Sterling Dehumidifier 350 2100 CFM User Manual

OPERATIONANDINSTALLATIONMANUAL  
SDA SERIES 350 - 2100 CFM  
LARGE DEHUMIDIFYING DRYERS  
IMPORTANT: PLEASE READ CAREFULLY BEFORE ATTEMPTING TO INSTALL OR OPERATE EQUIPMENT  
Bulletin No: DH1-655-1  
Part No: 882.00225.00  
Effective: 4-28-08  
 
Shipping Info  
Unpacking and Inspection  
You should inspect your 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 it. You should have:  
; 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 to expedite your  
return. Hold the items until you receive shipping instructions.  
Returns  
Do not return any damaged or incorrect items until you receive shipping instructions from the  
shipping department.  
DH1-655.1  
iii  
 
Table of Contents  
CHAPTER 1: SAFETY................................................................6  
1-1  
How to Use This Manual .............................................................................................6  
Safety Symbols Used in this Manual.....................................................................6  
Safety Tag Information................................................................................................7  
Dryer Safety Tags .................................................................................................7  
Warnings and Precautions ..........................................................................................8  
Responsibility ..............................................................................................................9  
General Responsibility ..........................................................................................9  
Operator Responsibility.........................................................................................9  
Maintenance Responsibility.................................................................................10  
Reporting a Safety Defect ...................................................................................11  
Responsibility ............................................................................................................11  
1-2  
1-3  
1-4  
1-5  
CHAPTER 2: FUNCTIONAL DESCRIPTION...........................12  
2-1  
2-2  
2-3  
2-4  
2-5  
2-6  
2-7  
2-8  
Models Covered in This Manual................................................................................12  
General Description...................................................................................................12  
Typical Features and Components ...........................................................................12  
Optional Features......................................................................................................12  
The Closed Loop Drying System...............................................................................13  
What is Desiccant?....................................................................................................13  
The Process/Regeneration Cycle..............................................................................13  
Specifying a Drying System ......................................................................................14  
CHAPTER 3: INSTALLATION..................................................17  
3-1  
3-2  
3-3  
3-4  
3-5  
3-6  
Work Rules................................................................................................................17  
Electrical Connections...............................................................................................17  
Check For Proper Blower Rotation............................................................................17  
Dryer/Drying Hopper Process Air Hose Connection .................................................17  
Aftercooler Cooling Water Connection......................................................................18  
Drying Hopper Air Trap .............................................................................................18  
CHAPTER 4: CONTROL PANEL.............................................20  
4-1  
4-2  
4-3  
4-4  
4-5  
4-6  
4-7  
Control Panel Indicator Lights ...................................................................................20  
Switches and Meters.................................................................................................22  
PLC Control...............................................................................................................23  
Process Air Temperature Controller..........................................................................23  
Temperature Controller LED Indicators.....................................................................25  
Temperature Controller Keys – (See Figure 5 in Section 3-6) ..................................26  
Optional Communications Protocols .........................................................................26  
CHAPTER 5: STARTUP, SHUTDOWN & OPERATION..........27  
5-1  
5-2  
5-3  
5-4  
Pre-Startup Checks...................................................................................................27  
Startup.......................................................................................................................27  
Shutdown ..................................................................................................................28  
Setting the Process Air Temperature ........................................................................28  
DH1-655.1  
iv  
 
5-5  
5-6  
5-7  
5-8  
5-9  
Setting the High and Low Temperature Alarms ........................................................28  
Temperature Controller Autotune Procedure ............................................................29  
Temperature Controller Internal Switches.................................................................29  
Temperature Controller Anti-Tamper Lockout Switch ...............................................29  
Changing the Display from Fahrenheit to Centigrade ...............................................30  
5-10 Setting the Dewpoint Extend Shift Point....................................................................30  
5-11 Regeneration Monitoring System Signal Processor..................................................31  
5-12 Auxiliary Process Safety System (Optional)..............................................................32  
5-13 Seven Day Timer (Optional)......................................................................................32  
CHAPTER 6: MAINTENANCE .................................................35  
6-1  
6-2  
6-3  
6-4  
6-5  
6-6  
6-7  
6-8  
6-9  
Servicing the Process Air Filters (Models 350-700) ..................................................35  
Filter Cleaning/Replacement.....................................................................................35  
Servicing the Process Air Filters (Models 850 through 2100) ...................................36  
Servicing the Regeneration Filter..............................................................................37  
Dirty Filter Alarm Calibration .....................................................................................37  
Dewpoint Control System Service.............................................................................38  
Symptoms of Worn Out Desiccant ............................................................................38  
Desiccant Replacement Procedure...........................................................................39  
Process Heater Replacement Procedure..................................................................40  
6-10 Regeneration Heater Replacement Procedure .........................................................41  
6-11 Restoring a Temperature Controller to the Factory Setup ........................................42  
6-12 Regeneration Monitor Advanced Programming ........................................................48  
CHAPTER 7: TROUBLESHOOTING .......................................52  
CHAPTER 8: APPENDIX..........................................................55  
8-1  
8-2  
Customer Satisfaction Warranty Program...................Error! Bookmark not defined.  
Technical Assistance.................................................................................................58  
Parts Department ..................................................Error! Bookmark not defined.  
Service Department...............................................Error! Bookmark not defined.  
Sales Department..................................................Error! Bookmark not defined.  
Contract Department.............................................Error! Bookmark not defined.  
DH1-655.1  
v
 
Chapter 1: Safety  
1-1 How to Use This Manual  
Use this manual as a guide and reference for installing, operating, and maintaining your  
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 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  
dehumidifying 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 your 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.  
350-2100 cfm Dryers  
Chapter 1: Safety  
6 of 58  
 
1-2 Safety Tag Information  
Dryer Safety Tags  
Hot!  
Read Operation  
and Installation  
Manual  
High Voltage  
Earth Ground  
Inside Enclosure  
PE Protected Earth  
Ground  
Lifting Point  
350-2100 cfm Dryers  
Chapter 1: Safety  
7 of 58  
 
1-3 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.  
; Use EXTREME CAUTION when working with dryer. HIGH HEAT can be  
dangerous. Keep body parts, tools, clothing, and debris away from dryer.  
; 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 close at hand and  
ready for use if needed.  
; Do not restore power until you remove all tools, test equipment, etc., and the  
equipment and related components are fully reassembled.  
; Only PROPERLY TRAINED personnel familiar with the information in this  
manual should work on this equipment.  
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.  
350-2100 cfm Dryers  
Chapter 1: Safety  
8 of 58  
 
1-4 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.  
Each individual must take responsibility for observing the prescribed safety rules as outlined.  
All warning and danger signs must be observed and obeyed. All actual or potential danger  
areas must be reported to your immediate supervisor.  
General Responsibility  
No matter who you are, safety is important. Owners, operators and maintenance personnel  
must realize that every day, safety is a vital part of their jobs.  
If your main concern is loss of productivity, remember that production is always affected in a  
negative way following an accident. The following are some of the ways that accidents can  
affect your production:  
Loss of a skilled operator (temporarily or permanently)  
Breakdown of shop morale  
Costly damage to equipment  
Downtime  
An effective safety program is responsible and economically sound.  
Organize a safety committee or group, and hold regular meetings. Promote this group from  
the management level. Through this group, the safety program can be continually reviewed,  
maintained, and improved. Keep minutes or a record of the meetings.  
Hold daily equipment inspections in addition to regular maintenance checks. You will keep  
your equipment safe for production and exhibit your commitment to safety.  
Please read and use this manual as a guide to equipment safety. This manual contains safety  
warnings throughout, specific to each function and point of operation.  
Operator Responsibility  
The operator’s responsibility does not end with efficient production. The operator usually has  
the most daily contact with the equipment and intimately knows its capabilities and  
limitations.  
Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or  
through a casual attitude toward machinery formed over a period of months or years. Your  
employer probably has established a set of safety rules in your workplace. Those rules, this  
manual, or any other safety information will not keep you from being injured while operating  
your equipment.  
350-2100 cfm Dryers  
Chapter 1: Safety  
9 of 58  
 
Learn and always use safe operation. Cooperate with co-workers to promote safe practices.  
Immediately report any potentially dangerous situation to your supervisor or appropriate  
person.  
REMEMBER:  
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 check the following:  
Remove all tools from the dryer;  
Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in 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 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 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.  
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.  
350-2100 cfm Dryers  
Chapter 1: Safety  
10 of 58  
 
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  
power. Attach warning tags to the disconnect switch.  
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 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 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 dryer over to the operator for production, verify all dryer 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.  
1-5 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, speed limitations, screens, and guard  
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.  
350-2100 cfm Dryers  
Chapter 1: Safety  
11 of 58  
 
Chapter 2: Functional Description  
2-1 Models Covered in This Manual  
This manual provides operation, installation, and maintenance instructions for  
WD/SDA/CDA 350, 425, 500, 600, 700, 850, 1000, 1250, 1500, 1800, and 2100 cfm large  
dehumidifying dryers in both standard 300˚ F and 400˚ F high temperature “-RT” models.  
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.  
2-2 General Description  
Dehumidifying Dryers are designed to generate heated, dehumidified air at carefully  
controlled temperatures for use in closed-loop plastic drying systems. Drying systems are  
sized to meet the 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.  
ACS 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.  
2-3 Typical Features and Components  
1. Branch Fusing provides additional protection to the operator and the components on  
the dryer's sub-panel.  
2. Dewpoint Monitor indicates dryer efficiency  
2-4 Optional Features  
Options can tailor an ACS dryer to meet the exact requirements of the drying task being  
performed.  
Dirty filter indicator to advise the operator when it's time to clean the filters.  
Water-cooled aftercooler for closed loop regeneration air cooling  
SMART PLC to combine PLC features and a "Plain English" interface. This option is  
fully described in its own manual.  
Heater Burnout Indicator to monitor the heater(s) amp draw.  
Compressed air filter cleaning to lower maintenance on regrind/dusty material drying  
processes.  
Auxiliary high temperature safety system to cut high voltage to the blowers and  
heaters in the event of run-away process heaters.  
Seven day timer to allow programmable dryer start up.  
Communications to meet customer needs.  
Drying Hoppers come in many sizes and mounting configurations.  
Conveying Equipment to transport material to and from the drying system.  
Insulated Process Air Hose to minimize heat loss between the dryer and the drying  
hopper.  
350-2100 cfm Dryers  
Chapter 2: Functional Description  
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2-5 The Closed Loop Drying System  
ACS 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, 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 ACS because the process air is typically much  
drier than ambient air, even after carrying moisture out of the plastic resin. Recycling process  
air maintains drying efficiency at a consistently high level.  
Figure 1: WD/SDA/CDA 350-2100 Dryer Specifications  
Model  
Number  
Amp  
Draw  
Dimensions  
Hose  
Connection  
Shipping  
Weight  
Process  
Blower  
Regen  
Blower  
Desiccant  
Lbs./Bed  
(Inches)  
W
(Inches)  
I.D.  
4
460-3-60  
L
H
Lbs.  
1000  
1000  
1100  
1100  
1200  
1200  
1450  
1450  
1600  
1600  
Hp.  
5
5
Hp.  
½
½
½
½
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
Large  
30  
30  
30  
30  
40  
40  
40  
40  
Small  
76  
76  
90  
90  
350  
350-RT  
425  
425-RT  
500  
500-RT  
600  
600-RT  
700  
700-RT  
850  
850-RT  
1000  
1000-RT  
1250  
1250-RT  
1500  
1500-RT  
1800  
1800-RT  
2100  
2100-RT  
56  
56  
61  
61  
63  
63  
58  
58  
59  
59  
88  
88  
88  
88  
88  
88  
94  
94  
94  
94  
94  
94  
56  
56  
52  
52  
66  
66  
56  
56  
66  
66  
84  
84  
84  
84  
84  
84  
73  
73  
82  
82  
94  
94  
88  
88  
93  
93  
90  
90  
90  
90  
90  
90  
90  
90  
90  
90  
98  
98  
4
5
5
5
5
6
6
6
6
8
8
8
8
8
8
8
7½  
7½  
7½  
7½  
10  
10  
10  
10  
3
100  
100  
120  
120  
135  
135  
120  
120  
130  
130  
180  
180  
240  
240  
310  
310  
360  
360  
40  
40  
103  
141  
113  
146  
138  
194  
156  
213  
179  
235  
203  
278  
120  
120  
120  
120  
120  
120  
120  
120  
120  
120  
120  
120  
3
7½  
7½  
7½  
7½  
7½  
7½  
10  
10  
15  
15  
100  
100  
100  
100  
100  
100  
8
8
8
10  
10  
2-6 What is Desiccant?  
Desiccant is a material which attracts and holds (absorbs) water from the air. The desiccant  
ACS 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".  
2-7 The Process/Regeneration Cycle  
ACS dryers have two desiccant beds. While one bed is on-line in the process air loop, the  
other is off-line being regenerated.  
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Chapter 2: Functional Description  
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Process Return Air  
From Drying Hopper  
Bleed  
When a desiccant bed is on-  
line, it absorbs moisture  
from the process air. In  
time, the bed becomes  
saturated with moisture and  
needs to be regenerated.  
The dryer automatically  
redirects the process  
Upper  
Control  
Valve  
Regeneration  
Blower  
Process  
Delivery  
Air  
Process  
Filter  
Desiccant  
Bed  
Desiccant  
Bed  
Assembly  
Regeneration  
Heater  
airflow to the second bed,  
and starts the regeneration  
cycle on the first bed.  
Process  
Blower  
Process  
Heaters  
Lower  
Control  
Valve  
During regeneration, air is  
heated to approximately  
550°F and forced through  
Figure Two:  
Airflow Diagram  
the desiccant bed. The moisture driven off the bed is bled to the atmosphere.  
If the temperature of the air bled to atmosphere (bleed temperature) is measured, a rise can be  
observed after a period of time. 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.  
Dryer models 350 through 2100 dryers are equipped with the Dewpoint Extend feature. 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.  
2-8 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, the manufacturer can advise you on necessary equipment and  
process time and temperature modifications.  
350-2100 cfm Dryers  
Chapter 2: Functional Description  
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Figure 3: Dryer Dimensions  
34" RADIUS  
DOOR CLEARANCE  
ELECTRICAL ENCLOSURE  
DESICCANT TOWER  
(LEFT SIDE)  
TOP VIEW  
OPTIONAL  
AFTERCOOLER  
A
REGEN BLOWER AND FILTER  
PROCESS BLOWER  
PROCESS  
AIR OUTLET  
1.5" MPT  
INLET  
1
2
3
4
E
B
1.5" MPT  
OUTLET  
C
REAR VIEW  
D
PROCESS AIR  
RETURN, FILTER  
INLET  
PROCESS RETURN  
FILTER  
PROCESS HEATER  
1) PROCESS BLOWER PRES SWITCH  
2) REGEN. DIRTY FILTER PRES. SWITCH  
3) REGEN BLOWER PRES. SWITCH  
4) DIRTY PROCESS FILTER PRES. SWITCH  
?
350-2100 cfm Dryers  
Chapter 2: Functional Description  
15 of 58  
 
Figure 4: Dryer Dimensions  
SUGGESTED  
MINIMUM  
VERTICAL  
24"  
CLEARANCE  
LEFT  
SIDE  
VIEW  
F
I
18"  
MINIMUM  
MAINTENANCE  
CLEARANCE  
G
H
Model  
850  
A
84  
B
C
56  
D
E
90  
F
G
H
74  
I
88  
88  
88  
34 ½  
34 ½  
34 ½  
44 ½  
44 ½  
44 ½  
87 ½  
87 ½  
87 ½  
88  
84 ½  
84 ½  
84 ½  
70 ½  
70 ½  
70 ½  
83  
83  
83  
83  
83  
83  
1000  
1250  
1500  
1800  
2100  
84  
56  
90  
74  
84  
56  
90  
74  
100  
100  
100  
90 ½  
90 ½  
90 ½  
82 ½  
82 ½  
82 1/2  
90 ½  
90 ½  
90 ½  
91 ½  
91 ½  
91 ½  
88  
88  
350-2100 cfm Dryers  
Chapter 2: Functional Description  
16 of 58  
 
Chapter 3: Installation  
3-1 Work Rules  
The installation, operation, and maintenance of this equipment must be conducted in  
accordance with all applicable work and safety codes for the installation location. This may  
include, but not limited to, OSHA, NEC, CSA, and any other local, national and international  
regulations.  
1. Read and follow these operating instructions when installing, operating and  
maintaining this equipment. If the instructions become damaged or unreadable,  
additional copies are available from the manufacturer.  
2. Only qualified personnel familiar with this equipment should work on or with this  
dryer.  
3. Work with approved tools and devices.  
4. Disconnect the electricity before maintenance or service. If the dryer is installed with  
a power cord that can be unplugged, unplug it. If the dryer is permanently wired to a  
power main, a fused power disconnect must be installed to allow the disconnect to be  
locked in the "OFF" position. Open and lock out the disconnect installed in the  
control enclosure.  
3-2 Electrical Connections  
The voltage, phase and amp draw information is listed on the serial tag.  
; Line voltage must be within ±10% of the voltage listed on the serial tag, or damage  
may occur. Phase imbalance must be less than 5%.  
; Fulfill all national, state and local safety and electrical code requirements.  
; Connection should be made by a qualified electrician.  
; 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.  
3-3 Check For Proper Blower Rotation  
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.  
Reverse the wires at the motor starters only if one blower is rotating incorrectly.  
3-4 Dryer/Drying Hopper Process Air Hose Connection  
; Use high-temperature flexible dryer hose or rigid tubing to connect the dryer to the  
drying hopper.  
350-2100 cfm Dryers  
Chapter 3: Installation  
17 of 58  
 
; 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.  
3-5 Aftercooler Cooling Water Connection  
The Aftercooler cools the moist air returning to the dryer from the drying hopper. The  
aftercooler can cool the return air from 250°F to about 150°F. This maintains the dryer's  
efficiency and condenses unwanted plasticizers from the airstream.  
1. Support both sides of the fitting when making the cooling water connections to  
prevent damage to the aftercooler coil.  
2. Connect 85°F water to the 1½" NPT 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.  
Aftercooler  
Model  
Recommended Cooling  
Water Flow Rate (GPM)  
6.6 gpm  
AFT350  
AFT425  
AFT500  
AFT600  
AFT700  
AFT850  
AFT1000  
AFT1250  
AFT1500  
AFT1800  
AFT2100  
10 gpm  
10 gpm  
13.2 gpm  
18 gpm  
18 gpm  
22 gpm  
22 gpm  
25 gpm  
25 gpm  
25 gpm  
3-6 Drying Hopper Air Trap  
ACS’s exclusive air trap assembly in the top of the drying hopper prevents ambient air from  
contaminating the material being dried.  
5. Keep the material level above the bottom edge of the air trap for maximum  
efficiency.  
6. Use a hopper loader or vacuum conveying system to maintain the proper material  
level.  
350-2100 cfm Dryers  
Chapter 3: Installation  
18 of 58  
 
Figure 5: Typical Control Panel  
Process Blower On  
Process Heater On  
WD Series  
Dehumidifying Dryer  
s Air Temperature Controller  
Regeneration Dirty Filter  
Process Delivery Temperature  
PV  
Process Dirty Filter  
Process  
Process  
Process  
Blower On  
Heater On  
Dirty Filter  
F
SV  
High Process  
Air Temp  
Low Process Process Blower  
Air Temp Failure  
Low Process Air Temp  
RMT  
AT  
Regeneration Heater On  
Regeneration Blower On  
Process Blower Failure  
High Process Air Temp  
High Dew Point  
Regeneration Exit Temperature  
Regen  
Blower On  
Regen  
Heater On  
Regen  
Dirty Filter  
DATA  
TEACH  
Left Bed In Regeneration  
High Regen  
Air Temp  
Low Regen  
Air Temp  
Regen Blower  
Failure  
High  
Dew Point  
Left Bed  
In Regen  
Right Bed  
In Regen  
Regeneration Monitor  
egeneration Air Temperature  
egeneration Air Temperature  
Regeneration Blower Failure  
Process Dew Point  
Valve Position  
Fault  
Set Point  
Critical Alarm  
Silence  
1
2
-15  
-25 -20  
-10  
-5  
-35  
-30  
0
-40  
DEW POINT(F.)  
Critical Alarm Silence  
Dual Set Point Selector  
Control Power  
Start/Stop  
Sequence  
Shutdown  
Off  
On  
Adjustment  
Valve Position Fault  
A0542533  
Process Air Dewpoint Meter  
Sequence Shutdown  
Start/Stop  
Control Power Switch  
Redundant High Temp Safety  
Redundant High Temp  
Reset  
Redundant High Temp  
Alarm  
DATA  
TEACH  
Redundant High Temperature Alarm  
Redundant High Temperature Rese  
Redundant High Temperature Safet  
A0542534  
Process Heater Amps  
100  
100  
100  
150  
50  
150  
50  
150  
50  
0
200  
0
200  
0
200  
A-C AMPERES  
A-C AMPERES  
A-C AMPERES  
Heater Burn Out Indicator Amp Met  
Regen Heater Amps  
30  
30  
30  
45  
45  
45  
60  
60  
60  
15  
15  
15  
0
75  
0
75  
0
75  
A-C AMPERES  
A-C AMPERES  
A-C AMPERES  
A0542757  
Seven Day Timer  
Programmed Start/Stop  
A0544749  
OPTIONAL EQUIPMENT SHOWN  
350-2100 cfm Dryers  
Chapter 3: Installation  
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Chapter 4: Control Panel  
4-1 Control Panel Indicator Lights  
PROCESS BLOWER ON  
This indicator lights when the process blower is energized.  
PROCESS HEATER ON  
This indicator lights when the process air heaters are energized.  
HIGH PROCESS AIR TEMPERATURE ALARM  
; This indicator lights when the temperature at the process air thermocouple is above  
the set high alarm value.  
; When the indicator lights, the alarm relay is energized and all the heaters turn off  
while the blowers remain on.  
; The alarm mode and value are factory-set to track 25°F above the process setpoint.  
The alarm value is a deviation above the process setpoint.  
; When the temperature at the process thermocouple returns to within the acceptable  
range, the alarm output is de-energized and all the heaters turn on again  
automatically.  
; The alarm range may be altered - See Section 5-5.  
REGEN BLOWER ON  
This indicator lights when the regeneration blower is energized.  
REGEN HEATER ON  
This indicator lights when the regeneration heater is on.  
LEFT BED REGENERATING & RIGHT BED REGENERATING  
The indicator lit shows which bed is currently being regenerated [off-line].  
HIGH DEW POINT ALARM  
This indicator lights when the process air delivery dew point exceeds the dew point shift  
point, as set by the adjustment pot on the control enclosure graphic panel. See Section 5-6.  
DIRTY FILTER ALARM  
; This indicator lights if the pressure differential across either the process air return  
filter or the regeneration inlet filter exceeds the pressure switch setting.  
; This indicates a filter in need of service.  
; The light resets automatically when the filter is serviced.  
; The pressure switch is adjustable - See Section 6-4.  
LOW PROCESS AIR TEMPERATURE ALARM  
; This indicator lights when the temperature at the process air thermocouple is below  
the set low alarm value.  
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Chapter 4: Control Panel  
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; The alarm mode and value are factory-set to track 25°F below the process setpoint.  
The alarm value is a deviation above the process setpoint.  
; This alarm is informational. If the alarm light stays lit for an extended period of  
time, check for blown fuses or possible burnt-out heaters.  
; When the temperature at the thermocouple returns within limits, the alarm clears  
automatically.  
; This alarm is delayed on initial start-up to avoid nuisance alarms.  
; The alarm range may be altered. See Section 5-5.  
PROCESS BLOWER FAILURE ALARM  
; This indicator lights if pressure switch 2PS detects a loss of process blower air  
pressure.  
; All heaters are shut-off until the alarm is cleared.  
REGEN BLOWER FAILURE ALARM  
; This indicator lights if pressure switch 1PS detects a loss of regeneration blower air  
pressure.  
; All heaters are shut-off until the alarm is cleared.  
HIGH REGEN AIR TEMPERATURE ALARM  
This indicator lights when the thermocouple below the regeneration heater assembly senses  
an abnormally high temperature.  
1
Note: Do not adjust the factory setpoint of 3CNTL, the  
temperature controller inside the enclosure.  
DIN panel-mounted  
16  
The regeneration heaters are shut-off until the temperature falls below the alarm point. The  
regeneration blower will continue to run and cool the heaters and desiccant bed.  
The alarm light will clear automatically when the temperature drops below the alarm point,  
and the heaters will re-energize automatically.  
LOW REGEN AIR TEMPERATURE  
This indicator lights if the regeneration bleed temperature has not reached the factory setpoint  
of 150°F within 30 minutes of the start of bed regeneration.  
The panel meter (2CNTL) and the PLC monitor the regeneration bleed temperature.  
This alarm is informational, and does not affect the regeneration process.  
This alarm may indicate a very wet desiccant bed or, if the light does not go off within an  
hour, malfunctioning or burnt out regeneration heaters. For more details on the regeneration  
monitoring system, see Section 5-7.  
CRITICAL ALARM SILENCE  
Press this button to turn off the audible alarm and flashing beacon when a critical, operation  
stopping alarm occurs.  
The alarm will repeat every five minutes unless the problem causing the alarm has been  
resolved.  
350-2100 cfm Dryers  
Chapter 4: Control Panel  
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VALVE POSITION ERROR  
A pair of position switches confirm proper shifting of the valves.  
If full travel is not confirmed by the switches, the cycle will not begin on the new bed.  
4-2 Switches and Meters  
ON/OFF SELECTOR SWITCH  
This energizes or de-energizes the dryer's control power.  
START/STOP PUSH-BUTTON  
Press this momentary contact switch to start the dryer. Press this switch to shut down an  
operating dryer. The dryer shutdown sequence is:  
1. Process heaters shut off immediately.  
2. Process blower continues to run for 20 minutes to cool the process heater, then shuts  
off.  
3. The regeneration cycle of the off-line bed will continue until finished, the  
regeneration heaters will shut off, followed by the regeneration blower.  
DEWPOINT METER  
; This meter indicates the current process air delivery moisture content.  
; When the Push To Set button is pressed, the meter indicates the Dewpoint Shift  
point. See Section 5-10.  
PUSH TO SET  
This push-button is used when setting or confirming the Dewpoint Shift point. See Section 5-  
6.  
DEWPOINT SHIFT ADJUST  
This potentiometer [pot] is used when setting the Dewpoint Shift point. See Section 5-6.  
SHIFT SET SELECTOR SWITCH  
In the "ON" position, the drying temperature is raised or lowered to the ¼ DIN controller's  
alternate temperature - see Section 4-5.  
OVER TEMPERATURE RESET [Optional]  
This push-button resets the control system to allow restart of heaters and blowers after  
process air temperature has dropped below the high value programmed into the 1/8 DIN  
panel meter (4CNTL)  
This is on dryers equipped with the auxiliary hi-temperature safety option.  
HEATER BURN-OUT INDICATOR METERS [Optional]  
; The six current indicating meters monitor the current draw on each phase of the  
process and regeneration heaters.  
; During normal operation, all three meters (phases) should read within one or two  
amps of each other.  
350-2100 cfm Dryers  
Chapter 4: Control Panel  
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; If one or two of a heater's three meters indicates a low reading, a burned-out heater is  
likely, and should be serviced.  
4-3 PLC Control  
These dryers are equipped with an Omron C28K programmable logic controller (PLC).  
The "brick" type PLC has 28 I/O points - 16 inputs and 12 outputs.  
All inputs are 115 VAC, except for the 24 VDC input #1 from the dewpoint circuit board.  
All programming and logic is factory installed on an EPROM, and cannot be modified.  
A battery backup retains the programming during power failures.  
Battery life is 5 years at room temperature.  
If the alarm indicator blinks intermittently, replace the battery [P/N A0544701] within one  
week.  
4-4 Process Air Temperature Controller  
Standard ACS dryers use a microprocessor based PID control for maintaining process air  
temperature. The controller is a modular, self-contained unit that can slide from its mounting  
housing. All parameters except for the process air setpoint are factory set and adjusted; no  
field adjustment to the internal controls is normally necessary.  
350-2100 cfm Dryers  
Chapter 4: Control Panel  
23 of 58  
 
Figure 6: Process Air Temperature Controller  
350-2100 cfm Dryers  
Chapter 4: Control Panel  
24 of 58  
 
4-5 Temperature Controller LED Indicators  
Process Value Numeric LED  
During normal operation, this red LED on the control displays the process temperature at the  
"To Process" thermocouple. It also lists parameters during setup and error messages if an  
error occurs.  
Set Value Numeric LED  
During normal operation, this green LED on the control displays the process set point you  
want the dryer to maintain. It also displays parameter and pre-set function values during  
setup.  
Output LED  
This orange LED lights when the control output energizes the process air heater.  
Remote LED  
This lights when remote operation occurs on dryers equipped with optional communications.  
Shift LED  
This orange LED lights if the optional Shift Set switch is closed. The process temperature  
will be changed by the amount set in the  
value in the Level 1 parameters. To shift to a  
lower value, be sure to enter a negative value.  
Auto-Tune LED  
This orange LED flashes during the Auto-Tune sequence. The controller will automatically  
determine the proper P.I.D. values for the operating conditions. See Section 6-11.  
Alarm One LED - High Temp Alarm  
This lights when the process air temperature has risen more than 25°F [factory default] from  
the setpoint. The alarm relay in the PLC is energized when this LED is lit.The audible/visual  
alarm will sound if the dryer is so-equipped. All heaters turn off and the blowers stay on to  
cool the heaters. It is adjustable - see Section 5-5.  
Alarm Two LED - Low Temp Alarm  
This lights when the process air temperature drops more than 25°F [factory default] from the  
setpoint. The alarm relay in the PLC is energized when this LED is out. The audible/visual  
alarm will sound if the dryer is so-equipped. It is adjustable - see Section 5-5.  
350-2100 cfm Dryers  
Chapter 4: Control Panel  
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4-6 Temperature Controller Keys – (See Figure 5 in Section 3-6)  
LEVEL KEY  
When pressed for two seconds or more, this key selects the next of the three indication levels  
(0, 1 and 2) where specific control parameters may be set. The control defaults to level 0 on  
power up.  
REMOTE KEY  
This key is on controls with optional communications. For information on RS-232C, RS-422,  
or RS-485 communications, refer to the Communications Manual [part number A0535959].  
For RS-232C units with the SPI CPC protocol converter, refer to the CPC Operation &  
Installation Manual [part number A0536527].  
MODE KEY  
This key scrolls through the parameters that can be set in indication levels 0 and 1.  
Note: During normal operation, use this key to change the alarm setting only. The  
factory alarm settings are 25°F above and below the setpoint and are  
satisfactory for most applications.  
DOWN KEY  
This key lowers the process air set point temperature. During setup, it decreases the value of  
the parameter displayed by the Set Value (SV) LED.  
UP KEY  
This key raises the process air set point Temperature. During setup, it increases the value of  
the parameter displayed by the Set Value (SV) LED.  
AUTOTUNE KEY  
When pressed and held for one second or more, this key starts the Auto-Tune function.  
4-7 Optional Communications Protocols  
For SPI, RS-232C, RS-422, and RS-485 communications, a connection port on the electrical  
cabinet permits easy hook-up to the host computer. The connection port is a direct pin to pin  
extension from the plug on the back of the temperature controller. For pin outs, consult the  
control module's communication manual [part number A0535959].  
350-2100 cfm Dryers  
Chapter 4: Control Panel  
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Chapter 5: Startup, Shutdown & Operation  
5-1 Pre-Startup Checks  
; Check the process and return hoses for tight connections.  
; Check that all companion equipment, such as the drying hopper, loading system and aftercooler are  
ready for operation.  
; Check the dryer electrical connections.  
Note: Clean the rust-preventive oil from inside the drying hopper. Failure to clean the hopper  
will cause fouling of the desiccant in the dryer, and will void the warranty.  
5-2 Startup  
Close the slidegate at the bottom of the drying hopper.  
1. Fill the drying hopper with material.  
2. Turn on (energize) the disconnect switch in your power drop, then turn on the one on the dryer.  
3. Flip the on/off switch to "ON."  
4. Press the stop/start button.The blowers should start, and the proper control panel indicators  
should light.  
5. Make sure both blowers are turning the right direction. Verify rotation direction is correct. If  
one or both blowers do not start:  
Check to see if an overload on the blower motor starter has tripped. If so, set it  
properly and reset. Check the blower fuses, too.  
If one of the optional Valve Position Error lights is lit, the blowers will not start.  
Make sure the valve arm has tripped the proper limit switch. If the electric  
actuator is not fully extended or retracted, check the line fuse (8FU) near the  
actuator's 24 VDC power supply.  
The valve actuator has built-in limit switches to shut off its motor.  
It must fully extend and retract to prevent the motor from burning out.  
If a blower failure light is lit after the blower has run for a few seconds and shut down, the blower  
pressure switch will need to be adjusted until the failure light goes out.  
The pressure switches at the rear of the dryer were adjusted during  
factory-testing. Pressure changes in the drying system as installed  
may make some adjustment to these necessary during initial startup.  
350-2100 cfm Dryers  
Chapter 5: Startup, Shutdown & Operation  
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6. If the dryer has an aftercooler, make sure there is proper flow of cooling water flow through the  
coil, and any trapped air has been bled from the system.  
7. Make sure the damper on the hopper air inlet tube is about 50% open.  
8. Remove the lower end of the 2½" flex hose from the tube stub on the lower drying hopper.  
Carefully adjust the damper valve on the return line back to the filter to achieve approximately  
200 cfm air flow out of the flex hose.  
9. Set the process setpoint on the temperature controller.  
10. After the proper pre-drying time for the initial hopper fill has elapsed, fully open the drying  
hopper slidegate.  
To allow proper residence time during continuous processing, the material level in the hopper should be  
maintained at the midpoint of the air trap assembly.  
5-3 Shutdown  
Turn off the conveying system supplying the drying hopper.  
When processing is complete, close the hopper slide gate and shut down any in-line  
companion equipment, i.e. an aftercooler.  
Push the Start/Stop button. After both blowers have shut down and regeneration is  
complete, turn the On/Off selector switch "OFF".  
Empty the drying hopper, if desired.  
For maintenance or long-term shut down, open (de-energize) the electrical disconnects at  
the dryer and in the power drop.  
5-4 Setting the Process Air Temperature  
To Change Process Air Temperature Set Point:  
Press  
to raise the Setpoint.  
Press  
to lower the Setpoint.  
5-5 Setting the High and Low Temperature Alarms  
To Change the Process Air High Temperature Alarm Setting:  
1. Press  
for at least two seconds to access the level 1 parameters.  
2. When the PV LED display shows  
temperature alarm value.  
, use  
and  
to set the desired high  
The high temperature alarm value is a deviation of the process air temperature set point. The alarm  
value will track the set temperature. If the high temperature alarm is set to "25", a high temperature  
alarm occurs if the process air temperature rises more than 25°F above the process air temperature  
setpoint.  
3. Press  
until the PV LED shows  
. Use  
and  
to set the desired low  
temperature alarm value.  
350-2100 cfm Dryers  
Chapter 5: Startup, Shutdown & Operation  
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The low temperature alarm value is a deviation of the process air temperature set point. The alarm value  
will track the set temperature. If the low temperature alarm is set to "-25", a low temperature alarm  
occurs if the process air temperature falls more than 25°F below the process air temperature setpoint.  
4. Press  
until the Level 0 values [process air temperature setpoint and process air  
temperature] are displayed. The High Temperature Alarm is now set.  
5-6 Temperature Controller Autotune Procedure  
Auto-tune fine tunes the control's PID to process requirements. Auto-tune whenever the process under  
control changes or when the controller cycles more than 2° or 3° above or below the setpoint.  
Don't be alarmed by the control's response. It may take the process temperature above and below the set  
points as many as three times. It will then level off and control to the process set point. Auto-tuning can  
take up to 30 minutes, and is best done before any process is being run.  
To Auto-Tune the Control:  
1. Press and hold down  
for several seconds until the "AT" indicator flashes. The AT LED  
flashes to indicate that the control is tuning itself.  
2. When the AT LED light stops flashing, the controller is tuned and ready for operation.  
5-7 Temperature Controller Internal Switches  
The control is set up and tested at the factory for optimum operation, and the internal switches don't  
need to be adjusted. If the control does not work properly, or you suspect someone has accidentally  
changed some settings, there are two solutions. First, try the AUTO-TUNE PROCEDURE as described  
in Section 6-11. If that doesn't work, see Section 6-15.  
5-8 Temperature Controller Anti-Tamper Lockout Switch  
This slide switch prevents unauthorized changes to set points. If this switch [SW101] is On,  
the  
,
,
and  
keys are disabled. Only the process set point and  
alarm settings may be viewed. Dryers are factory-set with the protection turned Off.  
Enabling the Lockout Feature:  
1. Disconnect main electrical power to the dryer.  
2. Press up the latch at the bottom of the control module's front panel and slide out the control  
chassis.  
3. Locate the slide-type switch SW101 {PROTECT} on the left circuit board. Slide it to ON.  
4. Slide the chassis back into the control module's housing.  
Tamper protection will now be enabled.  
350-2100 cfm Dryers  
Chapter 5: Startup, Shutdown & Operation  
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5-9 Changing the Display from Fahrenheit to Centigrade  
To change the display from the factory °F setting to °C:  
1. Disconnect main electrical power to the dryer.  
ON  
1
2
3
4
5
6
2. Press up the latch at the bottom of the control module's front panel and slide out the control chassis.  
3. Locate DIP switch SW201 {FUNCTION} on the right circuit board.  
4. Slide the #5 pin to OFF.  
5. Slide the chassis back into the control module's housing.  
6. Cover the °F label with the °C sticker included in the information packet.  
5-10 Setting the Dewpoint Extend Shift Point  
1. 350 - 2100 cfm dryers shift air flow from the on-line desiccant bed to the regenerated desiccant  
bed based on actual dewpoint demand, not by fixed time cycles.  
2. Set the Dewpoint Shift Point to the highest process air moisture content you would like to allow  
before the dryer shifts air flow to the regenerated desiccant bed.  
3. The Dewpoint Shift Point is set with the dewpoint meter, the Push To Set push-button, and the  
Dewpoint Shift Adjust potentiometer [pot].  
To Change the Dewpoint Shift Point:  
1. Carefully loosen the locking hex nut on the Dewpoint Shift adjust pot. The pot is just below the  
dewpoint meter.  
2. Press and hold the Push To Set push-button next to the Dewpoint Shift Adjust pot.  
3. With a small screwdriver, adjust the Dewpoint Shift Adjust pot until the dewpoint meter reads  
the highest acceptable process air dewpoint. This is the point that airflow will be shifted from  
the on-line bed to the regenerated bed, providing the regeneration cycle has been completed.  
4. Release the Push To Set push-button and re-tighten the locking nut on the Dewpoint Shift  
Adjust pot.  
Note: Don't let the adjusting screw move and change the setting.  
5. Reconfirm the Dewpoint Shift Point by pressing the Push To Test push-button.  
Note: Securely lock the Dewpoint Shift Adjust pot in place with the locknut. An inadvertent  
change in the pot's setting will cause a change in the Dewpoint Shift Point.  
350-2100 cfm Dryers  
Chapter 5: Startup, Shutdown & Operation  
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5-11 Regeneration Monitoring System Signal Processor  
Dryer models 350 through 2100 have a 1/8 DIN signal processor that monitors the bleed air discharged  
from the desiccant tower being regenerated. The signal processor has four programmable temperature  
setpoints that, when reached, signal the PLC to cycle through the regeneration process. The PLC  
interprets the outputs from the signal processor depending on the part of the regeneration process  
currently underway.  
The signal processor's setpoints are factory set for efficient operation in most situations. The  
manufacturer does not recommend changing the setpoints indiscriminately, but persons knowledgeable  
of the processing system may fine tune the setpoints for decreased energy consumption.  
LL Setpoint - Low Regeneration Alarm Setpoint - 130°F  
This setpoint alerts the PLC and operator to possible regeneration heater problems. If this bleed air  
temperature is not reached within 30 minutes of the regeneration heaters being energized, the Low  
Regen Air Temp Alarm lights. The light will go out automatically when the setpoint is reached. The  
alarm can indicate burnt out regeneration heaters, or an extremely moist desiccant bed.  
L Setpoint - Regeneration Blower Shutdown Temp - 160°F  
After a desiccant tower has been regenerated, the regeneration blower continues to cool the desiccant  
until this setpoint is reached. The signal processor informs the PLC, and the PLC shuts down the  
regeneration blower to prevent loading the regenerated bed with ambient moisture.  
H Setpoint - Optional Closed Loop Regeneration Cool Down Temp - 250°F  
This setpoint output is used on dryers equipped with optional closed loop regeneration cool down.  
When this setpoint is reached, the output signals the PLC to shift the Wye valve in this device's  
aftercooler and the cooling water valve to close loop and cool the regeneration air. The very dry  
regeneration bleed air is directed back into the aftercooler where it is cooled to about 150°, and then  
back into regeneration blower inlet. This ensures that no moisture will be added to the desiccant bed  
until it goes back on line.  
HH Setpoint - Heater Cut Off Temp - 300°F  
This setpoint is the temperature at which the PLC is signaled to shut off the regeneration heaters  
because the desiccant is dry, and begin the cool down process.  
Raising this setpoint will not significantly improve dryer performance, but merely increase energy  
consumption.  
Basic information is listed below. For more detailed information, refer to the processor manual shipped  
with the dryer.  
To change the Regeneration Monitor System Setpoints:  
Press  
until the LED above the parameter to be changed (LL, L, H, or HH)  
is lit. The number value displayed is the selected parameter's current set point.  
Within 5 seconds, press  
until the digit to be changed blinks.  
Press  
until the desired number value is displayed in that digit position.  
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Press  
again to move one digit to the right. Then press  
desired value.  
to display the  
Follow this procedure to set all four digits.  
When satisfied with the value displayed, press  
to save the new value to the  
regeneration monitor's memory, and move on to the next parameter, if desired.  
Press  
repeatedly to review the new settings.  
5-12 Auxiliary Process Safety System (Optional)  
This option provides an extra level of protection from hopper meltdown due to a runaway heat  
condition such as a fused heater contactor. When triggered, this system will drop out high voltage to all  
heater contactors and blowers. This drastic action, to protect the resin and the drying hopper, will only  
occur if a high temperature condition is not first handled by the ¼ DIN control [Section 4-1] on the  
dryer subpanel and/or the heater contactor(s) is/are fused.  
This system must be manually reset by pressing the OVERTEMP RESET button after fixing the  
problem.  
This option uses a signal processor identical to the one used in the regeneration monitoring system. It  
monitors the process temperature through a thermocouple mounted at the drying hopper inlet. Only one  
of the setpoints [H] is used. See Section 5-11 for instructions on setting the H setpoint.  
The H setpoint should be the highest temperature tolerable at the drying hopper, before resin or drying  
hopper degradation occurs. This temperature varies depending on the resin and the drying temperature,  
but a suggested starting temperature is 75°F above the drying temperature.  
5-13 Seven Day Timer (Optional)  
The seven day timer can be programmed for weekly ON/OFF operation of up to sixteen setpoints. An  
internal battery back-up holds the settings in memory when the dryer is de-energized.  
The dryer's Power toggle switch must be in the "ON" position for normal or programmed dryer  
operation.  
To bypass programmed operation, switch the manual override switch on the  
seven day timer to the "ON" position.  
To execute programmed operations, set the manual override switch on the seven  
day timer to the "RUN" position.  
To de-energize the seven day timer, set the manual override switch to the "OFF"  
position.  
The dryer will not run if the timer switch is "OFF".  
Program 1 is operational, Program 2 is not used.  
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Setting the Current Day of the Week, Hour and Minute:  
1. Apply main power to the dryer.  
2. Turn on the timer by sliding the left manual override switch to the "ON" position. The timer's  
memory is cleared on power up.  
MODE  
SUN  
TIM ADJ  
3. Press and hold  
until  
becomes visible and  
blinks.  
4. Press  
or  
until the current day of the week is displayed.  
5. Press  
to store the current day of the week in the timer's memory. The day of the week  
indicator will stop blinking.  
6. The current hour indicator should now be blinking. Press  
or  
to set the current hour.  
The time is set in a 24-hour format.  
7. Press  
blinking.  
to store the current hour in the timer's memory. The hour indicator will stop  
8. Press  
9. Press  
or  
to set the current blinking current minute indicator.  
to store the current minute in the timer's memory. The minute indicator should stop  
blinking.  
Setting the start up time:  
MODE  
PROG 1  
1. Press and hold  
until  
is lit and the hour indicator is blinking.  
2. Press  
or  
until the desired dryer start up hour is displayed. The start up time is set in a 24-  
hour format.  
3. Press  
blinking.  
to store the dryer start up hour in the timer's memory. The hour indicator will stop  
4. Press  
or  
until the desired dryer start up minute is displayed. The minute indicator should  
be blinking.  
5. Press  
blinking.  
to store the start up minute in the timer's memory. The minute indicator will stop  
6. Now the #1 output status indicator should be blinking. Press  
status.  
to turn the output to the ON  
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7. Press  
blinking.  
once. The hour and minute display returns to zeroes and the hour indicator should be  
Setting the stop time:  
1. Press  
or  
until the desired dryer shut down hour is displayed. The shut down time is set  
in a 24-hour format.  
2. Press  
blinking.  
to store the shut down hour in the timer's memory. The hour indicator should stop  
3. Press  
or  
until the desired dryer shut down minute is displayed. The minute indicator  
should be blinking.  
4. Press  
blinking.  
to store the shut down minute in the timer's memory. The minute indicator will stop  
5. Now the #1 output Status indicator should be blinking. Press  
OFF status.  
once to set the output to the  
6. Press  
once. The hour and minute display will return to zeroes and the hour indicator  
should be blinking.  
Set the days of the week for automatic operation:  
MODE  
1. Press  
flashing.  
. The Day of the Week indicator will appear and the Sunday indicator should be  
2. Press  
to automatically operate the dryer on Sunday, press  
to prevent the dryer from  
automatically operating on Sunday. Reverse video - white characters on a black background  
SUN  
indicates the day(s) selected for automatic operation. For example:  
3. Press  
set.  
to store Sunday in the timer's memory. Proceed until all desired days of the week are  
Put the timer into Run mode:  
MODE  
1. Press  
until the current time appears. The colon between the hours and minute  
should be blinking. The timer is now in run mode and automatic operation will begin as  
programmed.  
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Chapter 6: Maintenance  
6-1 Servicing the Process Air Filters (Models 350-700)  
WARNING: Operating the dryer without the process air filters installed will void the warranty.  
Filter Cleaning is an important part of dryer maintenance.  
Dryer models 350 through 700 have single high temperature [up to 350°F] cartridge cannister-type filter  
in the process air loop. It’s mounted above the process blower on the rear of the dryer. This filter  
protects the centrifugal blowers from plastic fines being drawn in from the drying hopper. Regular filter  
cleaning will keep your dryer operating at peak efficiency.  
The filter can be washed or blown out, but remember, the filter’s dirt holding capacity is reduced with  
each washing. The risk of dirt reaching the clean side of the filter during cleaning, plus possible filter  
damage from high pressure washing or blowing makes washing a gamble.  
Careful cleaning or washing can be done when the airflow restriction trips the dirty filter alarm. Filters  
should not be washed more than six times or used for more than a year, whichever comes first.  
Use a detergent that won’t damage the filter media. Such a detergent permits easy removal of dirt  
particles through flushing and rinsing. An effective detergent will remove the fine particles from the  
pores of the filter media.  
The filter’s manufacturer recommends FM 1400 washing compound. It is formulated specifically for air  
filter element cleaning. It is non-sudsing and works in hot or cold water. FM 1400 contains  
biodegradable synthetic detergents and is non-phosphate, non N.T.A. It is marketed by Filter Service  
Corp., 2603 A West Main, Farmington, New Mexico, [505] 326-1127.  
6-2 Filter Cleaning/Replacement  
Turn off and/or lock out electrical power [and compressed air, if so equipped] to the  
dryer.  
Remove the hand knobs or threaded fasteners securing the filter access cover and  
remove the cover.  
Remove the nut on the center retaining rod to remove a filter cartridge.  
Inspect the filter - a damaged filter should not be washed or reused.  
Remove loose dirt from the filter with compressed air or a water hose. Compressed air  
should be less than 100 psi – use a 1/8"diameter nozzle at least 2" away from the  
filter. Water should be less than 40 psi – don’t use a nozzle.  
Soak the filter in FM 1400 or comparable detergent solution for at least 15 minutes.  
Never soak more than 24 hours.  
Swish the filter around in the solution to agitate, loosen dirt particles, and put them in  
suspension.  
Rinse the filter from the “clean” side to the “dirty” side with a gentle stream of water  
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to remove all dirt and suds (less than 40 psi, no nozzle). If the clean or downstream side of the filter has  
been contaminated with dirty water during the soak cycle, rinse from both sides.  
Dry the filter before re-using. Circulate warm air at less than 160ºF. Do not use a light bulb to dry the  
filter.  
Inspect for holes and tears by looking though the filter toward a bright light. Check for damaged gaskets  
or dented metal parts. Do not re-use a damaged filter.  
6-3 Servicing the Process Air Filters (Models 850 through 2100)  
On 850 through 2100 cfm dryers, the multiple high temperature [up to 350°F] process filters are located  
in the housing under the blower platform on the left rear corner of the dryer. These filters protect the  
centrifugal blowers from plastic fines being drawn in from the drying hopper. Regular filter cleaning  
will keep your dryer operating at peak efficiency.  
Filter Cleaning/Replacement  
Turn off and/or lock out electrical power [and compressed air, if so equipped] to the dryer.  
Remove the hand knobs or threaded fasteners securing the filter access cover and remove  
the cover.  
Remove the nut on the center retaining rod to remove a filter cartridge.  
Blow or vacuum each filter until the filter is clean. If the filter is worn through or can't be  
cleaned, replace it.  
Remove the small fines cleanout cover from the lower back portion of the filter unit below  
the air outlet transition.  
Vacuum out the fines and reinstall the cover and gasket.  
Reinstall all the filter cartridges, tightening them securely.  
Replace the door or access cover, being careful to keep the gasket intact, if supplied.  
Recommendations for Cleaning Heavily Soiled 850 through 2100 cfm Process Filters  
Vacuuming  
Try vacuum cleaning a soiled filter first. Vacuuming removes most large particles and surface  
contaminants, and may be all that’s needed the first time a filter is cleaned. Use a commercial duty  
[recommended] or household vacuum cleaner. 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.  
Don’t shoot the air in a criss-cross motion against the grain of the pleats - you won’t end up with a  
clean filter, and you might damage it.  
Washing  
As a last resort, wash the filter. This is only necessary when the pressure drop is too high due to fine  
dirt embedded in the filter or there’s been oily mist near the intake air location. Use a mild, low sudsing  
detergent and warm water. Soak the filter 5–10 minutes, then gently agitate for several minutes. Rinse  
thoroughly with clean water to remove all detergent. Let the filter dry completely before returning it to  
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service. Satisfactory filtration should be obtained through the second or third washing , however the dirt  
holding capacity of the filter decreases after each washing.  
After Each Cleaning:  
Inspect the filter element – hold a light bulb behind the element to find 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.  
6-4 Servicing the Regeneration Filter  
WARNING:  
Operating the dryer without the regeneration air filters installed will void the warranty.  
Filter Cleaning is an important part of dryer maintenance.  
These dryers are equipped with a filter in the regeneration air loop. Regular filter cleaning will keep  
your dryer operating at peak efficiency.  
To Clean the Regeneration Filter:  
Turn off and/or lock out electrical power to the dryer.  
Slide the panel filter out of its housing.  
Vacuum or carefully blow out the filter with compressed air. If the filter is worn or can't be  
cleaned, replace it.  
Slide the filter back into its housing.  
6-5 Dirty Filter Alarm Calibration  
Dryer models 350-2100 may be equipped with an optional Dirty Filter Indicator. When this indicator  
lights, it is time to clean or change the filter. The Dirty Filter indicator is tested and calibrated at the  
factory, but it can be adjusted in the field.  
1. Be sure that your filter is clean, and use the following procedure.  
2. Remove the process air return filter element from its housing.  
3. Block off approximately 50% of the filter's surface area to simulate a dirty filter.  
4. Reinstall the cartridge and secure the cover.  
5. While the process blower is operating, adjust the trim screw on the differential pressure switch until  
the alarm light just comes on.  
6. 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.  
7. Re-install the obstructed cartridge filter. The alarm light should go on again if the switch is adjusted  
correctly.  
8. Fine tune the switch setting so it consistently warns of a blocked filter and does not falsely indicate  
a blockage of a clean filter.  
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9. Remove the restriction from the filter element and re-install the clean filter. The alarm light should  
remain off.  
6-6 Dewpoint Control System Service  
The Dewpoint Shift feature on dryer models 350 through 2100 depends on the proper operation of the  
dewpoint sensor and its control board. The dewpoint sensor is in the process airstream 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.  
Note: Note: 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 [part number A0549143]. This device simulates various  
dewpoint outputs. It can confirm proper operation of the dewpoint sensor and dewpoint system control  
board.  
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.  
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.  
6-7 Symptoms of Worn Out Desiccant  
The moisture adsorption capacity of the desiccant used in ACS 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.  
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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 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.  
6-8 Desiccant Replacement Procedure  
Follow the procedure below to change the desiccant.  
1. Disconnect electrical power to the dryer.  
2. Remove the bolts and nuts securing the cover of each desiccant tower. Remove the covers with a  
lifting fixture.  
3. With a shop vacuum, carefully remove all desiccant from each tower.  
4. Inspect each lower desiccant screen for tears or burn-through spots. Replace if necessary.  
5. After cleaning each tower, add a level layer of half the large bead desiccant on top of the screen.  
Next, carefully add the full amount specified "per bed" of small bead desiccant. Smooth the top  
level, and finally add another layer of the remaining large bead desiccant to the top. Make sure this  
layer is level and smooth.  
6. Repeat the above step for the other bed.  
7. Inspect the gasketing on each of the covers. Replace if necessary.  
8. Re-install the covers.  
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Figure 6: Desiccant Amounts Required  
Dryer  
Desiccant Required per Tower  
Model  
Large Bead  
Small Bead  
76  
Total  
106  
106  
120  
120  
140  
140  
160  
160  
175  
175  
240  
240  
250  
250  
300  
300  
360  
360  
430  
430  
480  
480  
350  
350-RT  
425  
425-RT  
500  
500-RT  
600  
600-RT  
700  
700-RT  
850  
850-RT  
1000  
30  
30  
30  
30  
40  
40  
40  
40  
40  
76  
90  
90  
100  
100  
120  
120  
35  
40  
35  
120  
120  
120  
120  
120  
120  
120  
120  
120  
120  
120  
120  
120  
120  
130  
130  
180  
180  
240  
240  
310  
310  
360  
360  
1000-RT  
1250  
250-RT  
1500  
1500-RT  
1800  
1800-RT  
2100  
2100-RT  
6-9 Process Heater Replacement Procedure  
ACS dryers have a number of single phase Calrod-type heater elements wired in a delta formation.  
They are mounted in the vertical compartment behind the right hand desiccant tower. The number and  
wattage of the heaters varies with model, voltage, temperature range, etc., but the replacement  
procedure is the same.  
WARNING!  
Disconnect and lock out power before heater replacement.  
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 gasketing.  
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.  
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6-10 Regeneration Heater Replacement Procedure  
Dryer models 350 through 2100 Dryers have four or eight three-phase regeneration heaters wired in the  
wye formation mounted in the insulated box directly above the lower valve.  
WARNING!  
WARNING! Disconnect and lock out power before heater replacement.  
1. Access the regeneration heaters from the rear of the dryer. Remove the cover plate secured by  
two bolts.  
3. Sketch the heater wiring configuration so the heaters may be re-assembled properly. Also, note  
that the loops of the heaters are vertical to prevent drooping when hot.  
4. Remove the jumper wires for the heater(s) being removed and/or replaced.  
5. Remove the four bolts securing each heater's 3 1/2" mounting plate. Slide out the heater, taking  
care to not damage the gasketing.  
6. Re-install the new heaters in reverse order. Be sure their loops are vertical, like the original  
heaters were. Securely tighten all fasteners.  
Caution!  
Caution! The heater loops should not touch each other. This will create "hot  
spots" and lead to premature heater failure.  
7. Re-install the jumper wires according to the sketch made earlier.  
8. Re-secure the regeneration heater access cover.  
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6-11 Restoring a Temperature Controller to the Factory Setup  
If the control's pre-set parameters have been tampered with and it will no longer control, try restoring  
the factory set up:  
1. Turn off the power switch on the graphic display and remove all electrical power to the dryer.  
2. Press up the latch at the bottom of the module's front panel and slide out the control chassis.  
3. Locate the slide-type lockout switch [SW101 {PROTECT}] on the left circuit board. It should be  
Off.  
ON  
OFF  
Protect (SW101)  
4. Check to make sure the control output relays are installed on the right-hand circuit board. Dryers  
use one E53-S Solid State Relay (SSR) mounted in the socket marked S201 (HEAT). This relay  
switches the heaters on and off.  
5. Set the output selector switch SW202 to PULSE. This slide-type switch is near the control output  
socket. If the dryer is equipped with an S.C.R. controller [an E53-C output module is installed], set  
the switch to Current.  
6. Set the rotary-type alarm mode selector switch SW203 to position 2 for upper limit alarm.  
0
9
1
8
7
2
3
ON  
OFF  
6
4
5
Pulse -- Current  
SW203  
0
9
1
8
7
2
3
6
4
5
SW203  
0
9
1
8
2
3
7
6
4
5
SW203  
7. Set the rotary-type ALM2 switch SW203 to position 3 for lower limit alarm.  
8. Set the rotary temperature sensor selector switch to position 2. It is marked SW206 (INPUT TYPE)  
and is on the right circuit board. ACS Dryers are factory-equipped with type K thermocouples; 6  
other temperature sensor types can be used if the switch is properly set. These are listed below.  
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Chapter 6: Maintenance  
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Display  
Characters  
Sensor Type  
Switch  
Position  
Temp  
Range  
°C  
°F  
Thermocouple Type R  
Thermocouple Type S  
0
1
0 - 1,700  
0 - 3,000  
0 - 1,700  
0 - 3,000  
Thermocouple Type K  
Thermocouple Type J  
Thermocouple Type T  
Thermocouple Type E  
2
3
4
5
6
7
-200 to  
1,300  
-100 to  
900  
-200 to  
400  
-300 to  
2,300  
-100 to  
1,600  
-300 to  
700  
0 to 1,100  
0 to 600  
Platinum RTD (JIS  
1981)  
Platinum RTD (DIN)  
-99.9 to  
450.0  
-99.9 to  
450.0  
-99.9 to  
800.0  
-99.9 to  
800.0  
Not Used  
Not Used  
8
9
9. Set both transmission output selector DIP switches OFF. They are marked SW207 (TRANSFER)  
and are on the right circuit board on controls equipped with optional communications. See the  
Communications Manual [part number A0535959].  
ON  
1
2
3
4
5
6
10. The function selector DIP switch [SW201 (FUNCTION)] selects 6 control modes. It is on the right  
circuit board. Put this switch in the set-up configuration at right while inputting the initial control  
parameters.  
SW201 Set-up Configuration  
1 OFF Control Mode  
2 OFF Normal/Reverse Output  
3 OFF Input Shift  
4 OFF Temperature Sensor  
Standard  
5 ON  
6 ON  
Scale Indication  
PID Constant Indication  
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11. Slide the control chassis back into the control housing. The remaining parameters are set with the  
keypad.  
12. Ready the dryer for startup with a real or simulated load. Restore the electrical power.  
13. Turn the control power on. The PV LED will display four zeros [0000] and then display the current  
process air temperature.  
14. Press  
to page through the Level-0 control parameters. The PV LED displays codes  
indicating the currently selected mode; the SV LED shows the selected parameter's current setting. Use  
and  
to select a setting.  
15. Set the Level-0 parameters according to Figure 10.  
16. Press  
for at least two seconds to access the Level-1 parameters. Set them using the procedure  
in the previous step.  
Note: You can proceed to Level-2, but these parameters are read- only. Controls with optional communications  
have user-set variables [unit address and ID] on Level-2.  
17. Turn off the power switch on the graphic display and remove all electrical power to the dryer.  
18. Press up the latch at the bottom of the control's front panel and slide out the control chassis.  
ON  
1
2
3
4
5
6
19. Set the #6 position of the DIP-type function selector switch to OFF. It is marked SW201  
[FUNCTION] and is on the right circuit board. Slide the control back into the chassis.  
20. Turn the control power on. The PV LED will display four zeros [0000] and seconds later display  
the current process temperature.  
21. Auto-tune the dryer using the procedure in Section 5-6. If the control still fails to control, call the  
Service Department  
.
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Chapter 6: Maintenance  
44 of 58  
 
Figure 7: Factory Pre-Set Control Parameters  
Parameter  
Setting  
Parameter  
Description  
PV  
LED  
Display  
Dryer  
SV LED  
Setting  
Levels  
Display at Power Up  
Alarm Range  
10°F  
10°F  
Proportional Bandwidth  
Reset Time  
90.0  
Seconds  
20 Seconds  
0
1
Rate Time  
0°F  
250°F  
Lower Limit Value of  
Control Range  
Dead Band  
1°F  
Cooling Coefficient  
Heating Control Period  
Cooling Control Period  
Shift Set Value  
1.0°F  
20 Seconds  
5 Seconds  
0°F  
Control Output Variable  
Temperature Sensor Type  
Alarm Mode  
Read Only  
2
Unit Number Setting  
w/Optional  
Communications  
Baud Rate Setting  
w/Optional  
Varies with  
Network  
Varies With  
Network  
Communications  
350-2100 cfm Dryers  
Chapter 6: Maintenance  
45 of 58  
 
Figure 8: Process Temperature Control Error Messages  
Message  
Cause  
Control Output  
Alarm Output  
With output unit  
With current output unit  
other than current  
output unit  
Input temperature  
has risen beyond the  
upper limit of the  
temperature range  
by more than 20°C  
OFF during  
4 mA during reverse  
(heating) action, 20 mA  
during normal (cooling)  
action.  
reverse (heating)  
action, ON during  
normal cooling  
action.  
Issues alarm  
outputs in  
accordance with the  
set alarm mode.  
[68°F] c  
Input temperature  
has fallen below the  
lower limit of the  
ON during reverse 20 mA during reverse  
(heating) action,  
OFF during  
(heating) action, 4 mA  
during normal (cooling)  
action.  
Issues alarm  
outputs in  
accordance with the  
set alarm mode.  
temperature range  
by more than 20°C  
normal (cooling)  
action.  
[68°F] d  
The thermocouple  
has burned out or  
the short circuit bar  
has been removed.  
The platinum RTD  
has burned out or A  
and B have been  
short circuited.  
Issues alarm  
outputs in  
accordance with the  
set alarm mode.  
Proportional alarm  
output is OFF  
OFF  
Approximately 1 mA  
Memory failure  
(E111) or analog to  
digital converter  
failure (E333) has  
occurred.  
Temperature  
OFF  
Approximately 1 mA  
OFF  
controller must be  
repaired if recovery  
is not made by  
turning power off  
once and on again.  
[FLASHES]  
c When a type J thermocouple is used, this error message is not displayed until the temperature has risen above the normal operating  
temperature operating range by more than 70°C [158°F].  
d When a platinum RTD sensor is used, this message is displayed when the temperature has fallen to -99.9°C [-147.82°F].  
350-2100 cfm Dryers  
Chapter 6: Maintenance  
46 of 58  
 
Figure 9: Regeneration Monitor Signal Processor Error Messages  
Output Status  
Item  
Condition  
Error  
Message  
Corrective  
Action  
Compara-  
tive  
BCD  
Output  
Linear  
Output  
Commun-  
ications  
Outputs  
CPU RAM  
error,  
external  
memory  
error,  
Turn the power OFF  
and then ON again  
once. If the error  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
persists, call Service.  
Device  
Failure  
memory  
data error.  
Turn the power OFF  
and then ON again  
once. If the error  
persists, press the  
mode key and set all  
parameters again.  
Corrupted  
Data  
Breakage or  
short circuit of  
sensor. When  
the  
Sensor  
Error  
thermocouple  
is used,  
terminals 11  
and 13 are  
not short  
Check sensors for  
breakage, short  
circuiting, or incorrect  
wiring.  
OFF  
OFF  
OFF  
OFF  
circuited.  
Input value  
or display  
Underflow value  
outside  
Overflow,  
Display  
Blinks  
Continues  
OVER  
ON  
Continues Keep the input value  
Continues OVER ON and display value  
within the range.  
Continues  
OFF  
range.  
Check the output type.  
If correct, press the  
mode key. This erases  
When  
output type  
has  
Output  
Type  
Change  
OFF  
OFF  
OFF  
the set the parameters,  
so re-enter them. If the  
problem persists, call  
Service.  
changed.  
Turn the power OFF  
and then ON again  
once. If the error  
Output type  
other than  
specified.  
Output  
Type Error  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
persists, call Service.  
Input  
Input type  
other than  
specified.  
Turn the power OFF  
and then ON again  
once. If the error  
Specifi-  
cation  
Error  
persists, call Service.  
350-2100 cfm Dryers  
Chapter 6: Maintenance  
47 of 58  
 
6-12 Regeneration Monitor Advanced Programming  
The regeneration monitor has three menu levels, numbered 0 through 2. Each menu level allows  
specific parameters to be viewed and/or set.  
Moving Between Levels  
Level 0, the RUN mode, is the default and automatically appears when the dryer is powered up. To  
move to Level 1, press and hold  
for 2 seconds. When Level 1 is reached, press and hold both  
and  
for 1 second to move up a level, or move back to RUN mode by pressing for 1 second.  
See the flow chart below.  
+
1 sec.  
Press  
Press  
2 sec.  
1 sec.  
Press  
+
1 sec.  
Press  
Press  
Level 0  
Level 1  
Level 2  
1 sec.  
Comparative output settings (when security is enabled)  
Output hysteresis  
Sensor type  
Display unit (°F/°C)  
Display refresh time  
Communication unit  
Process temperature  
Input shift value  
Comparative output settings (when security is disabled)  
Linear output range  
Security protection  
Present Value (PV)  
Regen Bleed Air Temp  
LEVEL 0  
In this, the default level, the present regeneration  
bleed air temperature is displayed, plus the  
monitor’s four setpoints can be viewed and  
changed.  
HH Set Value  
Heater Cut Off Temp  
If security is enabled, the setpoints cannot be  
changed. They may be reviewed by pressing  
If security is disabled, the setpoints can be  
.
H Set Value  
changed on this level by using  
and  
.
Closed Loop Regen Cool Down Temp  
When the desired setpoint is displayed, press  
to move to the digit you want to change, and use  
to change the digit. Then press  
the new setting to memory and to move on to the  
next setpoint.  
to save  
L Set Value  
Regen Blower Shutdown Temp  
LL Set Value  
Low Regen Temp Alarm  
350-2100 cfm Dryers  
Chapter 6: Maintenance  
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LEVEL 1  
In this level, the four setpoints can be  
Setpoints  
changed, plus Hysteresis, Input Shift  
and Security Protection can be set.  
Use  
to move from one parameter  
to the next.  
Hysteresis  
Input Shift  
When the desired parameter appears  
on the LED display, press  
to  
select that parameter for program-  
ming. The parameter’s current value  
appears on the LED display.  
When the desired parameter is  
Security Protection  
displayed, use  
and/or change the parameter. Then  
and  
to view  
press to save the new setting to  
memory, and to move on to the next  
parameter.  
Setpoints -  
When  
while security lockout is enabled.  
appears on the LED display, the HH, H, L, and LL setpoints can be changed even  
To set the values, press  
on the LED display. Use  
after  
and  
appears. The present value for the HH setpoint will appear  
to view and/or change the setpoint. Then press to save the  
new setting to memory, and to move on to the next setpoint. After all setpoints are set, the LED display  
returns to  
.
Hysteresis -  
The hysteresis value for the setpoints can range from 0° to 99° C or F.  
Press  
after  
appears on the LED display. Use  
and  
to set the value. Then press  
to save the new setting to memory.  
Input Shift -  
The input shift value can range from -99° to +99° C or F. The factory set value is “000”  
The input shift value offsets the displayed temperature by the value you set here. This may be useful to  
force the regeneration monitor to display the same temperature as a known [or supposed] temperature  
reading.  
350-2100 cfm Dryers  
Chapter 6: Maintenance  
49 of 58  
 
Press  
after  
appears on the LED display. Use  
and  
to set the value. Then press  
to save the new setting to memory.  
Security Protection -  
When Security Protection is enabled, the setpoints can’t be changed when the Regeneration Monitor is  
in “RUN” mode. The setpoints can only be changed in Level 1 using the function.  
Press  
after  
appears on the LED display.Use  
to toggle between ON and OFF. The  
to save the new setting to  
factory setting is “OFF”. When the selection has been made, press  
memory.  
350-2100 cfm Dryers  
Chapter 6: Maintenance  
50 of 58  
 
LEVEL 2  
In this level, parameters such as the type of  
Sensor Input Type  
temperature sensor connected to the  
regeneration monitor, Fahrenheit/centigrade  
display, and display refresh cycle can be set.  
Scale Indication °C or °F  
Display Refresh Cycle  
moves from one parameter to the next.  
When the desired parameter appears on the  
LED display, press  
to select that  
parameter for programming. The current  
value of the parameter is then displayed on  
the LED display. Use  
and  
to change  
the setting. When you are satisfied with the new setting, press  
to save the new setting to memory.  
Sensor Input Type  
The regeneration monitor is factory equipped with and configured to use a type K thermocouple. Type  
R, S, J, L, T, U, E, and 1OO W RTD’s can also be used. The factory setting is  
.
Press  
after  
appears on the LED display. Use  
to save the new setting to memory.  
to scroll through the available sensor  
types. Then press  
Scale Indication  
The regeneration monitor can display the regeneration bleed air temperature in either Fahrenheit (°F,  
the factory default) or Celsius (°C). The control is factory set to the scale indicated on the dryer at the  
time of purchase.  
Press  
after  
appears on the LED display. Use  
to save the new setting to memory.  
to toggle between the two choices.  
Then press  
Display Refresh Cycle  
The regeneration monitor’s display refresh speed can be set separately from the sampling speed.  
Press  
after  
appears on the LED display. Use  
(2 seconds). Then press  
to toggle between the two choices:  
(500 ms) or  
to save the new setting to memory. The  
factory setting is  
.
Note: Even if the display refresh speed is set to two seconds, the sampling times for the  
setpoints still remains at 500 milliseconds.  
350-2100 cfm Dryers  
Chapter 6: Maintenance  
51 of 58  
 
Chapter 7: Troubleshooting  
PROBLEM  
Little or no air coming from  
process delivery tube.  
POSSIBLE CAUSE  
A. Dirty Filters  
CORRECTIVE ACTION  
A. Clean or replace  
filters.  
B.  
Desiccant beds  
B. Replace desiccant  
contaminated by material  
or plasticizer leaking into  
the system. See Sec. 6-6.  
C. Blower fuse(s) blown.  
D. Overload tripped.  
C. Fix problem and  
Replace fuse(s).  
D. Fix problem and reset  
the overload.  
E. Blower fins filled with  
dust or contaminants.  
E. Remove blower  
sideplate, clean  
baffles, replace.  
Suction in delivery tube,  
pressure from the return  
tube.  
A. Phase is reversed on A.  
Stop the Dryer.  
power drop coming  
into 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.  
350-2100 cfm Dryers  
Chapter 7: Troubleshooting  
52 of 58  
 
PROBLEM  
Loss or reduction of  
process air temperature.  
POSSIBLE CAUSE  
A. Process heaters are  
faulty.  
CORRECTIVE ACTION  
A. Check for open or  
shorted heaters. Replace if  
required. Check the fuses.  
B. Solid-state temperature B. Replace.  
controller faulty.  
C. Process temperature  
was adjusted in error by  
plant personnel.  
C. Make sure that plant  
personnel are aware of the  
proper temperature  
setpoint. A sign posted next  
to the control would be  
helpful.  
Loss or reduction in drying A. Process heaters are  
A. Replace.  
capacity.  
faulty.  
B. Desiccant beds are  
contaminated.  
B. Replace desiccant.  
C. Material being dried  
differs from material  
specified at the time of  
purchase.  
C. Drying systems are  
designed for the material  
which was originally  
specified. Different  
materials may need a  
longer residence time or  
different drying  
temperature.  
D. Break in flex hose  
to/from drying hopper.  
E. Airflow valves sticking  
or failing to shift.  
D. Inspect for air leaks;  
replace if necessary.  
E. Check for proper  
operation of linear valve  
actuator. Check fusing.  
Repair or replace if  
necessary.  
F. Blower fins filled with  
dust or contaminants.  
F. Remove blower  
sideplate, clean baffles,  
replace. Replace filter  
elements.  
350-2100 cfm Dryers  
Chapter 7: Troubleshooting  
53 of 58  
 
PROBLEM  
POSSIBLE CAUSE  
CORRECTIVE ACTION  
Material in drying hopper  
A. Process temperature set A. Check resin  
cakes, or meltdown occurs. too high due to operator  
error.  
manufacturer's data sheet  
for proper drying  
temperature. Make sure  
plant personnel are aware  
of the correct process  
temperature Set Point.  
B. High temperature alarm B. See Section 5-5.  
not set properly.  
C. Process set point is out  
of acceptable range.  
C. Restore temperature  
controller to factory pre-  
sets. Auto-Tune if  
necessary. See Sec. 6-11.  
Poor Dew Point  
Performance.  
A. Burned out regeneration A. Repair or replace.  
heater.  
B. Contaminated or worn  
out desiccant.  
B. Replace.  
C. Leaking process air  
hoses.  
C. Repair or replace.  
D. Dryer is being operated  
beyond its capacity.  
E. Bad dew point sensor.  
F. Fouled dew point  
sensor manifold.  
D. Check dryer and drying  
hopper sizing.  
E. Replace.  
F. Clear obstruction. Air  
should flow freely through  
sensor.  
350-2100 cfm Dryers  
Chapter 7: Troubleshooting  
54 of 58  
 
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 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 a 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.  
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Chapter 8: Appendix  
55 of 58  
 
-Notes-  
350-2100 cfm Dryers  
Chapter 8: Appendix  
56 of 58  
 
Preventive Maintenance Checklist  
Dehumidifying Dryers  
Dryer Model #  
Serial #  
Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/  
By By By By By By By By By By By By By  
EVERY WEEK  
Inspect all filters for wear,  
replace/clean if dirty or  
worn  
Check air regulator to  
make sure pressure is 60-  
80 psi. [If applicable]  
EVERY MONTH Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec  
Lock out electrical power  
and inspect electrical  
wiring for integrity  
Lock out electrical power  
and check heater  
elements for continuity  
using an ohmmeter  
Check Dew point and  
temperature tracking with  
an external dew point  
monitor and pyrometer  
Visually inspect the  
shifting of the airflow  
valve  
during one cycle  
Next Scheduled  
Inspection  
Actual Inspection  
Date/By  
Next Scheduled  
Inspection  
Actual Inspection  
Date/By  
EVERY YEAR  
Inspect desiccant. Replace  
if brown or broken  
Scheduled  
Replacement Date  
Actual Replacement  
Date/Work Done By  
Scheduled  
Replacement Date  
Actual Replacement  
Date/Work Done By  
EVERY 2 YEARS  
Replace desiccant  
350-2100 cfm Dryers  
Chapter 8: Appendix  
57 of 58  
 
8-2 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 products. Service  
contracts are available for most of our products.  
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.  
Contract Department  
[
]
Call 262 641-8610 Monday–Friday, 8am–5pm CST  
Let us install your system. The Contract Department offers any or all of these services: project planning; system  
packages including drawings; equipment, labor, and construction materials; and union or non-union installations.  
Sterling, Inc.  
2900 S. 160th Street  
New Berlin, WI 53151  
350-2100 cfm Dryers  
Chapter 8: Appendix  
58 of 58  
 

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