ARID-X10B FLOOR MOUNT DRYER OPERATING MANUAL · OPERATING MANUAL - ARID-X10B FLOOR MOUNT DRYER Revision 3/28/02 The ARID-X10B dryer is a fully portable dryer designed to dry hygroscopic

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DRI-AIR INDUSTRIES, INC.

OPERATING MANUAL - ARID-X10B FLOOR MOUNT DRYERRevision 3/28/02

ARID-X10B FLOORMOUNT DRYER

OPERATING MANUAL

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16 THOMPSON ROADP.O. BOX 1020EAST WINDSOR, CT 06088-1020

Tel. (860) 627-5110FAX (860) 623-4477Internet http://www.dri-air.come-mail: [email protected]

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CONTENTS

DRYER DESCRIPTION Pg 4

AIR FLOW SCHEMATIC Pg 7

DRYER CYCLE DIAGRAM Pg 8

INSTALLATION PROCEDURESFACILITY REQUIREMENTS Pg 9HOPPER CONNECTION Pg 9ELECTRICAL CONNECTION Pg 10POST-INSTALLATION INSPECTION Pg 10

DRYER OPERATIONSTART-UP PROCEDURES Pg 11ALARMS Pg 12ROUTINE OPERATION Pg 13

TROUBLESHOOTINGBASIC TROUBLESHOOTING Pg 15DETAILED TROUBLESHOOTING Pg 16ZONE VALVE TROUBLESHOOTING Pg 18CONTROLS TROUBLESHOOTING Pg 18

PARTS LIST Pg 19

ELECTRICAL SCHEMATIC 110V Appendix84429

ELECTRICAL SCHEMATIC 220V Appendix84428

DRYER CONFIGURATION Appendix84430

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The ARID-X10B dryer is a fully portable dryerdesigned to dry hygroscopic resins quickly andefficiently. It is ideal for insert molders andlaboritory applications, or where production ratesare 10 lbs./hr or less.

The ARID-X10B dryer is available in 110 volt and230 volt models. The power requirements for the110 volt model are a voltage range of 105-130vAC at 50/60 Hz., single phase with a 20 amp currentrating and the 230 volt model requires a range 220-250v AC at 50/60 Hz., single phase with a 10 ampcurrent rating.

Regeneration Cycle

The ARID-X10 utilizes our HP4-X dual desiccantbed design that provides a constant supply of dryair to the material hopper. While one bed isremoving moisture from the process air stream, theother bed is being regenerated. The entire processis controlled by the PLC which is programmed withthe tower heat-up and cool down times required toregenerate the desiccant. When the regeneratedbed completes this cycle, the zone valve switchesthe air stream and the newly regenerated bed is nowused for drying the process air. The saturated bedis then regenerated, repeating the cycle. Please seethe Regeneration Cycle Diagram on page 8.

The airflow design of the ARID-X/HP4-X dryersmakes the regeneration cycle more efficientbecause we utilize a small amount of thedesiccated process air, rather than ambient air, toregenerate the desiccant bed. This reduces theimpact of the high moisture content of theambient air, which would contaminate thedesiccant bed, and allows the dryer to attain alower dew point. This cycle is depicted in theschematic on page 8.

HP4-X Design

Our patented HP4-X design incorporates 4desiccant beds where two are stacked, one overthe other in each tower. This nearly doubles the

DRYERDESCRIPTION

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amount of desiccant available for drying theprocess air stream, and because of the towerdesign, the dryer is able to regenerate thedesiccant in the same time as our ARID-X series.This allows the dryer to operate in very highhumidity conditions without affecting the processair dew point. In fact, this design produces dewpoint levels of –40° to -80° C for faster morecomplete drying of your material. Please seeAirflow diagram on page 7.

Material Hopper Requirements

The Arid-X10 dryer can be used with anymaterial hopper that is designed to allow properair flow. Hoppers that are equipped with amaterial spreader cone and diffuser basket willprovide the best performance. To obtain optimaldrying performance, we recommend that youutilize our uniquely designed material hoppers.

Dri-Air’s “all stainless” hopper design utilizes astainless steel inner shell surrounded by astainless steel jacketed insulation layer. Theeasily removable stainless steel spreader cone/diffuser basket assembly promotes propermaterial flow to ensure that the material is driedefficiently and no undried material is left at thehopper bottom that needs to be fed out prior tooperating. You must ensure that your hopper iskept filled, to ensure that you have sufficient timeto dry the material.

Dryer Controls

The Arid-X10 dryer is supplied with our standardPLC Control Module that includes a PLC ControlBoard, Display Control Board with Display/Touch Pad, and a Digital Temperature Controller.

PLC Control Board

The PLC Control Board controls the regenerationcycle described in the previous section. It hasbeen factory programmed and does not require

DRYER DESCRIPTION(Cont’d)

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any additional input by the operator. The boardwill automatically monitor and control thedryer’s operating parameters by timing theregeneration cycle as well as monitoring andcontrolling the regeneration heaters and dryeralarms.

Display Board with Control Panel Display/touchPad

The Display Control Board works in conjunctionwith the PLC Control Board to control thedryer’s regeneration heaters by actuating solidstate relays. The Touch Pad and Control Panelindicate the machine status and allow theoperator to start or stop the dryer.

Digital Temperature Controller

The Digital Controller works in tandem with thePLC Control Board to monitor and control theprocess air temperature. The controller’s touchpad allows the operator to input the dryer’sprocess air temperature settings and alarm points.These are explained in more detail later in thismanual.

Dri-Air Electric Rotary Zone Valve

The Arid-X10 utilizes our exclusive electricrotary valve technology, which helps make thisdryer truely portable and low maintenance. Asthe valve does not need compressed air tooperate, it is far more reliable than valves thatdepend on clean compressed air at a constantpressure.

The valve is designed to be practicallymaintenance free, as the seals are self seating andare designed to provide years of trouble freeservice. The electric controls are easilyaccessable for trouble-shooting, and are equippedwith lights to indicate the zone position of thevalve.

DRYER DESCRIPTION(Cont’d)

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Revision 3/28/02

Dryer CycleDiagram

Desicant Beds

Zone 1 Hea ting

Zone 2 Coo ling

Zone 2 Hea ting

Zone 1 Coo ling

Va lve Shifts

Va lve Shifts

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CAUTION: Prior to installing the dryer a qualifiedelectrician should ensure that the facility power supply iscompatible with the unit. Any wiring required forinstallation must be performed by a qualified electrician.

Installation Requirements

ElectricalThe power requirements for the unit are detailedon page 4 of this manual. The unit is supplied withpower connector cord and should be intalled asdirected below. All 230 volt models require aminimum operating voltage of 220v AC to operateproperly.

Facility LocationThe unit is suitable for use in industrial andlaboratory environments. The location should beadequately ventilated, with no flammable vaporsor gasses present. The unit must be postioned toallow the operator to view the control panel andaccess the controls. Do not locate the dryer in anenclosed area. Allow at least 3 feet (1 meter) ofclearance around each side for proper ventillationand heat dissipation. If the unit is to be installed ona bench or stand, be sure they are adequately sizedto accomodate the dryer’s weight (72 lbs/32Kg).

Hopper Connection

Each Arid-X10 dryer is supplied with a 6 footProcess Air Hose/Thermocouple Assembly and a6 foot Return Air Hose. To install the dryer, connectthe Process Air Hose/Thermocouple Assembly tothe material hopper by placing the end of the hosewith the thermocouple probe over the materialhopper inlet port (usually on the bottom of thehopper) and the end of the hose with thethermocouple plug over the dryer’s Process AirOutlet Port located on the top of the dryer. Connectthe Return Air Hose to the outlet port on the materialhopper (usually on top/cover of hopper) and to thedryer’s Process Inlet Port on top of the FilterCanister. Clamp each hose tightly with the hoseclamps provided with the dryer. Plug the

INSTALLATIONPROCEDURE

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thermocouple connector on the Process Air Hoseassembly into the receptacle located on the side ofthe dryer. See Dryer Configuration drawing (84430)in Appendix.

Electrical Connection

The Arid-X10 dryer is available in 110 or 220 volt,single-phase models. The 110 volt model issupplied with a pre-assembed power cord with agrounded three prong male plug already attached,while the 220 volt model requires the user to havea qualified electrician attach an appropriatelygrounded male plug, suitably configured to thefacility’s power supply outlet.

220 volt Connection - USA/CanadaConnect WHITE and BLACK wires to power leadson plug and the GREEN wire to the ground lead.

220 volt Connection - EuropeConnect BROWN and BLUE wires to the powerleads on plug and the GREEN/YELLOW wire tothe ground lead.

To connect the dryer to electrical power, plug inthe cord to any grounded power source. With allunits being single phase, blower rotation will becorrect.

CAUTION: Do not operate this dryer using anungrounded power receptacle.

Post-Installation Inspection

Prior to starting the dryer, inspect the unit to ensurethe following:

1. All hose couplings are tight and secure.2. Hoses are not crushed or obstructed.3. Process Air Thermocouple is connected.4. Hopper is clean and ports are clear.

INSTALLATIONPROCEDURE

(Cont’d)

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STARTUP PROCEDURE

CAUTION: Only personnel qualified to operatethis dryer should start and run this dryer.

Dryer Controls

Main Power - The rocker switch located on theleft side of the dryer face panel controls all powerto the dryer. It functions as the main circuitbreaker for the dryer and in emergencies, will cutall power to the unit.

Control Panel Power - Located on the ControlPanel are the ON and OFF buttons that initiatethe operation of the dryer. Pressing the ONbutton will start the dryer operating at theprevious operational settings. The OFF buttonwill interrupt dryer operation, but will not cutpower to the unit.

Dryer Start-up

To initiate dryer start-up, press the rocker switchon the unit’s face panel. The POWER light onthe Control Panel (shown on left) shouldilluminate; indicating power is supplied to theunit. To continue the start-up procedure, followthe instructions below.

1. POWER light indicates there is power to the controls.2. Press ON to start dryer. BLOWER light will illuminate;indicating system ready and operating.3. Flashing ZONE light means designated bed is in heatingportion of regeneration cycle.4. Steady ZONE light means designated bed is in coolingportion of regeneration cycle.5. Illuminated HEATER lights indicate designated heater ison.6. The dryer is now ready for setting the Process Airtemperature. Follow instructions in next section.7. The TEMPERATURE ALARM light will illuminate ifan alarm condition arises. Further diagnostics required.See sections on Alarms and Trouble-shooting.8. To stop dryer press OFF.

DRYER OPERATION

CONTROL PANEL TEMP CONTROLLER

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To Set Process Air Temperature:

Using the Digital Temperature Controller:

1. Press SET button on the controllerand the red Temperature Set display(labeled SV) will flash.

2. Press the < key to move the cursor toeach digit you wish to change. Using the↑ key to increase the flashing digit or the↓ key to decrease the digit. Set eachdigit to the desired temperature setting.

3. Press the SET key again to enter thenew temperature setting.

If the upper Process Air Temperature display(Labeled PV) flashes, the controller is indicatingthat the process air temperature is below thepreset lower control limit. The display willcontinue to flash until the temperature risesabove the lower control limit.

CAUTION: Do not operate this dryer below 140degrees F (60 deg. C) or above 350 degrees F(177 deg. C).

All of the alarm conditions discussed belowinitiate a “Dryer Shutdown” that cuts power tothe blower, digital controller and PLC outputrelays. To determine which alarm conditioncaused the shutdown, press the OFF button onthe Control Panel and then press and hold downthe ON button until the dryer restarts and thedisplays are actuated. See Trouble-Shootingsection of this manual.

Process Air Temperature Alarms

The PLC/Digital Control system ispreprogrammed with alarm set points that willshut the dryer down and activate theTEMPERATURE ALARM light on the dryercontrol panel and the ALM1 light on the digital

ALARMS

DIGITAL CONTROLLER

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controller.

The alarm will be activated if either the processair temperature fails to reach the set point withinthe alloted time period or the temperature exceedsthe high limit. The TEMPERATURE ALARMlight will flash and the red ALM1 light on theDigital Controller will illuminate for bothconditions.

Thermocouple Failure Alarm

If a failure is detected with the Process AirThermocouple, the upper Process AirTemperature display (labeled PV) on the DigitalController will flash and display 0000. Thisalarm will be displayed if the thermocouple is notconnected or is faulty.

When operating this dryer please follow theprocedures detailed below:

Routine Operation

The dryer should be operated in a dryenvironment at temperatures between 50 and 110degrees F (10-44 deg. C). The unit should besituated so that the air hoses are not crimped orrestricted after connection with the materialhopper and the controls are easily accessible tothe operator.

When moving the dryer allow the dryer to coolcompletely before handling. Recheck the hoseand thermocouple connections to ensure that theyare tight.

To shut the dryer down, press the OFF button onthe Control Panel and press the rocker switch tothe off position. Always unplug the unit whennot in operation.

ROUTINE OPERATION &MAINTENANCEPROCEDURES

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Emergency Shutdown

In the event that a condition should arise thatrequires the operator to immediately halt thedryer’s operation, the operator can press therocker switch to the off position and the unit willshut down completely. Remove the power plugfrom the facilty outlet to cut all power from thedryer.

Hopper Maintenance

1. Always clean hopper interior, air inlet portand diffuser basket prior to adding orchanging materials.

2. Never over-fill the hopper. Material shouldnot obstruct the exhaust port at the top of thehopper.

Filter maintenance

1. Open filter canister and clean filter elementon a daily basis using compressed air.

2. Change filter cartridge every 6 months(Sooner if process materials are dusty.).

Never operate dryer without filter element installed.

Dryer Cleaning

Always unplug the dryer before cleaning.

The dryer is supplied with a surface coating thatis easily cleaned and maintained by simplywiping the dryer with a moistened cloth or rag.Never clean the dryer with solvents or corrosiveliquids. Always allow the dryer to coolcompletely before cleaning.

ROUTINE OPERATION &MAINTENANCEPROCEDURESCont’d

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All maintenance and trouble-shooting should beperformed by a qualified electrician and a trained operator.

Nearly all diagnostic procedures can be performed witha volt ohmmeter and an AC/DC Ammeter.

In the event that the dryer will not start or shuts down inan alarm condition please take the following steps priorto other diagnostic steps.

1. Check the Power Circuit:a. Incoming power fuses or circuit breaker.b. Dryer fuse. It has a blown fuse indicator

that lights up if the fuse is defective.c. Is POWER light illuminated?d. Check heater continuity using a volt

ohmmeter.

2. Air Flow Circuit:a. Ensure Zone Valve position corresponds to

the regeneration cycle by comparing theZONE position lights on the Zone Valve tothe ZONE indicator lights on the controlpanel

b. Make sure that all hoses are connected, notcrushed, and free from obstructions.

c. Inspect filter and make sure cover is tight.

3. Control Circuit:a. Using the Control Panel ZONE indicator

lights as a guide for the status of the dryerregeneration cycle, check that all inputs areproper for the part of the regeneration cyclethat the unit is in.

b. Monitor the PLC output lights to ensure thecorresponding LED on the power board isilluminated and there is output voltage tothe heater.

4. Operating Conditions:a. Check the process air temperature. It should

not be set below 140 °F (60 °C) because theunit will go into high temp alarm.

TROUBLE-SHOOTING GUIDE

BASIC TROUBLE-SHOOTING

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POWER light is not on. Unit will not start:

1. Check Rocker Switch circuit breaker to see if itis tripped using multi-meter. Reset the RockerSwitch breaker by turning it off and then on.

2. Check small fuse next to contactor. The LEDwill be lit if it is blown. Replace if necessaryby opening the fuse holder and put new fuseinto holder.

3. Check that incoming power to the unit is proper.4. Check safety snap disc with multi-meter. (Should

be normally closed)

ALARM light is flashing. Unit will not run.

1. Check for Main Contactor failure by pressingOFF button on Control Panel and then pressand hold down the ON Button. If the unit doesnot start, the Main Contactor is not pulling in.

TEMPERATURE ALARM light is flashing. Unit willnot run:

This indicates that the process air temperaturehas; exceeded the high limit programmed into thetemperature controller, failed to reach the processair temperature set point, or there has been athermocouple failure. To determine which of theaforementioned conditions caused the alarm,perform the procedure below.

Press OFF button and restart machine by holding in theON button. View what is displayed on the digital controllerProcess Air Temperature display. If it exceeds the set pointan overtemp condition has occured. If it is below the setpoint, the dryer cannot reach the set point. If 0000 isdisplayed, a thermocouple failure has occured. Performthe following procedures for the indicated failure.

Depending on when the operator discovered thealarm, the dryer may restart if it had sufficienttime to cool down. If this happens simply allowthe dryer to operate until the alarm occurs andthen perform the above procedure.

DETAILEDTROUBLESHOOTING

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Machine will not reach temperature:

1. If the PROCESS HEATER light is not lit.A. Check output from temperature

controller and input to PLC.B. Check position of the Process Air

Thermocouple. The probe tip should bein the middle of the hose.

2. If the PROCESS HEATER light is lit.A. Check solid-state relays on power

board.B. Check airflow through process air hose.

Check the alarm limit first, by pressing andholding the SET button on the temperaturecontroller until AL is displayed. The settingdisplayed indicates the number of degrees overthe set point that the alarm will be actuated. It isfactory set to 50°F (30°C) and should not be setbelow 30°F (16°C) or it will actuate too quickly.

If the temp exceeds the set point, check the following:

1. Remove the hose from the top of the hopperto check airflow. There should be airflow outof the hopper exhaust port and a vacuum onthe hose. If there is little or no flow, checkthe inlet hose.

2. Inspect the filter to make sure that it is cleanand not affecting the airflow.

3. Check the to see if one of the power boardsolid state relays has failed on by using amulti-meter on the output to the heater. Therelay has failed if there is power to the heaterwhen the Solid-state relay’s LED is not lit.

If thermocouple has failed, check following:

1. Ensure thermocouple plug is securely insertedinto dryer outlet.

2. Check thermocouple continuity with multi-meter.

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The Dri-Air Electric Rotary Valve is designed toprovide very little process air flow restriction andno leakage between zones. It incorporates hightemperature, self adjusting seals for years oftrouble free service. The electrical controls arebuilt into the end of the valve and include zoneposition lights.

Trouble-shooting is easy. The valve is notworking properly if there are no lightsilluminated, or the lights indicating the valve’szone position do not match the ZONE lightdisplayed on the dryer’s control panel.

Check all electrical connections to valve to ensurethey are tight.

Do not attempt to adjust valve, contact factoryservice department with serial number of dryer toobtain replacement valve (Part # 83707).

DO NOT PUT FINGERS INTO VALVE WITHPOWER ON

PLC Mother BoardThe dryer control package includes a PLCcontroller that is programmed for the drying cyclediscussed previously. Each input/output terminalon the Mother Board has a corresponding LEDthat can be used for trouble-shooting. A lit LEDindicates the input or output is actuated. All PLCinputs are 12 volts AC and the outputs to thevalve and main contactor are 110 volts AC. (Seedrawings 84428 or 84429 for more detail.)

Display Panel & Display BoardThe Control Panel displays the dryer status,including heater operation and alarms. TheDisplay Board associated with the Display Panelactuates the heaters with 15 volt DC outputs tothe heater relays.

TROUBLE-SHOOTINGDRI-AIR ROTARY ZONEVALVE

TROUBLE-SHOOTINGCONTROLS - PLC &DISPLAY BOARD

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PARTS LIST: Arid X-10

General

110v Dryer

220v Dryer

PART NUMBER DESCRIPTION

84231 FILTER CARTRIDGE83707 ZONE VALVE82125 BLOWER84054 THERMOCOUPLE84016 TEMP. CONTROLLER (CB-100)80082 DESICCANT 4 lb./MACHINE80221 THERMAL SWITCH (500°)84101 PLC CONTROL84102 PLC w/7 DAY TIMER83401 DISPLAY BOARD81789 3 POLE RELAY83794 OUTPUT BOARD83443 .5A FUSE84183 ROCKER SWITCH81942 7 DAY TIMER

84414 UPPER REGEN HEATER 110 v84412 LOWER REGEN HEATER 110v84409 PROCESS HEATER 110v83625 TRANSFORMER – 110v

83437 TRANSFORMER – 220v84413 UPPER REGEN HEATER 220v84411 LOWER REGEN HEATER 220v84410 PROCESS HEATER 220v

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NOTES:

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NOTES:

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NOTES:

Documents

ARID-X10B FLOOR MOUNT DRYER OPERATING MANUAL · OPERATING MANUAL - ARID-X10B FLOOR MOUNT DRYER Revision 3/28/02 The ARID-X10B dryer is a fully portable dryer designed to dry hygroscopic