Sterling Dehumidifier Sda Ap 1 Users Manual 882.00295.00 DH1 615 AP1 Large

SDA AP-1 to the manual 680c915d-5c1e-479e-9007-53322393493f

2015-02-04

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SDA Large AP-1 Control

Dehumidifying Dryer

Part Number: 882.00295.00

Bulletin Number: DH1-615-1

Effective: 04/28/2008

Write Down Your Serial Numbers Here For Future Reference:

_________________________ _________________________

We are committed to a continuing program of product improvement.

Specifications, appearance, and dimensions described in this manual are subject to change without notice.

DCN No. ____________

Large Dehumidifying Dryers ii

Shipping Info

Unpacking and Inspection

You should inspect the large dehumidifying dryer for possible shipping damage.

Thoroughly check the equipment for any damage that might have occurred in transit, such as

broken or loose wiring and components, loose hardware and mounting screws, etc.

In the Event of Shipping Damage

According to the contract terms and conditions of the Carrier, the responsibility of the

Shipper ends at the time and place of shipment.

Notify the transportation company’s local agent if you discover damage.

Hold the damaged goods and packing material for the examining agent’s inspection. Do not

return any goods before the transportation company’s inspection and authorization.

File a claim with the transportation company. Substantiate the claim by referring to the

agent’s report. A certified copy of our invoice is available upon request. The original Bill of

Lading is attached to our original invoice. If the shipment was prepaid, write us for a

receipted transportation bill.

Advise customer service regarding your wish for assistance and to obtain an RMA (return

material authorization) number.

If the Shipment is Not Complete

Check the packing list as back-ordered items are noted on the packing list. You should have:

; Large Dehumidifying Dryer

; Bill of lading

; Packing list

; Operating and Installation packet

; Electrical schematic and panel layout drawings

; Component instruction manuals

Re-inspect the container and packing material to see if you missed any smaller items during

unpacking.

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the parts and service department

immediately at [262] 641-8610. Have the item and order numbers ready. Hold the items

until you receive shipping instructions.

Large Dehumidifying Dryers iii

Returns

Do not return any damaged or incorrect items until you receive shipping instructions from the

shipping department.

Large Dehumidifying Dryers iv

Table of Contents

CHAPTER 1: SAFETY................................................................7

1-1 How to Use This Manual .............................................................................................7

Safety Symbols Used in this Manual.....................................................................7

1-2 Warnings and Precautions ..........................................................................................8

1-3 Responsibility ..............................................................................................................9

General Responsibility...........................................................................................9

Operator Responsibility.........................................................................................9

Maintenance Responsibility.................................................................................10

Reporting a Safety Defect ...................................................................................11

CHAPTER 2: FUNCTIONAL DESCRIPTION...........................12

2-1 Models Covered in This Manual................................................................................12

2-2 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

2-3 Standard Features.....................................................................................................14

Auto Start Timer ..................................................................................................14

Mechanical Features ...........................................................................................14

Electrical Features...............................................................................................14

2-4 Options......................................................................................................................15

Dewpoint Extend .................................................................................................15

Closed-Loop Regeneration .................................................................................15

2-5 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

2-6 Safety Devices and Interlocks...................................................................................22

Dimensions and Specifications

Denotes availability..................................24

Mechanical Options

Denotes availability ..................................................24

Electrical Features...............................................................................................25

Electrical Options ................................................................................................25

CHAPTER 3: MECHANICAL INSTALLATION ........................26

3-1 Uncrating the Equipment...........................................................................................26

3-2 Rigging and Placing Unit...........................................................................................26

3-3 Making Electrical Connections ..................................................................................26

3-4 Making Gas Line Connections (Gas-Fired Models Only)..........................................27

3-5 Checking for Proper Blower Rotation........................................................................28

3-6 Making Dryer/Drying Hopper Process Air Connections ............................................29

Large Dehumidifying Dryers v

3-7 Connecting Aftercooler/Precooler Cooling Water (Optional).....................................32

3-8 Using the Drying Hopper Air Trap .............................................................................33

CHAPTER 4: CONTROLS........................................................34

4-1 Controller Description................................................................................................34

4-2 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

4-3 Process Air Temperature and Conveying Process Controller...................................35

...................................................................35

4-4 Identifying Controller Screens ...................................................................................36

Main Menu Screen...............................................................................................................36

Typical Dryer Screens..........................................................................................................36

System Screens ..................................................................................................43

Alarm Screens.....................................................................................................48

Alarm Screen Example........................................................................................49

See Section 7-4: Alarms on p. 57 for alarm descriptions.............................................................49

4-5 Redundant Safety Controller Display ........................................................................49

4-6 Setting the Redundant Safety Controller...................................................................50

CHAPTER 5: OPERATION.......................................................52

5-1 Start-up......................................................................................................................52

5-2 Using the Dryer Status Screen..................................................................................53

5-3 Alarms .......................................................................................................................54

................................................................................54

5-4 Alarm Descriptions ....................................................................................................54

5-5 Shutdown ..................................................................................................................55

CHAPTER 6: MAINTENANCE .................................................56

6-1 Maintenance Schedule..............................................................................................56

6-2 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

6-3 Corrective Maintenance ............................................................................................60

Symptoms of Worn Out Desiccant ......................................................................60

Replacing the Desiccant......................................................................................60

Replacing the Process Heater (Electric Dryers)..................................................61

Large Dehumidifying Dryers vi

Replacing the Regeneration Heater (Electric Dryers) .........................................62

CHAPTER 7: TROUBLESHOOTING .......................................64

7-1 Introduction................................................................................................................64

7-2 Basic Troubleshooting...............................................................................................64

7-3 Determining Temperature Controller Errors or Sensor Errors...................................66

Using a Thermocouple ........................................................................................66

Using a Platinum Resistance Thermometer........................................................66

CHAPTER 8: APPENDIX..........................................................67

8-1 Returned Material Policy ...........................................................................................67

8-2 Technical Specifications............................................................................................68

Annex B Information............................................................................................68

8-3 Spare Parts List.........................................................................................................69

8-4 8-5 Dryer Identification (Serial Number) Tag.............................................................70

8-4 8-5 Dryer Identification (Serial Number) Tag.............................................................71

8-5 Technical Assistance.................................................................................................72

Parts Department ................................................................................................72

Service Department.............................................................................................72

Sales Department................................................................................................72

Contract Department ...........................................................................................72

Large Dehumidifying Dryers Safety 7

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.

Large Dehumidifying Dryers Safety 8

Dryer Safety Tags

Tag Description Tag Description

Read Operation &

Installation Manual High Voltage Inside

Enclosure

Hot!

Lifting Point

PE Protected Earth

Ground

Earth Ground

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.

Large Dehumidifying Dryers Safety 9

; 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

Large Dehumidifying Dryers Safety 10

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.

Large Dehumidifying Dryers Safety 11

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.

Large Dehumidifying Dryers Functional Description 12

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,

Large Dehumidifying Dryers Functional Description 13

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

Regeneration

Filter

Regeneration

Blower

Process

Blower

Regeneration

Exhaust

Process

Heater

Process

Filter

Insulated

Drying

Hopper

Right Desiccant

Regeneration

Heaters

Dryer Valve

Left Desiccant

AD600-AD1500

Dryer Flow Schematic

Right Desiccant in

Regeneration

Filter

Regeneration

Blower

Process

Blower

Regeneration

Exhaust

Process

Heater

Process

Filter

Insulated

Drying

Hopper

Right Desiccant

Regeneration

Heaters

Dryer Valve

Left Desiccant

AD600-AD1500

Dryer Flow Schematic

Left Desiccant in

Regeneration

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.

Large Dehumidifying Dryers Functional Description 14

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

Large Dehumidifying Dryers Functional Description 15

• 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

AD600-AD1500

Dryer Flow Schematic

Regeneration Closed Loop

Cooling is Activated Regeneration

Filter

Optional

Regeneration

Closed Loop

Cooler

Regeneration

Blower

Optional

Regeneration

Closed Loop

Valve

Regenerarion

Exhaust

Left Desiccant

Regeneration

Heaters

Dryer Valve

AD600-AD1500

Dryer Flow Schematic

Regeneration Heating is

Activated Regeneration

Filter

Optional

Regeneration

Closed Loop

Cooler

Regeneration

Blower

Optional

Regeneration

Closed Loop

Valve

Regeneration

Exhaust

Left Desiccant

Regeneration

Heaters

Dryer Valve

Large Dehumidifying Dryers Functional Description 16

2-5 Drawings and Diagrams

Regen.

Filter

Regeneration

Blower

Process

Blower

Optional

After-cooler

Process

Air Filter

Insulated

Drying

Hopper

Left Desiccants Right Desiccants

Process

Heater

Optional

Regeneration

Closed Loop

Cooler

Optional

Regeneration

Closed Loop

Valve

Regen.

Exhaust

Dryer Valve

Airflow Schematic: 2000-3000 cfm dryers (4 desiccant beds). Left desiccant beds are

regenerating—closed loop regeneration is activated.

Regen.

Filter

Regeneration

Blower

Process

Blower

Optional

After-cooler

Process

Air Filter

Insulated

Drying

Hopper

Left Desiccants Right Desiccants

Process

Heater

Optional

Regeneration

Closed Loop

Cooler

Optional

Regeneration

Closed Loop

Valve

Regen.

Exhaust

Dryer Valve

Airflow Schematic: 2000-3000 cfm dryers (4 desiccant bed). Left desiccant beds are

regenerating in open-loop regeneration mode.

Large Dehumidifying Dryers Functional Description 17

Differential

Pressure

Switch

Filter Check

Gage

Dust Level

Indicator

Slide Gate

Clamp

Dust Pan

Filter Retainer

Dust Shroud

Cartridge Filter

Thumb Screws

Optional dryer dust collector

Large Dehumidifying Dryers Functional Description 18

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

High

Temperature

Gasket

Cooling Coil

Pipe Gasket

Mounting

Brackets

Stainless Steel

Cooler Housing

Cooling Coil

Cover Plate

High

Temperature

Gasket

Stainless Steel Cooler

Housing

Cooling Coil

Pipe Gasket

Cooling Coil

Cover Plate

Mounting Brackets

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.

Large Dehumidifying Dryers Functional Description 19

Figure 4: Process Air Dust Collector

Differential

Pressure

Switch

Filter Check

Gage

Dust Level

Indicator

Slide Gate

Clamp

Dust Pan

Filter Retainer

Dust Shroud

Cartridge Filter

Thumb Screws

Large Dehumidifying Dryers Functional Description 20

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

Coupling

Temperature

Probe

Drying

Hopper

Valve

Proofing

Switch

Large Dehumidifying Dryers Functional Description 21

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

Large Dehumidifying Dryers Functional Description 22

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.

Large Dehumidifying Dryers Functional Description 23

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 24

Dimensions and Specifications

Denotes availability

CFM 600 850 1000 1250 1500 2000 2500 3000

(Electric Dryer w/ Basic Control) 9 9 9 9 9 9 9 9

(Electric Dryer High Performance) 9 9 9 9 9 9 9 9

(Gas Dryer option in lieu of Electric- 180°F to 250°F) 9 9 9 9 9 9 9 9

Gas dryer 250°F -400°F temp. range, includes aftercooler,

insulated drying hose, & high temp. return air hose 9 9 9 9 9 9 9 9

Gas central dryer (no process gas heater) 9 9 9 9 9 9 9 9

Dimension and Specifications

(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) 159 225 265 331 397 528 661 793

High Heat Gas Flow Rate (CFH) 227 322 378 473 568 756 945 1,134

Exhaust Duct Sizes in inches (MM) 3(76) 4(102) 5(127) 6(152)

Comb. Flue Air Flow (CFM) 87 123 145 182 218 290 363 436

Overall Dimensions (Electric Dryers)

Height 67 81 83

Depth 96 118 150

Dimensions (in inches)

Width 63 73

Shipping Weight (in lbs.) 2100 2200 2950 4350 4700 6500 7300 8450

Overall Dimensions (Gas Dryers)

Height 67 83 85

Depth 96 118 150

Dimensions (in inches)

Width 63 73

Shipping Weight (in lbs.) 2950 3050 3800 5150 5800 8125 8875 9050

Mechanical Options

Denotes availability

CFM

Option Description 600 850 1000 1250 1500 2000 2500 3000

Low temp operation 120°F to 180o F. (Electric dryers only) 9 9 9 9 9 9 9 9

High temp operation for the electrical dryers, 180°F to 400o F. 9 9 9 9 9

High temp operation for the Gas dryers, 250°F to 400o F. 9 9 9 9 9 9 9 9

Plasticizer trap/ After Cooler w/Filter 9 9 9

Aftercooler 9 9 9

Over Drying Protection

Temperature Set Back 9 9

Automatic airflow reduction valve. (Not for gas dryers) 9 9

13X Desiccant STD

Closed Loop Cooling Valve

(Std. w/high performance) 9 9 9 9

Dew Point +15°F to –40°F 9 (Not with high performance)

Dew Point + 15°F to -80°F 9 (Standard with high performance)

Sound Insulation Package for under 85 DBA Noise Level Not Required 9 9

Dust Collector ADC 9 9 9

Process Heater 180°F to 250°F 9 9 9 9 9 9 9 9

Process Heater 180°F to 400°F 9 9 9 9 9 9 9 9

Large Dehumidifying Dryers Functional Description 25

Electrical Features

CFM

Dryer AMP Draw 600 850 1000 1250 1500 2000 2500 3000

Standard voltage Low Heat (Electric Dryers) Full load Amps

208v/3/60Hz. 152 217 249 314 378

230v/3/60Hz. 137 196 225 284 342

N/A

400v/3/50Hz. 79 113 129 163 197 270 339 424

460v/3/60Hz. 69 98 112 142 171 234 294 370

575v/3/60Hz. 55 78 90 114 137 188 236 295

Standard voltage High Heat (Electric Dryers) Full load Amps

208v/3/60Hz. 207 296 342 430

230v/3/60Hz. 187 267 309 389

N/A

400v/3/50Hz. 108 154 178 224 269 366 N/A

460v/3/60Hz. 94 134 154 194 234 318 399 494

575v/3/60Hz. 75 107 123 156 187 254 319 395

Standard voltage (Gas Dryers) Full load Amps

208v/3/60Hz. 36 47 48 61 75 120 150 191

230v/3/60Hz. 33 43 44 55 67 109 136 173

400v/3/50Hz. 19 25 32 39 62 78 99

460v/3/60Hz. 16 22 28 34 54 67 87

575v/3/60Hz. 13 17 22 27 43 54 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 9 9

Remote operator interface CF

Redundant process temperature safety 9 (Standard w/High Performance)

Ethernet module for remote communication w/ Data logging 9

CSA approval 9

UL rating 9

Supply voltages 400/3/50 (includes CE compliance) 9

Audible & Visual Alarm 9 (Standard w/High Performance)

Large Dehumidifying Dryers Mechanical Installation 26

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.

Large Dehumidifying Dryers Mechanical Installation 27

; 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

Fume

Exhaust

123

910

12 13

14 316 17 16

PS 3

21 21 21

20 20 20

22 22 22

PS PS

Gas Dryers Air

Fuel Train

Item Description Item Description

1 Manual gas shut off valve 14 Regeneration gas regulator

2 Gas regulator 15 Regeneration air solenoid valve

3 Gas pressure switch 16 Regeneration gas solenoid valve

4 Process gas solenoid valve 17 Regeneration gas proportionator

5 Manual adjustable butterfly valve 18 Regeneration butterfly orifice valve

6 Process gas proportionator 19 Regeneration air actuator

7 Process air actuator 20 Adjustable gas orifice

8 Air pressure switch 21 Regeneration thermocouple

9 Process ratiomatic burner 22 Regeneration SER burner

10 Process gas heat exchanger 23 Regeneration & combustion air filter

11 Gas pressure switch 24 Combustion air blower

12 Process combustion air blower 25 Air pressure switch

13 Process combustion air filter

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

http://www.eclipsenet.com/catalog/contents/Documents/08/826IM0503s.pdf

Large Dehumidifying Dryers Mechanical Installation 28

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

Large Dehumidifying Dryers Mechanical Installation 29

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

Process Air Heater on Dryer

Return air

thermocouple

location

(Do not insulate)

Large Dehumidifying Dryers Mechanical Installation 30

Process Air Heater on Drying

Hopper

Return air

thermocouple

location

Large Dehumidifying Dryers Mechanical Installation 31

Drying System with Dust Collector

and Process Air Heater on Dryer

Return air

thermocouple

location

Large Dehumidifying Dryers Mechanical Installation 32

After cooler

Model Water Flow

( GPM )

AD600 10

AD850 10

AD1000 15

AD1250 15

AD1500 20

AD2000 25

AD2500 30

AD3000 35

High

Temperature

Gasket

Stainless Steel Cooler

Housing

Cooling Coil

Pipe Gasket

Cooling Coil

Cover Plate

Mounting Brackets

High

Temperature

Gasket

Cooling Coil

Pipe Gasket

Mounting

Brackets

Stainless Steel

Cooler Housing

Cooling Coil

Cover Plate

After cooler

Model Water Flow

(GPM)

600 10

850 10

1000 15

1250 15

1500 20

2000 25

2500 30

3000 35

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

Large Dehumidifying Dryers Mechanical Installation 33

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

Suggested material level

for the optimum

efficiency.

Air Trap

Flapper Valve

of the loader

Return air from the

drying hopper.

Delivery low dew point,

heated air to the drying

hopper.

Insulation

Recommended process

temperature control

thermocouple location.

Large Dehumidifying Dryers Controls 34

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.

Large Dehumidifying Dryers Controls 35

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)

Large Dehumidifying Dryers Controls 36

• Copyright Information

• 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.

Large Dehumidifying Dryers Controls 37

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:

Large Dehumidifying Dryers Controls 38

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)

Large Dehumidifying Dryers Controls 39

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.

Large Dehumidifying Dryers Controls 40

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.

Large Dehumidifying Dryers Controls 41

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.

Large Dehumidifying Dryers Controls 42

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.

Large Dehumidifying Dryers Controls 43

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

Large Dehumidifying Dryers Controls 44

• 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

Large Dehumidifying Dryers Controls 45

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.

Large Dehumidifying Dryers Controls 46

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.

Large Dehumidifying Dryers Controls 47

(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 99 MIN

PASSWORD - OPERATOR 0000

PASSWORD SUPERVISOR 1234

PASSWORD OPERATOR DURATION 10 MIN

PASSWORD SUPERVISOR DURATION 10 MIN

DEWPOINT HIGH LIMIT ALARM VALUE 30 DEGF

(ALARM DISABLED)

OVERDRY SET BACK TEMPERATURE 170 DEGF

OVERDRY SET BACK SETPOINT 100 DEGF

OVERDRY SET UP TEMPERATURE 90 DEGF

PROCESS AIR TEMP. SETPOINT 180 DEGF

PROCESS AIR HI DEVIATION VALUE 35 DEGF

PROCESS AIR LO DEVIATION VALUE -35 DEGF

REGENERATION AIR SETPOINT 450 DEGF

PROCESS ACTUAL VALUE OFFSET 0.0 DEGF

REGEN ACTUAL VALUE OFFSET 0.0 DEGF

SERVICE (Service Menu Screen)

Large Dehumidifying Dryers Controls 48

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.

Large Dehumidifying Dryers Controls 49

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

Large Dehumidifying Dryers Controls 50

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 button until you

get to 10.

3. Press the Up button until you get to your desired temperature.

4. Press P again until you get to Run.

Large Dehumidifying Dryers Controls 51

Large Dehumidifying Dryers Operation 52

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.

Large Dehumidifying Dryers Operation 53

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

Large Dehumidifying Dryers Operation 54

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

VALVE

POSITION

The Main Air Valve did not maintain

position.

Possible Motor or Limit Switch Failure.

Immediate

Shut Down

VALVE

MTR

OVERRIDE

The Main Air Valve did not find

position.

Possible Motor or Limit Switch Failure.

Immediate

Shut Down

VALVE

MOTOR FAIL

The Main Air Valves expected and actual

positions do not match.

Possible Motor or Limit Switch Failure.

Immediate

Shut Down

PROCESS

SENSOR FAIL

The process supply air temperature

thermocouple is out of range.

Possible thermocouple failure.

Process

Shut Down

REGEN

SENSOR FAIL

The regeneration air temperature

thermocouple is out of range.

Possible thermocouple failure.

Regeneration

Shut Down

PROCESS

HIGH TEMP

Process air temperature deviation is

above high limit value.

Possible solid state relay failure.

Process

Shut Down

PROCESS

LOW TEMP

Process air temperature deviation is

below low limit value.

Possible heater failure. Alert Only

PROCESS

LOOP BREAK

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

Shut Down

REGEN

HIGH TEMP Regeneration air temperature deviation is

above high limit value. Regeneration

Shut Down

Large Dehumidifying Dryers Operation 55

Alarm

Comment Alarm

Description Alarm

Effect

REGEN

LOW TEMP

Regeneration air temperature deviation is

below low limit value.

Possible heater failure. Alert Only

DEWPOINT

SENSOR

The dew point sensor is out of range.

Possible transducer or electronics

failure.

Disables

Switch on

Dew Point

HIGH

DEWPOINT

The dew point value is above the high

limit value. Faulty sensor or PC board.

Possible ambient air contamination or

failed regeneration cycle.

Alert Only

PROCESS

BLOWER FAIL Process blower is not running.

Possible overload fault, contactor fault. Process

Shut Down

PROCESS

HEATER FAIL

Process heaters are not active.

Possible surface switch trip, redundant

temperature safety trip.

Process Shut

Down

REGEN

BLOWER FAIL Regeneration blower is not running.

Possible overload fault, contactor fault. Regeneration

Shut Down

REGEN

HEATER FAIL Regeneration heaters are not active.

Possible surface switch trip. Immediate

Shut Down

DIRTY FILTER Monitored filter(s) require cleaning. Alert Only

P RETURN

SENSOR FAIL

The process return air temperature

thermocouple is out of range.

Possible thermocouple failure.

Disables

Over dry

Protection

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 Maintenance 56

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 #

EVERY WEEK Date/

By Date/

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

EVERY YEAR Next Scheduled

Inspection Actual Inspection

Date/By Next Scheduled

Inspection Actual Inspection

Date/By

Inspect desiccant. Replace

if brown or broken

- Photocopy this page for your maintenance records -

Large Dehumidifying Dryers Maintenance 57

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

Stainless Steel

Filter Housing

Cover Filter Housing

Cover Latches Filter Housing

Cover Latches

High

Temeprature

Gasket Stainless Steel

Filter Housing

Cover

High

Temperature

Cartridge Filter

High

Temeprature

Gasket

Stainless Steel

Filter Housing

600-1500 cfm dryers 2000-3000 cfm dryers

Large Dehumidifying Dryers Maintenance 58

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 59

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 60

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 61

6. Inspect the gaskets on each of the covers. Replace if necessary.

7. Re-install the covers.

Figure 14: Desiccant Tower Assembly

Regeneration

Heater Cover.

High

Temperature

Gaskets.

Heater Element

Mounting Plate.

Access cover can be

removed in order to

replace desiccant.

Viewing Glass, for

checking the status of

the desiccant inside.

Regeneration

Heaters

High

Temperature

Gaskets.

Stainless Steel

Hollow Core

Desiccant Tank

Mounting

Platform

Figure 15: Desiccant Replacement Amounts

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.

Dryer Desiccant Required per Tower

CFM “13 X”, 8 x 12 Bead Total

600 175 350

850 175 350

1000 300 600

1250 300 600

1500 300 600

2000 300 1200

2500 300 1200

3000 300 1200

Large Dehumidifying Dryers Maintenance 62

High

Temperature

Gasket

Double Wall

Stainless Steel

Heater

Housing

Heater Elements

Heater Element

Mounting Plate

Stainless Steel

Heater Housing

Cover

High

Temperature

Gasket

Heater Assembly

Gude Bars

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.

Figure 16: Process Heater Box Assembly

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.

Heater Element

Bulkhead Fitting

Heater Element

Mounting Hex Nut

Hex Nut For

Securing the Heater

Wire

Washer

Heater Wire with

Crimped on Closed

Loop Connector

High Temperature

Washer / Gasket

Heater Mounting

Plate

Heater Assembly

Guide Bar

Heater Elements

Heater Element

Mounting Plate

High

Temperature

Gasket

Double Wall

Stainless Steel

Heater

Housing

Stainless Steel

Heater Housing

Cover

Heater Assembly

Gude Bars

Large Dehumidifying Dryers Maintenance 63

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

Regeneration

Heater Cover.

High

Temperature

Gaskets.

Heater Element

Mounting Plate.

Access cover can be

removed in order to

replace desiccant.

Viewing Glass, for

checking the status of

the desiccant inside.

Regeneration

Heaters

High

Temperature

Gaskets.

Stainless Steel

Hollow Core

Desiccant Tank

Mounting

Platform

Large Dehumidifying Dryers Troubleshooting 64

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 Possible Cause Corrective Action

Dirty Filters Clean or replace filters.

Desiccant beds contaminated by

material or plasticizer leaking

into the system. See Sec. 6-6.

Replace desiccant

Blower fuse(s) blown. Fix problem and Replace fuse(s).

Overload tripped. Fix problem and reset the

overload.

Wrong motor rotation. Turn off power. Reverse

incoming power.

Little or no air

coming from

process delivery

tube.

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.

Process heaters are faulty.

Check for open or shorted heaters.

Replace if required. Check the

fuses.

Solid-state temperature controller

faulty. Replace.

Loss or reduction of

process air

temperature.

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 65

Problem Possible Cause Corrective Action

Process heaters are faulty. Replace.

Desiccant beds are contaminated. Replace desiccant.

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.

Break in flex hose to/from drying

hopper. Inspect for air leaks; replace if

necessary.

Loss or reduction in

drying capacity.

Blower fins filled with dust or

contaminants. Remove blower side plate, clean

baffles, replace. Replace filter

elements.

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.

High temperature alarm not set

properly. See Section “Temperature Screen

Setup” on page 34.

Material in drying

hopper cakes, or

meltdown occurs.

Process set point is out of

acceptable range.

Restore temperature controller to

factory pre-sets. Auto-Tune if

necessary.

Burned out regeneration heater. Repair or replace.

Contaminated or worn out

desiccant. Replace.

Leaking process air hoses. Repair or replace.

Dryer is being operated beyond its

capacity. Check dryer and drying hopper

sizing.

Bad dew point sensor. Replace.

Poor Dew Point

Performance.

Fouled dew point sensor manifold. Clear obstruction. Air should flow

freely through sensor.

Large Dehumidifying Dryers Troubleshooting 66

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.

Large Dehumidifying Dryers Appendix 67

Chapter 8: Appendix

8-1 Returned Material Policy

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

RMS 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. Purchased

components are covered under their specific warranty terms.

Large Dehumidifying Dryers Appendix 68

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: 0 degrees Celsius – Maximum (104 degrees Fahrenheit)

3. Humidity range: 50% relative humidity

4. Altitude: Sea level

5. Environment: Clean and non-explosive

6. Radiation: None

7. Vibration: Minimal, i.e. machine mounting

8. Allowable voltage fluctuation: +/- 10%

9. Allowable frequency fluctuation: Continuous +/- 1%

Intermittent +/- 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 control⎯repetitive

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 69

8-3 Spare Parts List

600CFM

850CFM

1000CFM

1250CFM

1500CFM

2000CFM

2500CFM

3000CFM

LEVEL 1 ( Electrical Components )

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

PART # SIZE Description

A0536474 50 Fuse, Process Heater Elements 3

A0536471 35 Fuse, Regen Heater Elements 3

A0534846 20 Fuse, Process Blower 3

A0545343 3.5 Fuse, Regen Blower 3

A0538001 3.2 Transformer, Control Primary 2

A0538017 6 Transformer, Control Secondary 1

A0538005 5 Transformer, Valve Motor Primary 2

A0534842 10 Transformer, Valve Motor Secondary 1

A0540997 1 Fuse, Control, PLC 1

A0540995 0.75 Fuse, Control, Output/Power Supply 2

A0542207 3 Fuse, Control, Power Supply Out 1

LEVEL 1 ( Mechanical Components )

PART # SIZE Description

W00015435 Dew Point Sensor Insert

A0548556 Dew Point Sensor

A0568271 Dew Point Sensor Cable

A0566467 Valve switch

A0570595 Process Air Filter 600-850 CFM

A0568062 Process Air Filter 1000-3000 CFM

A0566531 Regeneration Air Filter 600-850 CFM

A0572408 Regeneration Air Filter 1000-3000 CFM

W00018051 13X molecular Sieve Desiccant ( 8 X 12 Beads )

W00013983 High Temperature Gasket (15 Ft Roll)

A0566564 Desiccant Tank Sight Glass

A0572479 Desiccant Tank Sight Glass Gasket

A0566676 High Temperature Snap Switch.

LARGE DRYER SPARE PARTS LIST 600,850,1000,

1250,1500,2000,2500, AND 3000

1111111

2222244

1111

111222

1111111

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

22222444

3333555

600CFM

850CFM

1000CFM

1250CFM

1500CFM

2000CFM

2500CFM

3000CFM

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

LEVEL 2 ( Electrical Components )

PART # SIZE Description

A0558000 9A Contactor, IEC 1

A0558002 16A Contactor, IEC 1

A0558004 32A Contactor, IEC 1

A0558040 Overload, IEC, 12-32A 1

A0558079 Overload, IEC, 1 - 2.9A 1

A0569887 Overload, IEC, 5 - 15A 1

A0569895 48A Relay, Solid State

A0505417 Relay, 4PDT, Regeneration T'Couple

A0567058 Relay, SPDT

A0554555 * Circuit Board, Dew Point

A0548556 * Sensor, Dew Point

LEVEL 2 ( Mechanical Components )

PART # SIZE Description

A0566544 3500 Watts Heater Element 208/220 Volts 21 30 39 39 45

A0566547 3500 Watts Heater Element 230 Volts 21 30 39 39 45

A0566549 3500 Watts Heater Element 400 Volts 21 30 39 39 45 66 78 90

A0566549 3500 Watts Heater Element 460 Volts 21 30 39 39 45 66 78 90

A0566549 3500 Watts Heater Element 575 Volts 21 30 39 39 45 66 78 90

A0566415 Heater Element Gasket

A0566682 1/4" OD Teflon Tube.

LARGE DRYER SPARE PARTS LIST 600,850,1000,1250,

1500,2000,2500, AND 3000

18 Feet 18 Feet 18 Feet 18 Feet 18 Feet 18 Feet 18 Feet 18 Feet

42 60 78 78 90 120 158 180

111111 1

1111111

Large Dehumidifying Dryers Appendix 70

8-4

LEVEL 3 ( Electrical Components )

600CFM

850CFM

1000CFM

1250CFM

1500CFM

2000CFM

2500CFM

3000CFM

PART # SIZE Description

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

208V 3PH

230V 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

400V 50 HZ 3PH

460V 3PH

575V 60 HZ 3PH

A0567930 PLC, Controller

A0567932 PLC, Temperature Control Module

A0569896 PLC, Analog Input Module

A0567933 PLC, Touch Screen

A0563932 Power Supply, 24VDC

A0568961 Redundant Temperature Safety Controller

LEVEL 3 ( Mechanical Components )

PART # SIZE Description

A0542302 8" O.D. by 12 Ft Long Hi Temp Hose.

A0571107 3" O.D. by 12 Ft Long Hi Temp Hose.

A0570519 Return Air Cooling Coil 600-850 CFM

A0566849 Return Air Cooling Coil 1000-1500 CFM

A0568147 Return Air Cooling Coil 2000-3000 CFM

A0568233 Closed Loop Cooling Coil

A0546119 208-230/460 Volt Blower, 600 CFM 1111

A0562555 575 Volt Blower, 600 CFM 1

A0565900 208-230/460 Volt Blower, 850 CFM 1111

A0572510 380 Volt Blower, 1000 CFM 1

A0572509 230/460 Volt Blower, 1000 CFM 1 1 1

A0572511 575 Volt Blower, 1000 CFM 1

A0559792 380 Volt Blower, 1250 CFM 1

A0559903 230/460 Volt Blower, 1250 CFM 11 1

A0559998 575 Volt Blower, 1250 CFM 1

A0553766 230/460 Volt Blower, 1500 CFM 11 1

A0572513 380 Volt Blower, 2000 CFM 1

A0572512 230/460 Volt Blower, 2000 CFM 1

A0572514 575 Volt Blower, 2000 CFM 1

A0572516 380 Volt Blower, 2500 CFM 1

A0572515 230/460 Volt Blower, 2500 CFM 1

A0572517 575 Volt Blower, 2500 CFM 1

A0559815 380 Volt Blower, 3000 CFM 1

A0568211 230/460 Volt Blower, 3000 CFM 1

A0560003 575 Volt Blower, 3000 CFM 1

W00015335 Dew Point Sensor Manifold

A0548558 Gasket for the Dew Point Sensor

W00015436 Plastic Nut for the Dew Point Sensor

A0572502 O-Ring for Main Valve

A0566879 Main Valve Motor

A0565249 Filter housing Latch

A0565250 Filter Housing Strike

A0566466 Closed Loop Cooling Valve Motor

A0547006 Knob for the Regeneration Filter

A0537908 Handle for Panels.

A0568205 Latch for Panels

A0542231 8" Hose Clamp

A0571107 3" Hose Clamp

LARGE DRYER SPARE PARTS LIST 600,850,1000,1250,

1500,2000,2500, AND 3000

11111

111

11111111

3.2 Feet 3.2 Feet 3.2 Feet 3.2 Feet 3.2 Feet 3.2 Feet 3.2 Feet 3.2 Feet

111

Large Dehumidifying Dryers Appendix 71

8-5 Dryer Identification (Serial Number) Tag

(Located on back of Dryer)

XXX Series Dryer

Model Number XXX-15

Max Drying Capacity HR

460V Serial Number 060701R

1 Date of Manufacture 06/2003

4.5A

Over-current Protection Device (s) 4.5A 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 72

8-5 Technical Assistance

Parts Department

Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610; Fax: [262] 641-8653

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] 423-3183 or call [262] 641-8610

Emergencies after 5pm CST, call [847] 439-5655

We have a qualified service department ready to help. Service contracts are available for most

products. Service contracts are available for most of our products. www.acscustomerservice.com

Sales Department

Call [262] 641-8610 Monday–Friday, 8am–5pm CST

Our products are sold by a world-wide network of independent sales representatives. Contact our Sales

Department for the name of the sales representative nearest you.

Contracting Department

Call [262] 641-8610 Monday–Friday, 8am–5pm CST

Let us install your system. The Contracting 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.

Sterling, Inc.

2900 S. 160th Street

New Berlin, WI 53151

www.sterlco.com

Sterling Dehumidifier Sda Ap 1 Users Manual 882.00295.00 DH1 615 AP1 Large

SDA AP-1 to the manual 680c915d-5c1e-479e-9007-53322393493f

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