a holiday occurs during the weekly operation, the off time for Sunday can be executed for the holidays.  
The override will execute for one week only, then the timer will automatically go back to the previous  
program.  
1. Hold the COPY key (#9) for one (1) second or longer. Make sure that the mode selector switch  
is in RUN mode.  
2. Select the day(s) you want with the SHIFT (#1) and SET keys (#2). If a previous override had  
been set, this will show up when you first hold the COPY key. To clear a previous override,  
press the CLR key (#10).  
3. Press the WRITE key (#6).  
4. Select Sunday (or another shutdown day) with the SHIFT (#1) and SET keys (#2).  
5. Press the WRITE key (#6).  
Canceling the Settings  
All the operations can be cancelled.  
1. Set MODE selector switch (#11) to P1.  
2. Press the CLR key (#10).  
Note: The 7-day timer cycle and pulse output are not used for dryer applications.  
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Chapter 5: Operation  
5-1 Pre-Startup Checks  
1. Verify that the drying hopper is clean of rust-prohibitive oil or any foreign objects.  
2. Verify that process and return hose connections are tight.  
3. If your dryer has a water-cooled aftercooler, make sure that sufficient cooling water flows  
properly through the coil and that you have bled any trapped air from the system. Make sure that  
the aftercooler has the proper supply water temperature.  
4. Check all companion equipment, such as the sight glass loader and drying hopper loader; verify  
that all convey tubing is in place and the loading system is ready for operation.  
5. Verify that all electrical connection are tight and the unit is properly grounded.  
6. With main power on, turn the dryer on until the process blower starts, verify blower rotation.  
Important!  
Clean the rust-preventing oil from inside the drying hopper.  
Failure to clean the hopper fouls the desiccant and voids your  
warranty!  
5-2 Startup  
1. Turn on (energize) the disconnect switch in your power drop.  
2. Turn the system ON/OFF switch to ON to energize the display panel.  
3. Close the slidegate at the bottom of the drying hopper.  
4. On three-phase models, make sure that the blowers turn in the right direction.  
5. Fill the drying hopper with material.  
6. Turn the DRYER ON/SEQUENCE SHUTDOWN switch to ON to start the dryer.  
7. The process blower will start.  
8. Set the process set point on the temperature controller to the recommend drying temperature  
provided by the resin manufacturer. Press and hold the Auto-Tune key on the process temperature  
controller for two (2) seconds to initiate the auto-tune function.  
9. 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, maintain the  
material level in the hopper at the midpoint of the air trap assembly.  
5-3 Shutdown  
1. Turn off the conveying system supplying the drying hopper.  
2. When processing is complete, close the hopper slide gate and shut down any in-line companion  
equipment, such as the aftercooler.  
3. Turn the dryer ON/OFF selector switch to the SEQUENCE SHUTDOWN position. The  
sequence shutdown operation turns off process heaters and keeps the process blower on for  
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twenty minutes to cool down the process. The regeneration cycle of the off-line bed completes the  
cycle before the dryer shuts down completely.  
4. To override the sequence shutdown turn the system ON/OFF switch to OFF.  
5. To completely shut off the unit after sequence shutdown has completed, turn the system ON/OFF  
switch to OFF.  
6. If needed, empty the drying hopper.  
7. For maintenance or a long term shutdown, open (de-energize) the electrical disconnects at the  
dryer and at the power drop.  
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Chapter 6: Maintenance  
6-1 Work Rules  
The installation, operation, and maintenance of this equipment is to be conducted in accordance  
with all applicable work and safety codes for the installation location. This may include, but is not  
limited to, OSHA, NEC, CSA, and any other local, national, and international regulations.  
In addition, you must observe the following specific work rules:  
; Keep these operating instructions on hand and follow them when installing, operating, or  
maintaining your dryer.  
; If these instructions become damaged or unreadable, you can obtain additional copies  
from the manufacturer.  
; Only qualified personnel familiar with this equipment should work on or with this unit.  
; Work only with approved tools and devices.  
Disconnect power before servicing your dryer. If the disconnect switch you installed has a lockout, lock it  
in the OFF position before you perform any maintenance or service.  
6-2 Servicing Process Air Filters  
Important!  
Operating the dryer without the process air filter installed voids your  
warranty! Filter cleaning is an important part of your dryer maintenance  
program.  
Our dehumidifying dryers have a single cartridge canister-type filter in the process and conveying  
air loop. The process filter is mounted above the process blower on the rear of the dryer. The  
conveying filters are located under the drying hopper next to the conveying blowers. These filters  
protect the blowers from plastic fines drawn in from the drying hopper. Regular filter cleaning is  
essential to keep your dryer operating at peak efficiency.  
You can wash or blow out the filters, but remember, you reduce dirt holding capacity with each  
washing. The risk of dirt reaching the clean side of the filter during cleaning, plus possible filter  
damage from high pressure washing or blowing, makes washing a gamble.  
You can carefully clean or wash the filter when airflow becomes restricted. Do not wash filters  
more than six (6) times or use them for more than a year, whichever comes first.  
Use a detergent that won’t damage filter media. Such a detergent permits easy removal of dirt  
particles through flushing and rinsing. An effective detergent removes the fine particles from the  
pores of the filter media.  
The filter manufacturer recommends FM 1400 washing compound. It is formulated specifically  
for air filter element cleaning. It is non-sudsing and works in hot or cold water. FM 1400 contains  
biodegradable synthetic detergents and is non-phosphate, non-NTA. For more information,  
contact Filter Service Corporation, 2603 A West Main, Farmington, NM, 1-505-326-1127.  
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Recommendations for Cleaning and Replacing Filters  
•
•
Turn off and/or lock out electrical power to the dryer.  
Remove the threaded fastener securing the filter access cover, and then remove the  
cover.  
•
Remove the nut on the center retaining rod to remove the filter cartridge.  
Vacuuming  
Try vacuum-cleaning a soiled filter first. Vacuuming removes most large particles and surface  
contaminants, and may suffice for the first time you clean a filter. Use a commercial-duty (recommended)  
or household vacuum cleaner. Vacuum the filter from the air intake (dirty) side only.  
Cleaning with Compressed Air  
Blow clean, dry compressed air up and down the pleats, blowing out the filter from the clean  
side. Remove loose dirt from the filter with compressed air or a water hose. Compressed air  
1
should be less than 100 psi (689.5 kPa/6.89 bars). Use a /8”  
(3 mm) dia. nozzle at least 2” (5 cm) away from the filter. Don’t shoot the air in a crisscross motion  
against the grain of the pleats—you may damage it.  
Washing  
As a last resort, wash the filter. However, do so only if the pressure drop is too high  
from fine dirt embedded in the filter, or if oily mist is present near the intake air  
location. Soak in a solution of FM 1400 or comparable detergent and warm water from  
five to ten minutes, then gently agitate for several minutes.  
Rinse thoroughly with clean water to remove all detergent.  
Caution!  
Let the filter dry completely before returning it to service! A damp filter  
can contaminate the closed loop system of the dryer.  
Do not use a light bulb to dry the filter. You should get satisfactory filtration after second or third  
washings; however, dirt-holding capacity of the filter decreases after each washing.  
After each cleaning:  
•
Inspect the filter element. Briefly hold a light bulb behind the element and  
look for any fatigued paper or residual dirt. Inspect for holes and tears by  
looking though the filter toward a bright light. Check for damaged gaskets  
or dented metal parts. Do not re-use a damaged filter!  
•
•
Inspect the end plates. Any damage here can allow air to bypass the filter.  
Look for rust on the end plates and metal core. Rust particles can flake off and  
contaminate the dryer and resin.  
•
•
Check the gasket for damage. A damaged gasket allows contaminants into the  
process. Replace as needed.  
Allow the filter to dry before re-using. Circulate warm air at less than 160ºF (71ºC).  
Do not use a light bulb to dry the filter.  
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Preventative Maintenance Checklist  
Dehumidifying Dryer Systems  
System model #  
Every week  
Serial #  
Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/  
By By By By By By By By By By By By By  
Inspect all filters for  
wear, replace/clean  
if dirty or worn.  
Check air regulator  
to make sure pres-  
sure is 60-80 psi  
(413.7 to 551.6 kPa  
/4.1 to 5.5 bars). (If  
applicable)  
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.  
Scheduled  
replacement date  
Actual replacement  
Date/Work done by  
Scheduled  
replacement date  
Actual replacement  
Date/Work done by  
Every two years  
Replace desiccant.  
- Photocopy this page for your maintenance records -  
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6-3 Servicing the Dew Point Monitor  
The accuracy of the dew point monitor on dehumidifying dryer systems depends on proper  
operation of the dew point sensor and the control board. The dew point sensor is in the process air  
stream and is therefore susceptible to contamination.  
Dew point sensor life depends on:  
Air temperature and flow passing over the sensor.  
The amount of fines (dust) in the process air.  
The amount of plasticizer vapor in the process air.  
The dryer operator should monitor the initial dew point sensor readings and establish a periodic  
replacement schedule as needed.  
Caution!  
Do not attempt to check the continuity or resistance of the dew point  
sensor. The sensor will be destroyed!  
6-4 Symptoms of Worn Desiccant  
The moisture absorption capacity of the desiccant used in your dehumidifying dryer 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 dehumidifying dryer may need new desiccant if it exhibits any of the following symptoms:  
•
•
Plastic material is not being dried sufficiently (high scrap/reject rate).  
Air temperature at the top of the regenerating desiccant bed rapidly climbs to 350°F  
(177ºC) or more shortly after the start of regeneration, even though a saturated bed  
has just started heating.  
•
The process air dew point measured with a portable dew point monitor is higher than  
-10°F (-23ºC) throughout the process drying cycle.  
•
•
Smoke or dust blows out of the process air outlet.  
Noticeable amounts of desiccant in the beds is a medium-brown color or darker.  
If you notice any of these signs, replace the desiccant in the desiccant beds. Desiccant  
replacement kits are available from the manufacturer’s parts department. If you want, a service  
technician can repack desiccant beds at your site.  
WARNING!  
Desiccant material causes eye irritation!  
Breathing may be harmful and may cause skin irritation!  
• Do not get in eyes.  
• Avoid prolonged contact with skin.  
• Use with adequate ventilation.  
• Wash thoroughly after handling.  
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First Aid:  
In case of eye contact, immediately flush eyes with plenty of water for at least 15  
minutes. If irritation persists, see a physician.  
6-5 Replacing Worn Desiccant  
Caution!  
Make sure desiccant beds are sufficiently cool before replacing worn  
desiccant.  
1. Disconnect the electrical and compressed air supply.  
2. Remove the rear and side shrouds to expose the desiccant beds.  
3. Free the bed covers by removing the hex nuts on the retaining rods and remove the upper screens  
from both beds.  
4. Remove the desiccant in one of the following ways:  
• Vacuum out the desiccant.  
• Remove the entire bed from the frame and dump it out. To do this, remove the hose  
connections, unclamp the beds, and unbolt from the regen heater assembly.  
Make sure the bed interiors are clean.  
Important!  
You should properly dispose of any discarded desiccant.  
Consult local disposal regulations for more information.  
Before re-packing the beds, determine the proper amount of desiccant for the dryer being  
serviced. See Figure 14 on the following page for more information. Pre-measured desiccant kits  
are available from the manufacturer’s parts department.  
Attach the beds to the frame for Steps 5 through 9.  
5. Carefully place half of the large bead in the bottom of the beds, in an even layer, on the  
bottom screen. Place the small bead on top of it, in an even layer. Carefully place an  
even layer of the remaining large beads over the small beads.  
6. Install the top screen, making sure that the edge is in contact with the sides of the bed all  
the way around. Install the washers and nuts and tighten down. Gently tap the around the  
sides of the desiccant canister with a rubber mallet to settle the desiccant. As settling  
occurs, re-tighten the nuts. Repeat the tapping and tightening process until little  
additional settling occurs.  
7. Install the covers and gaskets on the beds, making sure they are tight and sealed. Replace  
desiccant bed gasket if necessary.  
8. Re-connect any hoses that were disconnected.  
9. Re-install the rear and side shrouds. Re-connect the compressed air supply and electrical  
power.  
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Figure 7:  
Required Desiccant Amounts per Bed; Type 4X Desiccant (2 beds per unit)  
Dryer  
CFM  
90  
100  
150  
225  
Large bead (Type 4X)  
Small bead (Type 4X)  
Total per bed  
Part no.  
lbs.  
3.0  
3.0  
9.0  
9.0  
Kg  
Part no.  
lbs.  
21.0  
21.0  
Kg  
9.534  
9.534  
lbs.  
24.0  
24.0  
39.0  
39.0  
Kg  
1.362  
1.362  
4.086  
4.086  
10.896  
10.896  
17.706  
17.706  
W00000892  
W00000893  
30.0 13.620  
30.0 13.620  
Type 13X Desiccant  
Dryer  
CFM  
90  
100  
150  
225  
Large bead (Type 13X) Small bead (Type 13X)  
Total per bed  
Part no.  
lbs.  
3.0  
3.0  
9.0  
9.0  
Kg  
Part no.  
lbs.  
21.0  
21.0  
Kg  
lbs.  
24.0  
24.0  
39.0  
39.0  
Kg  
1.362  
1.362  
4.086  
4.086  
9.534  
9.534  
30.0 13.620  
30.0 13.620  
10.896  
10.896  
17.706  
17.706  
W00018050  
W00018051  
6-6 Replacing the Process Heater  
Our dehumidifying dryers use Calrod-type heater elements mounted in a heater tube located in  
the top rear of the cabinet. The wattage of the heater varies with model, voltage, temperature  
range, etc., but the replacement procedure is the same.  
If the process heater is mounted to the hopper, contact the manufacturer for the appropriate  
replacement procedure.  
WARNING!  
Disconnect and lock out power before you replace heater elements!  
Use the following procedure to replace the process heater:  
1. Remove the bolts securing the process heater access cover.  
2. Sketch the heater wiring configuration so you can properly re-wire the heater.  
3. Remove the wires to the heater plate assembly being removed or replaced.  
4. Remove the bolts securing the heater plate assembly, and slide out the assembly.  
5. Remove the heater from the mounting plate by removing the large brass nuts and  
washers.  
6. Re-install the heater and heater plate assemblies in reverse order. Install new heater  
gaskets and securely tighten all fasteners.  
Caution!  
Heater loops should not touch each other. “Hot Spots” lead to premature  
heater failure!  
7. Reinstall the wires based on the sketch you made earlier.  
8. Secure the heater access cover.  
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6-7 Replacing the Regeneration Heater  
The dehumidifying dryers use heater elements located below each desiccant bed.  
WARNING!  
Disconnect and lock out power before you replace heater elements!  
1. Remove the cover plate secured by bolts.  
2. Sketch the heater wiring configuration so you can properly re-assemble the heaters.  
3. Remove the wiring for the heater being removed or replaced.  
4. Remove the bolts securing each heater mounting plate. Slide out the heater.  
5. Re-install the new heaters in reverse order. Install new heater gaskets and securely  
tighten all fasteners.  
Caution!  
Heater loops should not touch each other. “Hot Spots” lead to premature  
heater failure!  
6. Re-install the wiring based on the sketch you made earlier.  
7. Secure the heater access cover.  
Changing the Controller Security Level  
1. To access protect mode, press and hold the AT button and the Display button for more than one  
and a half to two (1.5 to 2) seconds.  
2. The display should read SECr for security mode. If you press the Display button for short  
presses you will toggle between (SECr) and (KEYP) for AT protect.  
3. With the display reading SECr, set the security levels by the arrow up and down keys. Change  
the security level to 1 to make changes to the operating parameters. The temperature controller is  
factory set to Security Level 5, the dew point indicator is factory set to Security Level 3.  
Available Security Levels  
Security level  
Mode  
Calibration  
Option  
Expansion  
Setup  
Level 2  
Level 1  
Level 0  
0
X
X
X
X
X
X
X
1
2
3
4
5
6
X
X
X
X
X
X
X
X
X
X
X
X
X
Any mode marked with an X is displayed in the Security  
Level indicated. To return to the main display (run mode),  
press and hold the AT and display key for 1.5 to 2 seconds.  
Restoring Factory Defaults on the Process Temperature Controller  
1. Remove controller from housing and check for output board number E53-QR4R (Pulse  
NPN/Relay).  
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2. Make sure jumper setting for input type is set for thermocouple TC-PT, middle jumper.  
3. Return controller to housing.  
4. Press the Display button for one (1) second to enter Menu Display.  
5. Press the Up Arrow button to get to Setup mode.  
6. To switch parameters within Setup mode, press the Display button.  
Figure 8:  
Setting List for Process Temperature Controller, Part No. A0548565  
Mode  
Parameter  
Setting range  
Default  
Factory  
setting  
5
ON  
Default  
Protect SECr Security  
Protect YEYP A/M Key Protect ON/OFF  
Manual Manual MV  
0 to 6  
1
OFF  
0.0  
-5.0 to 105.0%  
Mode  
Parameter  
Setting range  
Default  
Factory  
setting  
Default  
Default  
Default  
Default  
25.0  
25.0  
Default  
4.4  
Level 0 SP Set Point  
Level 0 r-S Run/Stop  
Level 1 SP-0 Set Point 0  
Level 1 SP-1 Set Point 1  
Level 1 AL-1 Alarm Value 1  
Level 1 AL-2 Alarm Value 2  
Level 1 AL-3 Alarm Value 3  
Level 1 P Proportional Band  
Level 1 I Integral Time  
Level 1 d Derivative Timer  
Level 1 C-SC Cooling  
Coefficient  
SP Lower Limit to Upper Limit EU  
Run/Stop  
0
Run  
0
0
0
0
0
10.0  
233  
40  
1.00  
SP Lower to Upper EU  
SP Lower to Upper EU  
-1999 to 9999 EU  
-1999 to 9999 EU  
-1999 to 9999 EU  
0.1 to 999.9% FS  
0 to 3999 SEC  
84  
13  
Default  
0 to 3999 SEC  
0.01 to 99.99  
Level 1 C-db Dead Band  
Level 1 6F-r Manual Reset  
Value  
-19.99 to 99.99%FS  
0.0 to 100.0%  
0.00  
50.0  
Default  
Default  
Level 1 HYS Hysteresis (Heat) 0.01 to 99.99%FS  
Level 1 CHYS Hysteresis (Cool) 0.01 to 99.99%FS  
0.10  
0.10  
20  
Default  
Default  
Default  
Level 1 CP Control Period  
(Heat)  
1 to 99 SEC  
Level 1 C-CP Control Period  
(Cool)  
1 to 99 SEC  
20  
Default  
Mode  
Parameter  
Setting range  
Default  
Factory  
setting  
Default  
Default  
Default  
Default  
25.0  
Level 0 SP Set Point  
Level 0 r-S Run/Stop  
Level 1 SP-0 Set Point 0  
Level 1 SP-1 Set Point 1  
Level 1 AL-1 Alarm Value 1  
SP Lower Limit to Upper Limit EU  
Run/Stop  
SP Lower to Upper EU  
SP Lower to Upper EU  
-1999 to 9999 EU  
0
Run  
0
0
0
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Level 1 AL-2 Alarm Value 2  
Level 1 AL-3 Alarm Value 3  
Level 1 P Proportional Band  
Level 1 I Integral Time  
Level 1 d Derivative Timer  
Level 1 C-SC Cooling  
Coefficient  
-1999 to 9999 EU  
-1999 to 9999 EU  
0.1 to 999.9% FS  
0 to 3999 SEC  
0 to 3999 SEC  
0.01 to 99.99  
0
0
10.0  
233  
40  
25.0  
Default  
4.4  
84  
13  
Default  
1.00  
Level 1 C-db Dead Band  
Level 1 6F-r Manual Reset  
Value  
-19.99 to 99.99%FS  
0.0 to 100.0%  
0.00  
50.0  
Default  
Default  
Level 1 HYS Hysteresis (Heat) 0.01 to 99.99%FS  
Level 1 CHYS Hysteresis (Cool) 0.01 to 99.99%FS  
0.10  
0.10  
20  
Default  
Default  
Default  
Level 1 CP Control Period  
(Heat)  
1 to 99 SEC  
Level 1 C-CP Control Period  
(Cool)  
1 to 99 SEC  
20  
Default  
Mode  
Parameter  
Setting range  
Default  
Factory  
setting  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Level 2 r-L Remote/Local  
RMT/LCL  
LCL  
M
0
0
0.0  
0.0  
Level 2 SPrU Sp Ramp Time Unit  
Level 2 SPrE Sp Ramp Set Value  
Level 2 LbA LBA Detection Time  
Level 2 Au-5 MV at Stop  
Level 2 Au-E MV at PV Error  
Level 2 6L-L MV Upper Limit  
Level 2 6L-L MV Lower Limit  
M(Minutes)/H(Hours)  
0 to 9999 EU  
0 to 9999 SEC  
-5.0 to 105.0%  
-5.0 to 105.0%  
MV Lower Limit +0.1 to 105.0% 105.0  
-5.0 to MV Upper Limit –0.1%  
-5.0  
0.0  
0
0.02  
0.02  
0.02  
0.0  
Level 2 6rL MV Change Rate Limit 0.0 to 100.0%/SEC  
Level 2 CnF Input Digital Filter  
Level 2 ALH1 Alarm 1 Hysteresis  
Level 2 ALH2 Alarm 2 Hysteresis  
Level 2 ALH3 Alarm 3 Hysteresis  
Level 2 Cn5H Input Shift Upper  
Limit  
0 to 9999 SEC  
0.01 to 99.99%  
0.01 to 99.99%  
0.01 to 99.99%  
-199.9 to 999.9 °C  
Level 2 Cn5L Input Shift Lower  
Limit  
0.0  
Default  
-999.9 to 999.9 °C  
Factory  
setting  
3
Default  
Mode Parameter  
Setting range  
Setup Cn-E Input Type  
0 to 21  
2
Cn-H Scaling Upper  
Limit  
Setup  
Scaling Lower Limit +1 to 9999 EU  
-100  
Default  
Default  
Cn-L Scaling Lower  
Setup  
Limit  
-1999 to SP Setting Upper Limit -0.1 EU  
0
Setup dP Decimal Point  
0 to 3  
°C/F  
Yes/No  
0
°C  
No  
Default  
°F  
Default  
Setup  
d-U °C/F Selection  
Setup CnCE Parameter  
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Initialize  
6UE1 Control Output 1 Heat/Cool/Alarm 1/Alarm 2/Alarm 3/  
Setup  
Setup  
Setup  
Heat  
AL-1  
Default  
Default  
Default  
Assignment  
LBA  
6UE2 Control Output 2 Heat/Cool/Alarm 1/Alarm 2/Alarm 3/  
Assignment  
LBA  
Sub 1 Auxiliary Output  
1 Assignment  
Alarm 1/Alm 2/Alm 3/LBA/S.ERR/E333  
AL-1  
2
Setup ALE1 Alarm 1 Type  
0 to 11  
NO/NC  
0 to 11  
NO/NC  
0 to 11  
NO/NC  
Default  
Default  
AL1n Alarm 1 open in  
Setup  
alarm  
NO  
2
Setup ALE2 Alarm 2 Type  
Default  
Default  
Default  
Default  
AL2n Alarm 2 open in  
Setup  
alarm  
NO  
2
Setup ALE3 Alarm Type  
AL3n Alarm 3 open in  
Setup  
alarm  
NO  
6rEu Direct/Reverse  
Operation  
Setup  
OR-R/OR-D  
OR-R  
Default  
Factory  
setting  
Default  
Mode Parameter  
Setting range  
SL-H Set Point Upper SP Lower Limit +1 to Scaling Upper  
Expansion  
Expansion  
1300  
400.0  
Limit  
Limit  
SL-L Set Point Lower  
Limit  
Scaling Upper Limit to SP Lower Limit -200  
0
Expansion CnEL PID/ON/OFF  
PID/ON/OFF  
OFF/ON  
PID  
Default  
Default  
SE ST Adaptive Tuning  
Expansion  
(Fuzzy)  
OFF  
Expansion SE-b ST Stable Range  
15  
0.65  
Default  
Default  
0.1 to 999.9 °C/F  
0.01 to 1.00  
Expansion  
ALFA α  
AE-G AT Calculated  
Gain  
rESE Standby  
Expansion  
0.1 to 10.0  
1.0  
Default  
Default  
Expansion Sequence Reset  
Setting Method  
0/1  
0
rEE Automatic Return  
of Display Mode  
Expansion AE-H AT Hysteresis  
Expansion  
0 to 99 SEC  
0
Default  
Default  
Default  
0.1 to 9.9% FS  
0.0 to 999.9% FS  
0.2  
0.2  
LbAb LBA Detection  
Expansion  
Width  
Option Boards  
Available Option Boards  
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Option Type  
RE232C  
RS-485  
Event Input  
Transfer Output  
Board Number  
E53-CK01  
E53-CK03  
E53-CKB  
E53-CKF  
Factory  
Default  
Mode Parameter  
Setting range  
setting  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Option Eu-A Multi-SP Function  
Option Eu-1 Event Input Assign 1  
0/1  
STOP/MAN  
½ BITS  
7/8 BITS  
None/Even/Odd  
1.2/2.4/4.8/9.6/19.2  
0 to 99  
SP/SP-M/PV/O/C-O  
0
STOP  
Option SbCE Communication Stop Bit  
Option Len Comm. Data Length  
Option PrEY Commication Parity  
Option 6PS Comm. Baud Rate  
Option U-n6 Comm. Unit No.  
Option Er-E Transfer Output Type  
Option Er-H Xfer Output Upper Limit  
Option Er-L Xfer Output Lower Limit  
2
7
Even  
9.6 kbps  
0
SP  
5
5
5
5
Restoring Factory Defaults on the Dew Point Controller  
1. Make sure jumper setting for input type is set for Current Input (I), right jumper.  
2. Return controller to housing.  
3. Press the Display button for one (1) second to enter Menu Display.  
4. Press the Arrow Up button to switch between menus.  
5. To switch parameters within a menu, press Up Arrow button.  
Figure 9  
Setting List for Dew Point Controller, Part No. A0548567  
Mode  
Parameter  
Setting range  
Default  
Factory  
setting  
3
Protect SECr Security  
Protect YEYP A/M Key Protect  
Manual Manual MV  
Level 0 SP Set Point  
Level 0 r-S Run/Stop  
Level 1 AL-1 Alarm Value 1  
Level 1 AL-2 Alarm Value 2  
Level 1 C-db Dead Band  
Level 1 HYS Hysteresis (Heat)  
Level 1 CHYS Hysteresis (Cool)  
Level 2 SPrU Sp Ramp Time Unit  
Level 2 SPrt Sp Ramp Set Value  
Level 2 CnF Input Digital Filter  
Level 2 ALH1 Alarm 1 Hysteresis  
Level 2 ALH2 Alarm 2 Hysteresis  
Level 2 Cn5H input shift upper limit  
0 to 6  
ON/OFF  
-5.0 to 105.0 %  
1
OFF  
0.0  
0
Run  
0
ON  
Default  
Default  
Default  
SP lower limit to upper limit EU  
Run/Stop  
-1999 to 9999 EU  
-1999 to 9999 EU  
-19.99 to 99.99%FS  
0.01 to 99.99% FS  
0.01 to 99.99 FS  
M(Minutes)/H(Hours)  
0 to 9999 EU  
0 to 9999 SEC  
0.01 to 99.99%  
0.01 to 99.99%  
-199.9 to 999.9°C  
-10.0°F/-23°C  
-10.0°F/-23°C  
Default  
0
0.00  
0.10  
0.10  
M
0
0
0.02  
0.02  
0.0  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
Default  
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Level 2 Cn5L input shift lower limit  
0.0  
Default  
-999.9 to 999.9°C  
Factory  
setting  
17  
Default  
Mode  
Setup  
Setup  
Parameter  
Cn-t Input Type  
Setting range  
0 to 21  
Scaling Lower Limit +1 to  
9999 EU  
-1999 to SP Setting Upper  
Limit –0.1 EU  
0 to 3  
Yes/No  
Heat/Cool/Alarm 1/Alarm 2/  
Alarm 3/LBA  
Heat/Cool/Alarm 1/Alarm 2/  
Alarm 3/LBA  
Alarm 1/Alm 2/Alm 3/LBA/S.  
ERR/E333  
2
Cn-H Scaling Upper Limit  
Cn-L Scaling Lower Limit  
-100  
15°F/-9C  
Setup  
0
-40°F/-40C  
Setup  
Setup  
dP Decimal Point  
0
No  
Default  
Default  
CnCE Parameter Initialize  
6Ut1 Control Output 1  
Assignment  
6Ut2 Control Output 2  
Assignment  
Setup  
Setup  
SetUp  
Heat  
AL-1  
AL-2  
COOL  
Default  
Default  
Sub 1 Auxiliary Output 1  
Assignment  
Setup  
Setup  
Setup  
Setup  
ALt1 Alarm 1 Type  
AL1n Alarm 1 open in alarm  
ALt2 Alarm 2 Type  
AL2n Alarm 2 open in alarm  
6rEU Direct/Reverse  
Operation  
0 to 11  
NO/NC  
0 to 11  
NO/NC  
2
NO  
2
8
Default  
8
Default  
NO  
Setup  
OR-R/OR-D  
OR-R  
1300  
Default  
SP Lower Limit +1 to  
Scaling Upper Limit  
Scaling Upper Limit to Sp  
Lower Limit  
Expansion SL-H Set Point Upper Limit  
15°F/-9C  
Expansion SL-L Set Point Lower Limit  
Expansion CntL PID/ON/OFF  
-200  
PID  
0
-40°F/-40C  
ON-OFF  
Default  
PID/ON-OFF  
rESt Standby Sequence  
Expansion  
0/1  
Reset Setting Method  
rEt Automatic Return of  
Expansion  
0 to 99 SEC  
0
Default  
Display Mode  
6-8 Restoring the E5CK Temperature Controller and Dew Point  
Meter to Factory Setup  
If preset parameters on the controller have been tampered with and it no longer properly controls  
temperature and displays dew point, you can restore the controller to factory setup.  
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- Notes -  
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Chapter 7: Troubleshooting  
Problem  
Possible cause  
Dirty filter.  
Corrective action  
Clean or replace filter.  
Desiccant beds are  
contaminated by material or  
plasticizer leaking into the  
system.  
Replace desiccant.  
Little or no air coming from  
the process delivery tube.  
Fix the problem and reset the  
overload.  
Blower overload has tripped.  
Blower fins filled with dust or  
contaminants.  
Remove blower side plate,  
clean baffles, replace.  
Stop the dryer.  
If the dryer was connected to  
the drying hopper, check to  
see if the desiccant and  
Suction in delivery tube,  
pressure from the return  
tube.  
process air heater has been  
contaminated with resin.  
Phase is reversed on power  
drop coming into the dryer.  
If so, replace the desiccant  
and remove any resin carry-  
over. Otherwise, change the  
phase of two legs of the  
three-phase power drop.  
Check for open heaters.  
Replace if required.  
Process heaters are faulty.  
Solid-state temperature  
controller faulty.  
Replace.  
Loss or reduction of process  
air temperature.  
Make sure that plant  
personnel are aware of the  
proper temperature set point.  
A sign posted next to the  
controller is helpful.  
Process temperature was  
adjusted in error by plant  
personnel.  
Process heaters are faulty.  
Desiccant beds are  
contaminated.  
Replace.  
Replace desiccant.  
Drying systems are designed  
for the material which was  
originally specified. Different  
materials may need a longer  
residence time or different  
drying temperature.  
Material being dried differs  
from material specified at the  
time of purchase.  
Loss or reduction in drying  
capacity.  
Inspect for air leaks; replace  
if necessary.  
Break in flex hose to/from  
drying hopper.  
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Problem  
Possible cause  
Corrective action  
Check for proper operation of  
valve actuators. Repair or  
replace if necessary.  
Remove blower side plate,  
clean baffles, replace.  
Replace filter elements.  
Check power supply and  
power wiring to PLC.  
Airflow valve sticking or  
failing to shift.  
Loss or reduction in drying  
capacity. (Cont’d.)  
Blower fins filled with dust or  
contaminants.  
Insufficient power to PLC  
(Power LED is off).  
Faulty PLC (PLC Power light  
is on, Run light is off, and/or  
Error light is on).  
PLC Regeneration Bed LED  
indicators both off.  
Replace PLC.  
Regenerating bed cool down. None.  
Verify that blower contactor is  
Blower Input indicator is off.  
on. Check input wiring to  
PLC.  
PLC Regeneration Heater  
Left/Right output indicators  
both off.  
Process air in high-  
None.  
temperature condition.  
Insufficient power to PLC  
(Power light is off).  
Check power supply and  
power wiring to PLC.  
Faulty PLC (PLC Power light  
is on, Run light is off, and/or  
Error light is on).  
Replace PLC.  
Check resin manufacturer’s  
data sheet for proper drying  
temperature. Make sure plant  
personnel are aware of the  
correct process temperature  
set point.  
Process temperature set too  
high due to operator error.  
Material in drying hopper  
cakes, or meltdown occurs.  
High temperature alarm not  
set properly.  
Reset high temperature  
alarm.  
Process set point is out of  
acceptable range.  
Restore temperature  
controller to factory pre-sets.  
Function set for degrees  
Celsius (ºC), set point at  
degrees Fahrenheit (ºF).  
Burned out regeneration  
heater.  
Verify correct Celsius or  
Fahrenheit settings.  
Repair or replace.  
Replace.  
Contaminated or worn out  
desiccant.  
Leaking process air hoses.  
Dryer operates beyond its  
capacity.  
Repair or replace.  
Check dryer and drying  
hopper sizing.  
Poor dew point performance.  
Bad dew point sensor.  
Fouled dew point sensor  
manifold.  
Replace.  
Clear obstruction. Air should  
flow freely through sensor.  
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Problem  
Possible cause  
The internal mechanism is  
not inserted properly into the  
housing.  
Corrective action  
Properly insert the internal  
mechanism into the housing.  
The power supply is not  
connected to its terminals  
properly.  
No power is supplied, or the  
supplied power is not within  
the specified range.  
Properly connect the power  
supply to the power supply  
terminals.  
Supply a voltage of 85 to 125  
VAC to the power supply  
terminals of the controller.  
Check control power fuse for  
continuity. Turn disconnect  
switch and control power  
switch ON.  
Nothing displays when the  
controller is turned on.  
Disconnect switch or Control  
Power switch not set to ON.  
Control Power fuse blown.  
Input polarity on thermo-  
couple is wrong or  
Properly wire the terminals.  
connection is wrong.  
No compensating lead wires  
used for extension of the  
thermocouple.  
Use proper compensating  
lead wires and terminals.  
Use a dedicated thermo-  
couple connector. If a  
connector is a metal different  
from the thermocouple and  
controller, a temperature  
error may result.  
Thermocouple and controller  
are connected by wires other  
than proper lead wires.  
Process value is abnormal or  
not obtained.  
Sensor is broken or short-  
circuited.  
Replace with a good sensor.  
Separate input wires as far  
as possible from the origin of  
the noise.  
The controller is influenced  
by noise or other induction.  
Celsius temperatures used  
instead of Fahrenheit or vice  
versa.  
Setup mode level 2 display  
d-U. S-V display shows  
setting.  
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.  
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