SCD 10 Compressed Air Dryer
Part Number: 882.00280.00
Bulletin Number: DH1-625.1
Effective: 04/28/08
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. ____________
© Copyright 2008
All rights reserved.
Table of Contents
CHAPTER 1: SAFETY ...............................................................5
1-1
How to Use This Manual .............................................................................................5
Safety Symbols Used in this Manual.....................................................................5
General Safety Regulations ........................................................................................6
Responsibility ..............................................................................................................6
Warnings and Precautions ..........................................................................................7
1-2
1-3
1-4
CHAPTER 2: FUNCTIONAL DESCRIPTION ............................8
2-1
2-2
2-3
2-4
2-5
Models Covered in This Manual..................................................................................8
General Description.....................................................................................................8
Typical Features and Components .............................................................................8
Options........................................................................................................................8
Safety Features...........................................................................................................9
Safety Circuit Standards........................................................................................9
High Temperature Safety System .........................................................................9
Airflow monitoring Safety System..........................................................................9
Line Cord Plug (115/1/60 units only).....................................................................9
Drying Hopper Air Trap ...............................................................................................9
Remote Membrane Dryer for Low-Dewpoint Operation (Optional) ...........................10
Microprocessor Controls ...........................................................................................11
Identifying the Controller’s Buttons and Indicators..............................................12
Understanding the Controller’s Parameters ........................................................13
Restoring Factory Default Settings............................................................................14
2-6
2-7
2-8
2-9
CHAPTER 3: INSTALLATION.................................................15
3-1
3-2
3-3
3-4
3-5
3-6
Uncrating the Equipment...........................................................................................15
Connecting a Hopper-Mount Dryer to a Hopper........................................................15
Connecting a Floor-Mount Dryer to a Hopper ...........................................................16
Making Electrical Connections ..................................................................................16
Making Compressed Air Connections.......................................................................17
Installing the Remote-Mount Membrane Dryer (Optional).........................................18
CHAPTER 4: OPERATION......................................................19
4-1
4-2
4-3
4-4
Auto-tuning the Dryer ................................................................................................19
Setting the Alarm Value.............................................................................................19
Start-up......................................................................................................................20
Shut-down .................................................................................................................20
CHAPTER 5: MAINTENANCE.................................................21
5-1
5-2
5-3
Preventative Maintenance Schedule.........................................................................21
Cleaning and Replacing the Filters ...........................................................................21
Replacing the Process Heater...................................................................................21
CHAPTER 6: TROUBLESHOOTING.......................................22
10 CFM Compressed Air Dryer
iii
CHAPTER 7: APPENDIX.........................................................25
7-1
Returned Material Policy ...........................................................................................25
7-2 Technical Assistance………………………………………………………………………26
7-3
7-4
Technical Specifications............................................................................................27
Dryer Operating Parameters ...............................................................................28
Dimensions..........................................................................................................29
Spare Parts List ........................................................................................................30
10 CFM Compressed Air Dryer
iv
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
dryer. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.
This manual covers only light preventative 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, and preventive maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the 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 ensure that your 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.
10 CFM Compressed Air Dryer
Chapter 1: Safety
5 of 30
1-2 General Safety Regulations
Read and follow the instructions in this manual before installing, operating or maintaining
any equipment. Additional copies are available from the manufacturer.
Install, operate, and maintain this equipment according to applicable work and safety codes
for your location. This includes OSHA, CE, NEC, CSA, SPI, and many other local, national,
and international regulations. Only qualified persons should work on or with this equipment.
Work only with approved tools and devices.
Before removing, adjusting, or replacing parts on a machine, remember to turn off all air and
electric supplies and all accessory equipment at the machine. You must also disconnect and
lock out electrical and pneumatic power and attach warning tags to the disconnect switch and
air shut off valve.
When you need to perform maintenance or repair work on a 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 dryers, 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 on-current carrying parts of electrical apparatus, electrical enclosures, and the
dryer frame are correctly connected to earth ground with an electrical conductor that complies
with current codes Install in accordance with national and local codes, which apply.
When you have completed the repair or maintenance procedure, check your work, remove
your tools, rigging, and handling equipment. Do not restore power to the dryer until all
persons are clear of the area. Do not start and run the dryer until you are sure all parts are
functioning properly.
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 machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Becoming familiar with materials, inspection, and maintenance and total user responsibility
will assist you in learning potential areas in need of observation for danger.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, warning and danger signs must be observed and obeyed. All actual or potential
danger areas must be reported to your immediate supervisor.
10 CFM Compressed Air Dryer
Chapter 1: Safety
6 of 30
1-4 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.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this dryer, use good judgment and follow these safe practices:
; 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 dryer, remove all objects (tools, nuts, bolts, clamps, bars) from
the hopper area.
; If your dryer has been inoperative or unattended, check all settings before starting the
unit.
; 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 be
adjusted only by authorized personnel, and the keys removed after setting.
; Report unsafe operation, unsafe conditions, unusual dryer action, leakage, and
improper maintenance immediately.
; Never stand or sit where you could slip or stumble into the dryer while working on it.
; Do not wear loose clothing or jewelry, which can be caught while working on a
dryer. In addition, cover or tie back long hair.
; Clean the dryer and surrounding area daily, and inspect the machine for loose,
missing, or broken parts.
; Shut off power to the dryer when it is not in use. Turn the switch to the off position,
or unplug it from the power source.
; Never attempt to move the dryer while it is in operation.
; Always allow time for the dryer to cool off before moving it or servicing the fuse or
air filter.
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.
10 CFM Compressed Air Dryer
Chapter 1: Safety
7 of 30
Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides instructions for installing and operating your 10 cfm compressed air
dryer.
2-2 General Description
Mini compressed air dryers are designed to generate heated, dehumidified air at carefully
controlled temperatures for use in plastic drying systems. Drying systems are sized to meet
specific requirements stated by the purchaser at the time of purchase.
Moisture removal from hygroscopic (moisture attracting) plastic pellets is an essential step in
the manufacture of high-quality plastic products. This dehumidifying dryer is used to
generate very low dew point air, heated to a controlled temperature for drying plastic pellets
and regrind.
Many variables were considered in the selection of your drying system, including type of
materials, residence time, throughput of the extruder or injection molding machine. Should
your operating environment change, the manufacturer can advise you on necessary equipment
and process time and temperature modifications required for your system.
2-3 Typical Features and Components
Electrical solenoid valve
Compressed air filter, regulator, and gauge
Drying temperature range of 120ºF to 400ºF
Display of process temperature set point and actual settings
Process thermocouple located in the process air stream just before the hopper inlet
Nema 1 control enclosure:
a. Fusing
b. Power On light
c. IEC process heater contactor
d. Solid state relay
e. Alarm light
f. High temperature safety system
g. Airflow detection system
2-4 Options
Options can tailor your dryer to meet the exact requirements of the drying task being
performed.
Floor-mount configuration
Membrane compressed air dryer for low dew point operation
220/1/50 operation
230/1/60 operation
10 CFM Compressed Air DryerChapter 2: Functional Description
8 of 30
2-5 Safety Features
This section includes information on safety devices and procedures that are inherent to the 10
cfm compressed air 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.
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 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.
High Temperature Safety System
A high temperature safety system will disable the dryer if the process temperature is too hot.
The high temperature safety is designed so that if it fails, the failure causes a “safe”
condition, and the dryer will not run. The compressed air continues flowing to cool down the
system.
Airflow monitoring Safety System
If the airflow source to the compressed air dryer is below 35 PSI, the unit will shut down and
not run. This is an indication that there is not enough pressure and flow for proper operation
of the unit.
Line Cord Plug (115/1/60 units only)
The line cord plug allows the operator or maintenance personnel to unplug the dryer from its
power source and tag it out. This plug may be tagged with any number of approved electrical
lockout tags. These tags are available at most electrical supply stores. Always disconnect
power before servicing or moving this unit.
DANGER! At no time should anyone remove the lockout or reconnect the twist plug,
other than the person who installed the lockout or who unplugged the twist
plug.
2-6 Drying Hopper Air Trap
Refer to the drying hopper Operation and Installation manual for proper operation of the
drying hopper.
10 CFM Compressed Air DryerChapter 2: Functional Description
9 of 30
2-7 Remote Membrane Dryer for Low-Dew point Operation
(Optional)
Membrane dryers take a small percentage of the dried gas and direct it back in a sweeping
pattern through the module shell. This provides a driving force to remove the moisture with
the minimum purge required.
The moisture vent membrane dryer consists of thousands of hollow-fiber membranes made of
tough temperature and pressure-resistant plastic. The inside surface of these hollow fibers is
coated with an ultra-thin layer of a second plastic that actually separates the water vapor from
the air. This second coating allows air to pass through it over 20,000 times easier than it
allows water to pass. As a result, moisture is expelled rapidly with very little air loss. Two-
stage drying provides the option of using the moisture vent directly at the point-of-use in
combination with refrigerated air dryer.
As a single stage unit, the dryer provides consistent performance from 60ºF to –20ºF outlet
dew point. When combined with a refrigerated air dryer, the moisture vent system will
suppress or reduce the inlet pressure dew point to below –40ºF with very low sweep
requirements.
Figure 1: Remote-Mount Membrane Dryer Airflow Schematic
Water
Air
Dry Air
Humid Air
Purge
Dry Air
10 CFM Compressed Air DryerChapter 2: Functional Description
10 of 30
2-8 Microprocessor Controls
The 10 cfm compressed air dryer uses a microprocessor-based PID temperature controller for
maintaining process air temperature. The controller is a modular, self-contained unit that you
can remove from the mounting housing. All parameters except for the process air set point
are factory set and adjusted. Normally, no field adjustment to the internal controls is
necessary.
Figure 2: Microprocessor Controller
10 CFM Compressed Air DryerChapter 2: Functional Description
11 of 30
Identifying the Controller’s Buttons and Indicators
Button or Indicator
Function
During normal operation, the PV numeric LED
indicator displays the process temperature at the To
Process thermocouple. It also lists parameters during
set-up and error messages if any errors occur.
PV display
During normal operation, the SV numeric LED
indicator displays the set point temperature selected for
the dryer. The dryer then maintains this set point
temperature. This LED indicator also displays
parameter and preset function values during
configuration set-up.
SV display
This LED indicator displays the temperature units (ºF
or ºC) that the dryer is configured to use.
Temperature Unit display
Level button
The Level button is used to enter set-up. There are two
set-up levels available: Operation and Adjustment.
Mode button
The Mode button is used to scroll through paramenters
in set-up modes.
Down Arrow button
The Down Arrow button is used to decrease the set
point temperature during operation. It also decreases
the parameter values in set-up modes.
Up Arrow button
The Up Arrow button is used to increase the set point
temperature during operation. It also increases the
parameter values in set-up modes.
The Alarm 1 indicator lights when the process
temperature exceeds the set point temperature by more
than the alarm deviation value. Alarm output de-
energizes the heaters. Heaters re-energize when the
temperature falls within the acceptable range.
AL1 Alarm 1 indicator
AL2 Alarm 2 indicator
HB Heater Burnout indicator
The Alarm 2 indicator is not used.
(Optional) The Heater Burnout indicator lights when a
heater burnout is detected. The heater burnout alarm
remains On by setting the heater burnout latch. To
reset, turn the power supply off and then on or set the
heater burnout alarm vale to 0.0A.
The Output 1 indicator lights when the controller
signals the process heaters to be energized.
OT1 Output 1 indicator
OT2 Output 2 indicator
STOP Stop indicator
The Output 2 indicator is not used.
The Stop indicator lights when the controller has been
stopped.
CMW Communications indicator
The Communications indicator is not used.
10 CFM Compressed Air DryerChapter 2: Functional Description
12 of 30
Lights when the auto/manual mode is set to manual
mode.
MANU Manual Mode
(Key)
Lights when the setting change protect is ON.
Understanding the Controller’s Parameters
Set-
up
Parameter
Function
Level
Can be set to “RUN” or “STOP.” When “RUN” is selected,
the control is running. When “STOP” is selected, the control
is stopped, and the Stop indicator lights. The default value is
“RUN.”
Run/Stop (r-S)
Can be set from –1999 to 9999. This parameter is used to
indicate how many degrees the process temperature will be
allowed to exceed the set point temperature. An alarm output
will de-energize the heaters. The default value is 25.
Alarm Value (AL-1)
Can be set to “ON” or “OFF.” This feature is used to
automatically set the optimum PID parameters “proportional
band,” “integral time” and “derivative time” for the set point
value by changing the variables that had been modified
previously. The default value is “OFF.”
Auto-tune (At)
Can be set from –199.9 to 999.9. This setting is used to offset
an error between the set point and the actual temperature. The
entire input range is shifted by a set figure preprogrammed by
the operator. The default value is 0.
Temperature Input
Shift (Tns)
Can be set from 0.1 to 999.9. This setting controls the amount
in which the manipulated variable (MV) is proportionate to
the deviated value or controller error. The default value is 8.0.
Proportional Band
(P)
Can be set from 0 to 3999. Setting this feature gives the
control an action that is proportionate to the time integral of
the control error. By using this setting, proportional action is
used in combination with integral action to offset the control
error and the set point will begin to match the control
temperature (PV or process value). The default value is 233.
Integral Time (I)
Can be set from 0 to 3999. Setting the derivative control
provides the controller with the ability to correct for a future
error in the previously set process output. The default value is
40.
Derivative Time (d)
10 CFM Compressed Air DryerChapter 2: Functional Description
13 of 30
2-9 Restoring Factory Default Settings
If the preset parameters on the controller have been tampered with and it no longer properly
controls temperature and displays dew point, you can restore the controllers to the factory
setup. Contact the Service department for detailed instructions.
10 CFM Compressed Air DryerChapter 2: Functional Description
14 of 30
Chapter 3: Installation
3-1 Uncrating the Equipment
The 10 cfm compressed air dryer has a handle at the top of the cabinet to use for lifting. For
hopper-mount configurations, be sure to support the hopper when lifting and placing the
dryer. Use caution and observe safety rules when lifting and placing your dryer. Be sure it is
securely attached and additional bracing is used if necessary.
3-2 Connecting a Hopper-Mount Dryer to a Hopper
When mounting the dryer to an existing hopper, use the adapter and the self-tapping screws
that are provided with the unit to mount the dryer to the inlet of the hopper. The adapter is
pre-drilled with three holes that are used to mount it to the hopper.
Note: In some cases, depending on the drying hopper model, an adapter may not be
required. If an adapter is not required, attach the dryer to the hopper with the
clamps provided, and install the exhaust filter to the drying hopper
outlet/return line.
Use the following procedure to mount the dryer to a hopper using an adapter (See Figure 3):
1. Mark the holes in the inlet tube of the hopper for drilling.
2. Use a 9/64” drill bit to pre-drill for the #8-32 screws that are provided.
3. Spread silicone adhesive over the area where the adapter will mount to the hopper inlet
tubing.
4. Place the adapter onto the tubing and install the three screws to hold it in place. Allow
sufficient time for the silicon to cure before you operate the dryer.
5. Attach the dryer to the hopper with the clamps provided.
6. Install an exhaust filter to the drying hopper outlet/return line.
Figure 3: Typical Hopper-Mount Configuration
10 CFM Compressed Air Dryer
Chapter 3: Installation
15 of 30
3-3 Connecting a Floor-Mount Dryer to a Hopper (Optional)
Use high-temperature flexible dryer hose or rigid tubing to connect the dryer to the drying
hopper. Keep the delivery hose to the drying hopper as short as possible to minimize heat
loss. We strongly recommend insulated hose for maximum energy savings. Make sure that
hoses are not kinked or collapsed.
Use the following procedure to connect a floor-mount dryer to a hopper:
1. Using the clamps provided, clamp a hose adaptor onto the dryer and the hopper. (See
Figure 4.)
Note: Depending on the drying hopper model, the clamp and hose adapter may not be
required. Connect the dryer hose with the hose clamp directly to the process air
inlet of the drying hopper.
2. Install an exhaust filter to the drying hopper outlet/return line.
3. Drying hopper air inlet and outlet locations vary, but always connect hoses so the dry
process air from the dryer enters the bottom of the drying hopper and flows out the
top.
Figure 4: Floor-Mount Configuration
10 CFM Compressed Air Dryer
Chapter 3: Installation
16 of 30
3-4 Making Electrical Connections
The serial tag lists voltage, phase, and amp draw information. Line voltage must be within
plus or minus ten percent of the voltage listed on the serial tag, or damage may occur. Never
supply any voltage other than what the dryer is configured for.
Fulfill all national, state, and local safety and electrical code requirements. A qualified
electrician should make all electrical connections.
Connect main power to the dryer. Install a fused disconnect with a lockout feature in the
power main leading to the dryer. The power drop must include a ground wire. Make sure all
electrical connections are tight.
Note: Due to variances in 220-240 V connections, customers must supply the plug for
these dryer models.
3-5 Making Compressed Air Connections
The compressed air supply must be regulated to 80 PSI (5.5 bars). Low air pressure will
create poor drying performance. If the pressure in the system drops below 35 PSI, the alarm
light will activate and the process heater and solenoid valve will shut off.
Note: For maximum drying efficiency, we recommend a refrigerated compressed air
connection. Not using refrigerated compressed air (to provide pre-conditioned
compressed air to this unit) will affect drying performance and material drying
capabilities.
To achieve the lowest possible dew points, an optional remote-mount membrane dryer
assembly is available. See Section 2-7 on page 10 for more information about the remote-
mount membrane dryer assembly.
Connect a minimum of 3/8” (9 mm) air line to the top of the filter regulator. Compressed air
must be clean, dry, and free of oil. A shut-off is recommended for your in-plant air supply.
In-line filters can handle small amounts of moisture; in-line desiccant filters or packed beds
of granular absorbing polymer can remove oil mist and condensed oil.
10 CFM Compressed Air Dryer
Chapter 3: Installation
17 of 30
3-6 Installing the Remote-Mount Membrane Dryer (Optional)
The membrane drying kit can be mounted anywhere near the compressed air dryer. The kit is
pre-assembled with a bracket that can be mounted to any flat surface with two screws. Use
Figure 5 as a reference for this installation.
1. Remove the large particle filter, including the close nipple, from the inlet of the
compressed air dryer.
2. Attach the large particle filter (including the close nipple) to the membrane drying kit.
Note: The membrane drying kit must have the large particle and the coalescing filters
in place and functioning properly to ensure full drying capabilities of the
membrane. Both filters must be checked and cleaned regularly.
3. Attach the 1/4” NPT elbow to the inlet of the compressed air dryer.
4. Run the 3/8” hose between the outlet of the membrane drying kit and the inlet of the
compressed air dryer. Use thread sealant on all threaded connections.
Figure 5: Membrane Dryer Assembly
10 CFM Compressed Air Dryer
Chapter 3: Installation
18 of 30
Chapter 4: Operation
Before beginning dryer operation, make sure that there is a good compressed air connection
and that the main power is securely plugged in. Check the process hose and hopper exhaust
filter for tight connections. Check all companion equipment, such as the drying hopper; verify
that the loading system is ready for operation. The dryer will not run if a fault condition
exists. Investigate the cause of any faults.
DANGER! Always turn the dryer off before servicing. Do not attempt to check the
alarms on the controller located within the unit enclosure unless you are a
qualified electrician.
4-1 Auto-tuning the Dryer
Although the controller is calibrated at the factory, the unit should be auto-tuned prior to
dryer start-up.
Use the following procedure to auto-tune the dryer:
1. Press the Level button one time to enter the Adjustment level.
2. Press the Mode Key one time. The PV display will read “At.”
3. Press the Up Arrow button to change the value to “ON.”
4. Press the Level button to begin auto-tuning and return to the Operation level.
The unit will automatically auto-tune. While this process is taking place, the SV
display will blink the set point value. When the SV display stops blinking, the auto-
tune process is finished.
Note: It is recommended that the unit be auto-tuned when the pressure and airflow of
the compressed air have been adjusted, and the dryer is running close to
process temperature set point.
4-2 Setting the Alarm Value
The Alarm Value setting determines how many degrees the process temperature is allowed to
exceed the set point temperature before the high temperature alarm is triggered and the heater
turned off.
Use the following procedure to set the alarm value:
1. Press the Mode button two times to select the Alarm Value 1 parameter. (The PV
display will read “AL-1”).
2. Use the Up Arrow and Down Arrow buttons to change the value.
3. Press the Mode button to accept the value and begin operation.
Note: The factory default valve for this setting is 25.
10 CFM Compressed Air Dryer
Chapter 4: Operation
19 of 30
4-3 Start-up
Use the following procedure to start the dryer:
1. Turn on the disconnect switch in the power drop, close the slide gate at the bottom of
the drying hopper.
2. Close the slide gate at the bottom of the drying hopper.
3. Fill the drying hopper with material.
4. Turn the ON/OFF switch to “ON” to energize the display panel and turn on the
solenoid and the heater.
5. Use the Up Arrow and Down Arrow buttons to set the process set point on the
temperature controller.
Note: Consult the resin manufacturer for the recommended drying temperature.
6. Press the Mode button one time to make sure the controller’s Run/Stop parameter is
set to “RUN.”
7. Use the Up Arrow or Down Arrow button to change the value to “RUN.”
8. Press the Mode button to begin operation.
9. After the proper pre-drying time for the initial hopper fill has elapsed, fully open the
drying hopper slide gate.
Note: To allow proper residence time during continuous processing, maintain the
material level in the hopper at the midpoint of the air trap assembly.
4-4 Shut-down
Use the following procedure to shut down the dryer:
1. When processing is complete, close the hopper slide gate and shut down any in-line
companion equipment.
2. Lower the process temperature controller set point to a value of 100º Fahrenheit.
3. Allow at least one minute of run time so that the compressed air continues to flow
through the unit and cool down the heating components.
4. Turn the On/Off switch to “Off.”
5. If needed, empty the drying hopper.
6. For maintenance or a long-term shutdown, open the electrical disconnects at the dryer
and at the power drop.
10 CFM Compressed Air Dryer
Chapter 4: Operation
20 of 30
Chapter 5: Maintenance
This dryer is designed to be virtually maintenance-free. This unit is factory-sealed. Any
service required on this unit must be performed by factory personnel at the manufacturer’s
facility.
WARNING! The 10 cfm compressed air dryer is sealed at the factory. Removing
this seal and opening the box that houses the dryer will void your
warranty. Please contact the manufacturer for assistance.
5-1 Preventative Maintenance Schedule
Weekly
Inspect all filters for wear, and replace/clean if dirty or worn
Check to make sure that all hose connections are air tight
Monthly
Lock out electrical power and inspect the main power supply for integrity.
5-2 Cleaning and Replacing the Filters
The 10 cfm compressed air dryer uses a large particle air filter in the process air system to
clean the compressed air before it enters the drying cabinet. The optional remote-mount
membrane dryer assembly features a coalescing filter in addition to the large particle air filter.
Regular filter cleaning is essential to keep the dryer operating at peak efficiency.
Use the following procedure to clean or replace the process air filter or the membrane dryer
coalescing filter:
1. Turn off and lock out electrical power to the dryer.
2. Remove the clear bowl at the bottom of the filter. (See Figure 6).
3. Discard the contents of the clear filter bowl.
4. Visually inspect the filter element.
5. If needed, clean the filter element with compressed air or replace it.
Caution! Do not clean or wash the filter with water.
6. Replace the clear bowl.
Figure 6: Large Particle Filter
10 CFM Compressed Air Dryer
Chapter 5: Maintenance
21 of 30
5-3 Replacing the Fuse Outside of the Cabinet
Note: If the compressed air dryer does not start when the ON/OFF switch is in the
“ON” position, check the main power supply to ensure that it is properly installed. If
the main power supply is correct, check the fuse. This is located on the front of the
driver cabinet. Use the following procedure to check and, if needed, replace the fuse.
1. Make sure that the main power to the dryer is shut off and locked out.
2. Locate the fuse holder that houses the fuse for the dryer (see picture below for fuse
holder location).
3. Using a standard flat-head screwdriver, remove the insert that holds the fuse from the
fuse holder.
4. Separate the insert from the fuse.
5. Using a multimeter, check for continuity between the two ends of the fuse.
6. If there is no continuity, replace the fuse. See Spare Parts List for fuse part number.
7. Insert new fuse into the fuse holder.
8. Using a standard flat-head screwdriver, turn the fuse into the installed position within
the fuse holder.
Fuse Holder
10 CFM Compressed Air Dryer
Chapter 5: Maintenance
22 of 30
Chapter 6: Troubleshooting
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 unit turned off, power disconnected, and with the machine tagged as
out of service.
Problem
Possible Cause
Possible Remedy
Drying systems are designed
for the material that was
Material being dried differs
from material specified at the originally specified.
time of purchase.
Different materials may need
a longer residence time or a
different drying temperature.
Loss or reduction in drying
capacity.
Inspect for air leaks; replace
as needed.
Break in flex hose to drying
hopper.
Check resin manufacturer’s
data sheet for proper drying
temperature. Make sure plant
personnel are aware of the
correct process temperature
set point.
Process temperature set too
high due to operator error.
Material in drying hopper
cakes, or meltdown occurs.
High temperature alarm not
set properly.
Reset high temperature
alarm.
Process set point is out of
acceptable range.
Restore temperature
controller to factory pre-sets.
Function set for degrees
Celsius (ºC), set point at
degrees Fahrenheit (ºF).
Verify correct Celsius or
Fahrenheit settings.
Nothing displays when the
controller is turned on.
Verify that the thermocouple
is properly installed in the
inlet tube.
Process thermocouple not in
airflow.
The internal mechanism is
not inserted properly into the
No setting change possible on housing.
Properly insert the internal
mechanism into the housing.
temperature controller.
The power supply is not
connected to its terminals
properly.
Properly connect the power
supply to the power supply
terminals.
Supply a voltage of 85 to
No power is supplied, or the 125 VAC to the power
supplied power is not within supply terminals of the
the specified range.
controller or 220-240 V for
higher voltage units.
10 CFM Compressed Air Dryer Chapter 6: Troubleshooting
23 of 30
Problem
Possible Cause
Possible Remedy
Check control power fuse for
continuity. Turn disconnect
switch and control power
switch ON.
Disconnect switch or Control
Power switch not set to ON.
Control Power fuse blown.
The key protection switch is Set the key protection switch
set to ON.
to OFF.
Compressed air source is no
longer sufficiently above 35
Check compressed air source
for proper functioning.
Alarm light is on and unit has psi.
no air pressure.
Regulator is set below 35
psi.
Check regulator for proper
functioning.
10 CFM Compressed Air Dryer Chapter 6: Troubleshooting
24 of 30
Chapter 7: Appendix
7-1 Returned Material Policy
Credit 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 returned material purchased from the manufacturer 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.
10 CFM Compressed Air Dryer
Chapter 7: Appendix
25 of 30
7-2 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 of our
products. www.acscustomerservice.com
Sales Department
Call [262] 641-8610 Monday—Friday, 8am—5pm CST, fax [262] 641-8653
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
10 CFM Compressed Air Dryer
Chapter 7: Appendix
26 of 30
7-3 Technical Specifications
Average dew point: -10ºF (-23ºC)
Average dew point with optional membrane dryer: -40ºF (-40ºC)
Heating capabilities up to 400ºF
Large particle compressed air filter
Exhaust air cartridge filter
1/16 DIN PID temperature controller
High process temperature alarm light
Automatic shutoff system to monitor compressed air supply
Full load amps:
12.5 @ 115V
6.25 @ 240V
1.5”, 2”, 2.5”, or 3” OD process air outlet (specify)
Approximate weight: 25 lbs. (11.3 kg)
10 CFM Compressed Air Dryer
Chapter 7: Appendix
27 of 30
Dryer Operating Parameters
Material
Drying
Temp, ºF,
(ºC)
Drying Drying Hopper Capacity,* lbs./hr (kg/hr)
time in
hours
Initial
Final
0.4 cu. ft. 0.8 cu. ft. 0.9 cu. ft.
moisture moisture (11 liter) (22 liter) (25 liter)
content. content
H20 in % H20 in % hopper
drying
drying
hopper
drying
hopper
ABS
ASA
CA
CP
EVA
176 (80)
212 (100)
176 (80)
167 (75)
176 (80)
2-3
3
0.45
0.15
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)
4.6 (2.1) 9.2 (4.2) 10.4 (4.7)
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)
5.6 (2.5) 11.2 (5.1) 9.0 (4.1)
2-3
2-3
2-3
3.5
4-6
4-6
4-6
4-6
4-6
0.7
1.0
0.15
0.15
Ionomere 194 (90)
4.0 (1.8) 8.0 (3.6)
2.8 (1.3) 5.6 (2.5)
2.8 (1.3) 5.6 (2.5)
2.8 (1.3) 5.6 (2.5)
2.8 (1.3) 5.6 (2.5)
2.8 (1.3) 5.6 (2.5)
5.2 (2.3)
6.3 (2.9)
6.3 (2.9)
6.3 (2.9)
6.3 (2.9)
6.3 (2.9)
PA11
PA12
PA6
PA6.6
PA6.6
GF35
PBT
167 (75)
167 (75)
176 (80)
176 (80)
176 (80)
0.7
0.7
0.5
0.5
0.5
0.07
0.07
0.05
0.05
0.04
266 (130)
248 (120)
3-4
2-4
3-4
1-2
4
4
4
4-6
0.25
0.16
0.5
0.02
0.01
0.02
0.01
4.0 (1.8) 8.0 (3.6)
4.6 (2.1) 9.2 (4.2)
4.6 (2.1) 9.2 (4.2)
9.0 (4.1)
10.4 (4.7)
10.4 (4.7)
15.8 (7.1)
7.9 (3.6)
7.9 (3.6)
7.9 (3.6)
5.2 (2.3)
PC
PE Filled 185 (85)
PE
PEEK
PEI
PES
PETP
194 (90)
302 (150)
302 (150)
302 (150)
300-392
(150-200)
149 (65)
176 (80)
212 (100)
194 (90)
212 (100)
284 (140)
176 (80)
302 (150)
176 (80)
158 (70)
176 (80)
176 (80)
230 (110)
194 (90)
0.05
7 (3.2)
14 (6.4)
3.5 (1.6) 7 (3.2)
3.5 (1.6) 7 (3.2)
3.5 (1.6) 7 (3.2)
2.3 (1.0) 4.6 (2.1)
0.25
0.43
0.25
0.01
0.02
0.002
PETG
PMMA
POM
PP
PPO
PPS
4-5
2-3
3-4
2
2-3
3-4
1-2
3-4
3-4
1-2
2-3
2
0.1
0.25
0.2
0.1
0.2
0.1
0.05
0.3
0.4
0.3
0.3
0.3
0.04
0.02
0.05
0.05
0.02
0.05
0.02
0.05
0.01
0.10
0.03
0.03
3.5 (1.6) 7 (3.2)
7.9 (3.6)
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)
4.6 (2.1) 9.2 (4.2)
7 (3.2) 14 (6.4)
10.4 (4.7)
15.8 (7.1)
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)
4.6 (2.1) 9.2 (4.2)
7 (3.2) 14 (6.4)
4.6 (2.1) 9.2 (4.2)
4.6 (2.1) 9.2 (4.2)
10.4 (4.7)
15.8 (7.1)
16.4 (7.4)
16.4 (7.4)
PS
PSU
PUR
PVC
SAN
SB
9.3 (4.2) 18.6 (8.4) 41.9 (19)
5.6 (2.5) 11.2 (5.1) 25.2 (11.4)
7 (3.2)
4.6 (2.1) 9.2 (4.2)
14 (6.4)
31.5 (14.3)
16.4 (7.4)
TPE
TPU
3-4
2-3
0.4
0.02
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)
* Performance may vary based on initial quality of the compressed air supply to the dryer.
10 CFM Compressed Air Dryer
Chapter 7: Appendix
28 of 30
Dimensions
12
(305)
13.4
(339)
12.25
(311)
15.7
(398)
6.8
(172)
7.3
(185)
10 CFM Compressed Air Dryer
Chapter 7: Appendix
29 of 30
7-4 Spare Parts List
Parts not included in this list must be replaced by the factory.
Part No.
Quantity
Description
35452
1
1
1
2
1
Filter Regulator
Fuse (110 volt)
Fuse 220/1/50
Fuse 230/1/60
Hopper Mounting
CLDMP
725.00002.00
725.00001.00
725.00001.00
CT92241
CT94233
1
Hopper Mounting
Gasket
10 CFM Compressed Air Dryer
Chapter 7: Appendix
30 of 30
|