ACS 882.02569.00 User manual

Central Drying System
with MDB Dehumidifying Dryers
Mechanical Manual
Part Number: 882.02569.00
Bulletin Number: DRY2-600.00
Effective: August 18, 2014

ii
Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________
_________________________ _________________________
_________________________ _________________________
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2014
All rights reserved.

iii
Shipping Info
Unpacking and Inspection
You should inspect the Central Drying System for possible shipping damage.
Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the Shipper
ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the agent’s
report. A certified copy of our invoice is available upon request. The original Bill of Lading is
attached to our original invoice. If the shipment was prepaid, write us for a receipted
transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
!Dehumidifying Dryer, Drying Hoppers, and any other equipment that has been
ordered for your drying system.
!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 shipping department immediately. For
immediate assistance, please contact the correct facility located in the technical assistance section
of this manual. Have the order number and item number available. Hold the items until you
receive shipping instructions.

iv
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
Credit Returns
Prior to the return of any material authorization must be given by the manufacturer. A RMA
number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00
minimum) restocking charge.
ALL returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
No credit will be issued for material that is not within the manufacturer’s warranty period and/or
in new and unused condition, suitable for resale.
Warranty Returns
Prior to the return of any material, authorization must be given by the manufacturer. A RMA
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, and it was
manufactured by our company, purchased components are covered under their specific warranty
terms.

v
Table of Contents
CHAPTER 1:!SAFETY..............................................................VII!
1-1!How to Use This Manual ............................................................................................vii!
Safety Symbols Used in this Manual....................................................................vii!
1-2!Warnings and Precautions ..........................................................................................ix!
1-3!Responsibility .............................................................................................................. x!
General Responsibility .......................................................................................... x!
Operator Responsibility......................................................................................... x!
Maintenance Responsibility .................................................................................xii!
Reporting a Safety Defect ....................................................................................xii!
CHAPTER 2:!GENERAL INFORMATION ................................ 13!
2-1!Models Covered in This Manual................................................................................ 13!
2-2!Necessary Documents .............................................................................................. 13!
2-3!General Description .................................................................................................. 13!
The Process/Regeneration Cycle ....................................................................... 15!
Material Overdrying Protection (DryPro Control Only) ........................................ 15!
2-4!Central Drying System Options................................................................................. 17!
Mechanical Options............................................................................................. 17!
CHAPTER 3:!INSTALLATION.................................................. 18!
3-1!Positioning Your Dryer .............................................................................................. 18!
3-2!Connecting the Process and Return Air Hoses......................................................... 18!
3-3!Drying Hopper ........................................................................................................... 21!
Removing the Rust Inhibitor.................................................................................... 21!
Air Trap Considerations ......................................................................................... 21!
3-4!Positioning Your Hopper ........................................................................................... 21!
3-5!Optional Damper Valve ............................................................................................. 21!
3-6!Optional Pressure Orifice (Required with Damper Valve)......................................... 22!
3-7!Optional Bypass Valve ............................................................................................. 23!
CHAPTER 4:!OPERATION....................................................... 24!
4-1!Pre-Startup Checks................................................................................................... 24!
4-2!Using the Optional Isolation Valves .......................................................................... 24!
CHAPTER 5:!MAINTENANCE ................................................. 25!
5-1!Work Rules................................................................................................................ 25!
5-2!Optional Damper Valve Maintenance ....................................................................... 25!
5-3!Optional Bypass Valve Maintenance ........................................................................ 26!
5-4!Replacing the Process Heaters................................................................................. 27!
5-5!Preventative Maintenance Checklist......................................................................... 28!
CHAPTER 6:!TROUBLESHOOTING ....................................... 29!
Determining Temperature Controller Errors or Sensor Errors................................... 32!

vi
CHAPTER 7:!APPENDIX.......................................................... 33!
7-1!Technical Assistance ................................................................................................ 33!
Parts and Service Department ............................................................................ 33!
Sales and Contracting Department ..................................................................... 33!
7-2!Annex B Information.................................................................................................. 34!
7-3!Drawings and Schematics......................................................................................... 35!
7-4!Revisions to Manual.................................................................................................. 36!

vii
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining the Central
Drying System. 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 General Information 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 Central Drying System. We can also provide the assistance of a factory-trained technician to
help train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the dryer. These
instructions are intended to supplement standard shop procedures performed at shift, daily, and
weekly intervals.
The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly
instructions for those areas of the equipment requiring service. Preventive maintenance sections
are included to ensure that the dehumidifying dryer provides excellent, long service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and available
options. A spare parts list with part numbers specific to your machine is provided with your
shipping paperwork package. Refer to this section for a listing of spare parts for purchase. Have
your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER indicates an imminently hazardous situation that, if not avoided, will result
in death or serious injury.
WARNING indicates a potentially hazardous situation or practice that, if not avoided,
could result in death or serious injury.
CAUTION indicates a potentially hazardous situation or practice that, if not avoided,
may result in minor or moderate injury or in property damage.

viii
Dryer Safety Tags
Hazard Alert Symbol
Description/Explanation
Preventative Maintenance
High Voltage Hazard. The
electrical enclosure is supplied
with 3-phase electrical power.
Use caution when using or
maintaining this product.
Every six months inspect all
electrical connections for
secure attachment
Auto start Hazard.
Equipment may start at any
time. Lock out/tag out
before servicing the
machine.
Every month inspect all
electrical connections for
secure attachment and that all
warning labels are in place.
Hot Surface Hazard.
When the unit operates
above 212F (100C) the
surface of the unit may
reach excessive
temperatures. Use caution
when using or maintaining
this product.
Every month check heater
elements for continuity using
an ohmmeter. For further
information see the
Maintenance Chapter in this
manual.
Mandatory Symbol
Description/Explanation
Read Operators Manual. This equipment must be operated and
maintained by properly trained personnel. The information
contained within this manual must be read and understood prior to
operating this equipment.
Lock Out. This equipment is operated with 3-phase electrical
power. Therefore, when performing any maintenance operations
we recommend following the local standards for performing a
lock-out/tag-out procedure.
Prohibition Symbol. Do not reach into any of the equipment while
the equipment is running and/or the power is on. Lock out all
power before performing maintenance on the machine(s).

ix
1-2 Warnings and Precautions
Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes. This may include, but is
not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations.
To avoid possible personal injury or equipment damage when installing, operating, or maintaining
this equipment, use good judgment and follow these safe practices:
!Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.
!Follow all SAFETY CODES.
!Wear SAFETY GLASSES and WORK GLOVES.
!Work only with approved tools and devices.
!Disconnect and/or lock out power before servicing or maintaining the equipment.
!Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
!Operate this equipment within design specifications.
!OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
!Make sure the equipment and components are properly GROUNDED before you
switch on power.
!When welding or brazing in or around this equipment, make sure VENTILATION is
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with
sheet metal. An approved FIRE EXTINGUISHER should be nearby and ready for
use if needed.
!Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
!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.

x
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard operating
conditions and when recommended instructions are followed in the maintenance and operation of
the machine.
All personnel engaged in the use of the machines should become familiar with their operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its vicinity.
Each individual must take responsibility for observing the prescribed safety rules as outlined. All
warning and danger signs must be observed and obeyed. All actual or potential danger areas must
be reported to your immediate supervisor.
General Responsibility
No matter who you are, safety is important. Owners, operators and maintenance personnel must
realize that every day, safety is a vital part of their jobs.
If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can affect
your production:
•Loss of a skilled operator (temporarily or permanently)
•Breakdown of shop morale
•Costly damage to equipment
•Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group from the
management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.
Hold daily equipment inspections in addition to regular maintenance checks. You will keep your
equipment safe for production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.
Operator Responsibility
The operator’s responsibility does not end with efficient production. The operator usually has the
most daily contact with the equipment and closely 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.
Learn and always use safe operation. Cooperate with co-workers to promote safe practices.
Immediately report any potentially dangerous situation to your supervisor.

xi
"NEVER place your hands or any part of your body in any dangerous location.
"NEVER operate, service, or adjust the dryer without appropriate training and
first reading and understanding this manual.
"NEVER try to pull material out of the dryer with your hands while it is
running!
"Before you start the dehumidifying dryer, check the following:
•Remove all tools from the dryer;
•Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the
area;
"If your dryer has been inoperative or unattended, check all settings before
starting.
"At the beginning of your shift and after breaks, verify that the controls and
other auxiliary equipment are functioning properly.
"Keep all safety guards in place and in good repair. NEVER attempt to
bypass, modify, or remove safety guards. Such alteration is not only unsafe,
but will void the warranty on your equipment.
"When changing control settings to perform a different mode of operation, be
sure selector switches are correctly positioned. Locking selector switches
should only be adjusted by authorized personnel and the keys removed after
setting.
"Report the following occurrences IMMEDIATELY:
•unsafe operation or condition
•unusual dryer action
•leakage
•improper maintenance
"NEVER stand or sit where you could slip or stumble into the dehumidifying dryer
while working on it.
"DO NOT wear loose clothing or jewelry, which can be caught while working
on the dryer. In addition, cover or tie back long hair.
"Clean the dehumidifying dryer and surrounding area DAILY, and inspect the
machine for loose, missing or broken parts.
"Shut off power to the dryer when it is not in use. Turn the switch to the OFF
position, or unplug it from the power source.

xii
Maintenance Responsibility
Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety
a priority to effectively repair and maintain equipment.
Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric
supplies and all accessory equipment at the machine, and disconnect and lockout electrical and
pneumatic power. Attach warning tags to the disconnect switch and air shutoff valve.
When you need to perform maintenance or repair work on a dehumidifying dryer above floor
level, use a solid platform or a hydraulic elevator. If there is a permanently installed catwalk on
your dryer, use it. The work platform should have secure footing and a place for tools and parts.
DO NOT climb on the dehumidifying dryer, machines, or work from ladders.
If you need to repair a large component, use appropriate handling equipment. Before you use
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes) be
sure the load does not exceed the capacity of the handling equipment or cause it to become
unstable.
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using them to
lift a load.
Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.
When you have completed the repair or maintenance procedure, check your work and remove
your tools, rigging, and handling equipment.
Do not restore power to the dehumidifying dryer until all persons are clear of the area. DO NOT
start and run the dryer until you are sure all parts are functioning correctly.
BEFORE you turn the dehumidifying dryer over to the operator for production, verify all
enclosure panels, guards and safety devices are in place and functioning properly.
Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should immediately
discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working area.

General Information 13
Chapter 2: General Information
2-1 Models Covered in This Manual
This manual will cover the information necessary for operating your Central Drying System.
Other manuals and guides will be provided for the conveying equipment used in your system.
2-2 Necessary Documents
The documents listed below are necessary for the operation, installation, and maintenance of
Central Drying Systems. You can obtain additional copies from the manufacturer. Make sure
that the appropriate personnel are familiar with these documents:
!This manual.
!The schematic and assembly drawings included in the customer information packet.
!The Customer Parts List included in the information packet.
!Operation and installation manuals for any optional controls or auxiliary equipment in the
drying system.
2-3 General Description
Moisture removal from hygroscopic (moisture attracting) plastic pellets is an essential step in the
manufacture of high-quality plastic products.
Our Dehumidifying Dryers are used by the plastics industry to generate very low dewpoint air
that is heated to a controlled temperature for drying plastic pellets and regrind.
The drying system consists of a dry air source and drying hoppers with process heating controls.
The dry air source controls two primary sub-systems, the process air and the regeneration circuit.
Each dryer has a left and a right desiccant bed so that one bed can regenerate while the other is in
use.
The drying system can be configured for more than 3 hoppers (consult factory for your
application requirements). The process air heater can be located on the dryer or on each individual
drying hopper. Heaters that are located on the drying hoppers can be set up with their own
independent controls or can be controlled centrally using the main dryer controller.

General Information 14
Orange: Standard Hosing
Green: Option Specific Hosing

General Information 15
The Process/Regeneration Cycle
There are two desiccant beds in each of the dryers. While one desiccant bed is on-line in the
process air loop, the other is off-line being regenerated.
When a desiccant bed is on-line, it absorbs moisture from the process air. The desiccant will
become saturated with moisture and need to be regenerated. The dryer automatically redirects the
process airflow to the second bed and starts regenerating the first bed.
During regeneration, air is heated to approximately 550°F and forced through the saturated
desiccant. The moisture driven off the desiccant is bled to the atmosphere. The regeneration
heater is then turned off while the regeneration blower continues to blow air through the desiccant
bed until it is cooled.
Material Overdrying Protection (DryPro Control Only)
Material Overdrying Protection is an automatic system used to reduce the chance of over-drying,
and possibly melting, the resin in the drying hopper. Material Overdrying Protection activates
when the return temperature reaches the Setback@ value, indicating that all the resin in the
hopper is dry.
When the return air temperature reaches the Setback@ value, the process heaters adjust their
temperature to the Setback Setpoint. As soon as the return air reaches the Setup@ value, the
heaters begin to heat up again to their original setpoint. The graph below illustrates how the
settings control the temperatures.

General Information 16
Safety Circuit Standards
Safety circuits used in industrial systems protect the operator and maintenance personnel from
dangerous energy. They also provide a means of locking out or isolating the energy for servicing
equipment.
Various agencies have contributed to the establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the National Fire Protection Agency (NFPA 70&79) are just a few
of the organizations that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the dehumidifying
dryer; however, it is the responsibility of the personnel operating and maintaining the equipment
to familiarize themselves with the safety procedures and the proper use of any safety devices.
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a “Safe”
condition.
Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning the dehumidifying dryer. Failure to do so may result
in serious injury. No one but the person who installed the lockout may remove it.

General Information 17
2-4 Central Drying System Options
Options can tailor your dehumidifying dryer system to meet the exact requirements of the drying
task being performed. Consult ACS for any additional options that your application may require.
Mechanical Options
!WH Series Stainless Steel Drying Hoppers (30-800 Liter Capacities)
!Hopper Mounted Heater Boosters (Consult Factory for available kW)
!Isolation Valves
!Premium Slidegate
!Different Size Manifolds (Insulated or Non-Insulated)
!Self-balancing Damper Valves for regulation of hopper airflow
!Manual or Automated Bypass Valve
!Take-Off Boxes for Conveying Dried Resins from the Hopper
!Pressure Orifice (Required with the Damper Valve)

Installation 18
Chapter 3: Installation
3-1 Positioning Your Dryer
It is important to leave room to access the dryer from the front, rear, and at least one side, for
repair and regular maintenance. Keep in mind the amount of hoppers in your system so that
ample room is set aside.
!Some dryers are equipped with durable casters, so the dryer may be wheeled
into the appropriate place.
!Place the dryer near any water or convey lines that are applicable to your
system’s needs.
!Allow enough room above the dryer for the exhaust to escape. The exhaust
can be extremely hot so keep the exhaust port away from any objects that
may be damaged by the heat.
!To position the hoppers, a forklift may have to be used. Only properly
trained personnel may operate the forklift.
!Position the hoppers so that they are facing the same direction. This is
important so that the manifolds behind each hopper may be connected.
Use caution and observe safety rules when placing your dryer!
Do not lift a hopper if it contains material!
3-2 Connecting the Process and Return Air Hoses
Due to the size of the Central Drying System and the number of hoppers, the process and return
air hoses from the dryer cannot directly be attached to a hopper inlet and outlet. Instead the two
main hoses are clamped to the two manifolds on the very first drying hopper next to the dryer.
The arrows on the manifolds indicate the direction of the airflow and what air hose should be
attached to it. On the subsequent hoppers and hopper carts in the system, use just enough dryer
hose to connect the manifold to the one directly across from it, until all the manifolds are
connected in a row. The very last manifold gets a Bypass Valve or a plug at the very end of the
line.
Each cart has two manifolds, one for the process air and one for the return air. Each manifold has
a tube stub that corresponds to that cart’s hopper. Run just enough hose from the tube stubs to the
inlet and outlet, and make sure that the correct connections are made. The airflow diagram in the
previous section provides an illustrated look at how the hosing should be connected.
Make sure the hoses are properly clamped to the manifolds, inlets, and outlets to
ensure maxiumum efficiency while drying. Minimize bends in the dryer hose and try
to reduce the hose length to the hoppers.

Installation 19
Return Air Manifold: Air returns to
the Dryer Inlet
Process Air Manifold: Air travels to the
Hopper Inlet
Process Air Hose: Connected to a
Heater Booster at the Hopper Inlet
Return Air Hose: Air returns to the
Dryer from the Hopper Outlet

Installation 20
This is the optional
heater booster, which
is attached to the
hopper inlet. The air
coming from the
dryer passes through
here before entering
the hopper.