ARID-X10C FLOOR MOUNT DRYER OPERATING MANUAL

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DRI-AIR INDUSTRIES, INC.

OPERATING MANUAL - ARID-X10C FLOOR MOUNT DRYERRevision 7/28/04

ARID-X10C FLOORMOUNT DRYER

OPERATING MANUAL

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DRI-AIR INDUSTRIES, INC.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 Appendix85257

ELECTRICAL SCHEMATIC 220V Appendix85258

DRYER CONFIGURATION Appendix84430

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The ARID-X10C 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-X10C 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 an ELC factory 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 a factoryprogrammed ELC Control Module and a DigitalTemperature Controller.

ELC Control Module

The ELC Control Module controls theregeneration cycle described in the previoussection. It has been factory programmed anddoes not require any additional input by the

DRYER DESCRIPTION(Cont’d)

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operator. The module will automatically monitorand control the dryer’s operating parameters bytiming the regeneration cycle as well asmonitoring and controlling the regenerationheaters and dryer alarms.

Digital Temperature Controller

The Digital Controller works in tandem with theELC Control module 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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FROMMATERIALHOPPER

FILTERVORTEXBLOWER

4-WAY ZONE VALVE

VENT

TO HOPPER

HEATERSREGENERATION

AIR FLOW SCHEMATIC FOR ARID-X 10 DRYER

PROCESS HEATER

SAFETY THERMAL

AIRAHM1

LOWER

REGENERATIONHEATERS

UPPER

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Dry

erC

ycle

Dia

gram

Des

ican

tBed

s

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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 hose

INSTALLATIONPROCEDURE

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clamps provided with the dryer. Plug thethermocouple 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.

Dryer Start-up

To initiate dryer start-up, press the rocker switchon the unit’s face panel. The Rocker Switchshould illuminate; indicating power is supplied tothe unit. The dryer is now operating, follow theinstructions below to set the process airtemperature or to shut the dryer off.

1. Rocker Switch POWER ON light indicates there ispower to the controls, heaters, valve and blower.2. The dryer is now ready for setting the Process Airtemperature. Follow instructions in next section.3. The AMBER TEMPERATURE ALARM light willilluminate if an alarm condition arises. Further diagnosticsrequired. See sections on Alarms and Trouble-shooting.4. To stop dryer press the Rocker Switch to the OFFposition.

To Set Process Air Temperature:

Using the Digital Temperature Controller:

1. Press SEL button on the controller toenable the red Temperature Set display(labeled SV) to be altered.

DRYER OPERATION

TEMP CONTROLLER

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2. Press the up arrow ↑ key to increasethe set point or the down arrow ↓ key todecrease the setting until the desiredprocess air temperature set point isdisplayed.

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

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

The High Temp Alarm condition discussedbelow will initiate a “Dryer Shutdown” that cutspower to the blower, digital controller and ELCoutput relays. See Trouble-Shooting section ofthis manual.

Process Air Temperature Alarms

The ELC/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 digitalcontroller.

The alarm will be activated if either the processair temperature fails to reach the set point withinthe alloted time period or the temperatureexceeds the high limit. The HIGH TEMPALARM light 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 isnot connected or is faulty.

ALARMS

DIGITAL CONTROLLER

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When operating this dryer please follow theprocedures detailed below:

Routine Operation

The dryer should be operated in a dryenvironment at ambient temperatures between 50and 110 degrees F (10-44 deg. C). The unitshould be situated so that the air hoses are notcrimped or restricted after connection with thematerial hopper and the controls are easilyaccessible to the 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.

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.

ROUTINE OPERATION &MAINTENANCEPROCEDURES

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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 (F1 & F2).b. Dryer fuse (F3). It has a blown fuse

indicator that lights up if the fuse isdefective.

c. Is POWER light in Rocker Switchilluminated?

d. Check heater’s continuity using a voltohmmeter.

2. Air Flow Circuit:a. Ensure Zone Valve is operating correctly

and is in proper zone position. See VALVETROUBLE SHOOTING.

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 ELC LCD Output/Input

Enunciators as a guide for the status of thedryer regeneration cycle, check that allinputs are proper for the part of theregeneration cycle that the unit is in. Seepage 18.

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

VALVE TROUBLESHOOTING

To determine proper ZONEPOSITION for valve, followprocedures detailed below:

1. Open front panel of dryer toview ELC’s LCD.2. Open Right Side Panel toview Valve Control Board.3. Note if enunciator under #4on ELC LCD is on, indicatingdryer is in Zone 2. If no enun-ciator is visible, the dryer is inZone 1.4. Note which Zone Light isilluminated on Valve ControlBoard. Light should correspondto ELC LCD.

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Rocker Switch light is not on. Unit will not start:

1. Check small fuse. The LED ill be lit if it is blown.Replace if necessary by opening the fuse holderand put new fuse into holder.

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

be normally closed)

HIGH TEMP ALARM light is illuminated. 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 Rocker Switch to OFF position and restart machineby moving switch to ON position. View what is displayedon the digital controller Process Air Temperature display.If it exceeds the set point an overtemp condition hasoccured. If it is below the set point, the dryer cannot reachthe set point. If 0000 is displayed, a thermocouple failurehas occured. Perform the following procedures for theindicated 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.

Machine will not reach temperature:

1. If the Output Light (C1) on Digital Controlleris not lit.

A. Check position of the Process AirThermocouple. The probe tip should bein the middle of the hose.

B. Check Digital Controller - may be faulty.

DETAILEDTROUBLESHOOTING

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2. If the Output Light (C1) on Digital Controlleris lit.

A. Check the solid-state relay on panel.B. Check airflow through process air hose.

Check the alarm limit first, by pressing andholding the SEL button on the temperaturecontroller until STBY is displayed. Then pressthe DOWN arrow key until AL1 is displayed inthe upper (PV) display. The setting displayed inthe lower (SV) display indicates the number ofdegrees over the set point that the alarm will beactuated. It is factory set to 50°F (30°C) andshould not be set below 30°F (16°C) or it willactuate 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 the solid state relay hasfailed on by using a multi-meter on theoutput to the heater. The relay has failed ifthere is power to the heater when the Solid-state relay’s input power is not activated.

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 LCD Enunciatoron the ELC.

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

ELC Control ModuleThe dryer control package includes a ELCcontroller that is programmed for the drying cyclediscussed previously. Each input/output terminalon the Module has a corresponding enunciatordisplayed on the Module’s LCD display that canbe used for trouble-shooting. In normal operationthe LCD displays numbers 1 to 6 with with a rowof enunciators above the numbers for the inputsand a row of enunciators below for the outputs.(See Reference Guide to the left.) When theenunciator is displayed the input or output isactuated. All ELC inputs/outputs are 120 voltsAC.

Dryer Control PanelThe Control Panel for the dryer includes an ON/OFF Rocker switch that acts as the Main PowerSwitch and EMERGENCY STOP. When thisswitch is in the OFF position all power is cut tothe Controllers, Blower and Electric Valve.

TROUBLE-SHOOTINGDRI-AIR ROTARY ZONEVALVE

TROUBLE-SHOOTINGCONTROLS - ELC

REFERENCE GUIDELCD ENUNCIATORS

The following list details thecorresponding inputs & outputsto the numbered enunciatorsdisplayed on the ELC’s LCD.

UPPER ENUNCIATOR ROW

NO. INPUT# DESC. 1 I1 Main Power 2 I2 High Temp Alm3-6 Spare

LOWER ENUNCIATOR ROW

NO. OUTPUT# DESC. 1 Q1 Z1 Heaters 2 Q2 Z2 Heaters 3 Q3 Main Contactor 4 Q4 Zone Valve

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PARTS LIST: Arid X-10

General

110v Dryer

220v Dryer

PART NUMBER DESCRIPTION

84231 FILTER CARTRIDGE83707 ZONE VALVE82125 BLOWER84054 THERMOCOUPLE85241 TEMP. CONTROLLER (FUJI)80082 DESICCANT 4 lb./MACHINE80221 THERMAL SWITCH (500°)85232 FUJI ELC CONTROL80857 2 POLE RELAY82496 1 POLE RELAY82303 SOLID STATE RELAY82035 .5A FUSE HOLDER83443 .5A FUSE84691 LARGE FUSE HOLDER80907 AMBER LIGHT83079 ROCKER SWITCH81942 7 DAY TIMER

84414 UPPER REGEN HEATER 110 v84412 LOWER REGEN HEATER 110v84409 PROCESS HEATER 110v83625 TRANSFORMER – 110v80800 20 AMP FUSE

83437 TRANSFORMER – 220v85261 TRANSFORMER - 220v EUROPE84413 UPPER REGEN HEATER 220v84411 LOWER REGEN HEATER 220v84410 PROCESS HEATER 220v81583 10 AMP FUSE

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NOTES:

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NOTES:

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NOTES:

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ARID-X10C FLOOR MOUNT DRYER OPERATING MANUAL