Colortronic CTT 30 User manual

Operating Instructions
Dehumidified air dryer
CTT 30
CTT 60
CTT 120
Colortronic GmbH

Technical service:
Service department
Telephone: [phone]
Telefax: (0 61 75) 7 92-1 19
Email ctde.ser[email protected]m
Spare parts department
Telephone:[phone]
Telefax:(0 61 75) 7 92-1 08
Edition: 06/98
Order number: 64.10-0076GB01A
CTT 30 / CTT 60 / CTT 120
2
These operating instructions are for*:
(* Please fill in personally)
Serial number:
Built in:
Date of delivery:
Number of delivery:
Date of commissioning:
Location:
Group of machines:
Colortronic GmbH
Otto-Hahn-Straße 10-14
D-61381 Friedrichsdorf
Telephone [phone]
Telefax (0 61 75) 7 92-1 79
Email [email protected]m
USA
Colortronic, Inc.
VPR Commerc Center, Suite 406/407
1001 Lower Landing Road
Blackwood, NJ 08012
Telephone [phone]
Telefax [phone]
Email [email protected]m

Colortronic GmbH retains all rights to change the information in these operating
instructions at any time without notice.
Weassumenoliabilityfor anyerrorsor directorindirect damageresultingincon-
text with these operating instructions.
Copying, translation or publication in any form except for personal use of pur-
chaser requires approval from Colortronic GmbH.
All rights reserved.
CTT 30 / CTT 60 / CTT 120
3

Table of contents
1. Safety instructions............................................6
1.1. Warnings and symbols..................................7
1.2. Explanations and information.............................8
1.3. For your safety.........................................9
1.4. For the Safety of the Devices............................13
2. Assembly instructions........................................15
2.1. Transport............................................17
2.2. Installation...........................................18
2.3. Installation of the exhauster fan for regeneration of exhaust air19
2.4. Electrical Connection...................................20
2.5. Connection of Return Air Cooler (Optional).................21
3. Functional description........................................22
3.1. General Information....................................23
3.2. Drying Hopper (Optional)...............................25
3.2.1. Hopper Heater................................26
3.3. Connection to a Pneumatic Conveying System..............27
3.4. Return Air Cooler (Optional).............................28
3.5. Timer Clock (Optional).................................28
4. Start up.....................................................29
4.1. Initial Operation.......................................30
4.1.1. Switching on the Dryer.........................30
4.1.2. Setting the Drying Temperature..................31
4.2. Continuous Operation..................................32
4.2.1. Switching the Dryer on.........................32
4.2.2. Setting the Drying Temperature..................33
4.3. Switching the Dryer off.................................34
4.4. Alarm Messages......................................35
CTT 30 / CTT 60 / CTT 120
Table of contents 4

5. Maintenance.................................................36
5.1. Maintenance schedule.................................38
5.2. Cleaning or Replacing the Air Filter.......................39
5.2.1. Cleaning or Replacing the Return Air Filter.........40
5.2.2. Cleaning or Replacing the Air Filter of the Suction
Box (Optional)................................42
5.3. Disposing of Drying Agents..............................43
5.4. Checking the Signal Lamps.............................44
5.4.1. Replacing the Bulb of the Signal Lamp............44
5.5. Cleaning the Drying Hopper.............................46
6. Technical data...............................................48
6.1. CTT 30..............................................48
6.1.1. Dimension Sheet CTT 30.......................49
6.2. CTT 60..............................................50
6.2.1. Dimension Sheet CTT 60.......................51
6.3. CTT 120.............................................52
6.3.1. Dimension Sheet CTT 120......................53
7. Annex......................................................54
7.1. Spare parts list........................................55
7.1.1. Parts list CTT 30..............................56
7.1.2. Parts list CTT 60..............................59
7.1.3. Parts list CTT 120.............................62
7.2. Electrical manual......................................65
CTT 30 / CTT 60 / CTT 120
Table of contents 5

1.Safety instructions
»
Thesesafetyinstructionsapplytoallpersonswithintherangeof
action of the equipment.
Pleaseinformallpersonswithintherangeofactionoftheequip-
ment of the direct and indirect hazards connected with the
equipment.
These operating instructions are to be used by all persons as-
signed activities connected with the equipment.
Knowledge of the English language is prerequisite.
Ensure in each case that the operating personnel are familiar
with the operating instructions and the function of the equip-
ment.
CTT 30 / CTT 60 / CTT 120
Safety instructions6

1.1.Warnings and symbols
The following warnings and symbols are used in these operating instructions:
»
This symbol indicates danger to life! Fatal or serious injury is
possible if the corresponding instructions, regulations or warn-
ings are not observed.
LThissymbolindicates thatseriousinjuryis possibleifthecor-
responding instructions, regulations or warnings are not ob-
served.
FThissymbolindicates thatextensivedamageto equipmentis
possible if the corresponding instructions, regulations or
warnings are not observed.
&Thissymbol indicates information important for becoming fa-
miliar with the equipment, i.e. technical correlations.
$This symbol indicates that a technical term is explained at
this point.
CTT 30 / CTT 60 / CTT 120
Safety instructions7

1.2.Explanations and information
Various terms and designations are used in these operating instructions to en-
sure clarity. Therefore please note that the terms used in the text stand for the
corresponding explanations listed below.
•Equipment
“Equipment” can mean an individual unit, a machine or an installation.
•Operating personnel
The “operating personnel” are persons operating the equipment on their own re-
sponsibility or according to instructions.
•Operator
The “operator” of the equipment (production manager, foreman, etc.) is the per-
son responsible for all production sequences. The operator instructs the operat-
ing personnel of what is to be done.
•Operating instructions
The“operatinginstructions”describetheinteractionoftheequipment,production
sequencesormethods.Theoperatinginstructionsmustbecompiledbytheoper-
ator of the equipment.
•Equipment foreman
When several operating personnel work on one machine, the “equipment fore-
man”coordinates the sequences. The equipment foreman must be appointed by
the operator.
•Trained personnel
“Trainedpersonnel”arepersonswho,duetotheirtraining,areauthorizedtocarry
out the required work.
CTT 30 / CTT 60 / CTT 120
Safety instructions8

1.3.For your safety
•The operator of this machine must be at least 16 years old.
•Readthese operating instructions carefully before the initialstart-up. Observe all
points. Contact us if anything is unclear.
This avoids injury and damage to equipment!
•Theseinstructionsmustbestoredinsuchawaythattheyareavailableatalltimes
at the place of operation of the machine.
Danger of accidents arising through improper use!
•Please note that for reasons of clarity not every conceivable case of operation or
of maintenance can betaken into consideration.
•Observe all safety and hazard warnings on the equipment.
This avoids injury and damage!
•Allow all work on the machine to be carried out only by persons whose qualifica-
tions are set out in the relevant chapters of the operating instructions.
Danger of accidents from improper use!
•For all work carried out on the equipment only the prescribed working clothes
should be worn.
This avoids injury!
•Compare the electric supply values with those of the mains supply.
Danger of accidents from electric shock!
•When using lifting gear, please observe the relevant regulations.
Danger of accidents!
•Pleasenotethatallinstallation,start-upandmaintenanceworkistobecarriedout
only by qualified, trained staff.
Danger of accidents from improper use!
CTT 30 / CTT 60 / CTT 120
Safety instructions9

•The local regulations and requirements pertaining to the equipment must be ob-
served.
•The “5 safety rules” as provided in DIN VDE 0105, Section 1, must be observed
for all work carried out on the equipment.
•Disconnect electrical components from the mains supply before work is carried
out on these components.
Danger to life and limb from electric shock!
•Do not modify, add other equipment or change the design of the equipment with-
out the approval of the manufacturer.
Danger of accidents!
•Compile detailed operating instructions based on the operating instructions sup-
plied for the sequence of procedures to be carried out on this machine.
Danger of accidents from improper use!
•Appoint a machine foreman to be responsible for the machine.
•Ensure that the operating staff are thoroughly trained in the operation of the
equipment.
Danger of accidents from improper use!
•If the machine is switched off for safety reasons, it must be secured against un-
authorised activation.
Danger of accidents!
•Before starting maintenance work, appoint a supervisor.
•Inform the staff responsible before starting maintenance work.
Danger of accidents!
•Disconnect the equipment from the mains supply before starting maintenance
work to ensure that it cannot be switched on accidentally.
Danger of accidents!
CTT 30 / CTT 60 / CTT 120
Safety instructions10

•Repair work may be carried out only by trained staff!
Danger of accidents!
•Never operate the equipment when it is partly dismantled!
Danger! Limbs may be caught in machinery! Electric shock!
•The machine may only be operated when all the associated components are
properly connected up and in accordance with the relevant regulations.
•In case of malfunction, shut down the equipment immediately. Have faults cor-
rected immediately.
Danger of accidents!
•The machine is intended only for the drying of granulated plastics. Any other or
additional use is contrary to specifications.
•This machine is not suitable for food-drying.
•Please note that sound levels exceeding 85 db(A) may in the long term damage
your health. Use the appropriate ear muffs.
This avoids impairment of hearing!
•Attachments not supplied by Colortronic must be manufactured in accordance
with safety regulation EN 294.
Danger of accidents!
•All pipes, hoses and screwed connections should be checked regularly for leaks
and damage. Any faults which arise should be corrected immediately.
Danger of accidents!
•The safety instructions of the connected machines must be followed.
•The return air filter should only be cleaned/replaced when the the main switch is
off and the blower has stopped.
This avoids injury and damage to equipment!
CTT 30 / CTT 60 / CTT 120
Safety instructions11

•Never operate the dryer without side panels.
Danger: Limbs may be caught in machinery! Injury through burns!
•When drying plastics which emit gases dangerous for human health, take care
thattheregenerationexhaustairisdisposedofwithoutpollutingtheenvironment.
•Open drying hoppers only if they are completely empty.
•Never open drying hoppers while the device is in operation.
Danger: Iinjury through burns!
•Open drying hoppers only if they have been cooled down sufficiently.
Danger: Injury through burns!
•Remove any granules remaining on the ground.
Danger of accidents!
•Arrest the wheels after installation if the dryer is mounted on a movable frame.
This will prevent danger to people and material!
•Take care that the device is not standing on the mains cable.
This will prevent danger to people and material!
•Please note that the drying cells, drying hoppers and air pipings grow hot during
use. Avoid touching any of these parts!
Danger: Injury through burns!
•Operate the dryer only if there is at least one drying hopper operating.
This will prevent damage of material!
CTT 30 / CTT 60 / CTT 120
Safety instructions12

1.4.For the Safety of the Devices
•Never change settings without carefully assessing the consequences.
•Use only original Colortronic spare parts.
•Observe the maintenance instructions.
•Keep a record of all maintenance works and repairs.
•Please note that electronic components can be damaged by static discharge.
•Before initial operation and in regular intervals, make sure that no electrical con-
nections are loose.
•Never readjust sensors without exactly knowing their functions.
•Please note that the maximum ambient temperature may not exceed +35 °C.
•Clean the drying hoppers before the first filling.
•Note the instructions of the material manufacturer for the maximum drying tem-
perature.
•Note the drying instructions of the material manufacturer.
•Takecarethat thedrying hoppersare alwayscompletelyfilled andthat thereten-
tion period is respected if continual removal is taking place.
•Note that too large amounts taken from the dryinghopper lead to insufficient dry-
ing of the material.
•Close the air stop valves of drying hoppers which are empty or have not been
used.
CTT 30 / CTT 60 / CTT 120
Safety instructions13

•Note down all data which you have entered into the control system.
•When you dispose of drying agents, observe all official rules.
•NotethatdryingcellsarereplacedorrefilledbyColortroniconlyiftheyareempty.
•Note that the dryer may be neither tipped nor laid on its side.
•Clean or replace the return air filter only if the main switch is switched off and the
blower has stopped.
•Operate the device only if the drying hopper is sufficiently filled with material.
•Operate the device only if at least one drying hopper is operating.
•Read the operating manuals of the connected devices.
CTT 30 / CTT 60 / CTT 120
Safety instructions14

2.Assembly instructions
»
These installation instructions are intended for persons with
skillsinelectricalandmechanicalareasduetotheirtraining,ex-
perience and received instructions.
Personnel using these installation instructions must be
instructed in the regulations for the prevention of accidents, the
operating conditions and safety regulations and their
implementation.
Ensure in each case that the personnel are informed.
Theinstallationinstructionsprovidedinthecorrespondingoper-
ating instructions apply for all connected equipment.
Observesafetyregulationswithregardtoliftinggearhandling.
All installation work must be carried out with the equipment dis-
connected from electrical power and compressed air supply.
LFor installationwork taking place at heights of over approx. 6
feet, use only ladders or similar equipment and working plat-
forms intended for this purpose. At greater heights, the
properequipmentforprotectionagainstfallingmustbeworn.
Useonlysuitableandtechnicallysoundliftingequipmentand
loadsuspensiondeviceswithsufficientcarryingforce.Donot
stand or work under suspended loads!
Use suitable workshop equipment.
CTT 30 / CTT 60 / CTT 120
Assembly instructions15

FInstall the equipment such that all parts are easily
accessible; this facilitates maintenance and repair work.
CTT 30 / CTT 60 / CTT 120
Assembly instructions16

2.1.Transport
The dryer or the compact unit is delivered on a pallet.
The dryer should only be moved by means of the appropriate lifting equipment
(e.g. a fork lift).
»
Attention should be paid to the load capacity of the lifting equip-
ment.
All safety regulations regarding work with lifting equipment
should be obeyed.
FThe machine must not be tilted or laid on its side.
CTT 30 / CTT 60 / CTT 120
Assembly instructions17

2.2.Installation
Becauseofitscompactconstructionthedryercanbeinstalleddirectlybesidethe
processing machine (drying hopper on the processing machine) or supplied with
a drying hopper as a mobile attachment (compact unit).
Special foundations are not necessary for installation.
Thedryer mustbe installedon a levelsurface andmust not beexposed to exces-
sive humidity. The maximum permissible ambient temperature is 35 °C.
Tofacilitateservicing,thedryershould beinstalledinsuch awaythatthat itisac-
cessible from 3 sides.
»
The main switch must be freely accessible.
FThe equipment must not be tilted or laid on its side.
To conserve energy, keep the distance between dryer, hopper and processing
machine as small as possible.
The wheels of the compact unit should be locked to ensure stable installation.
The foil should be removed from the drying hopper.
CTT 30 / CTT 60 / CTT 120
Assembly instructions18

2.3.Installation of the exhauster fan for regeneration of exhaust air
When plastics are being dried that release harmful gases during the drying pro-
cess,caremustbetakenthattheregenerationexhaustairisdisposedofinanen-
vironmentally sound way. At the same time the throughput of the regeneration
blower must not be altered. It should be noted when assembling a disposal sys-
tem (e.g. an exhauster system) that the regeneration exhaust air is very humid.
Thus condensation may form, which must not under any circumstances return to
the dryer.
CTT 30 / CTT 60 / CTT 120
Assembly instructions19

2.4.Electrical Connection
»
Theelectrical connection ofthe dryer and of thehopper heaters
may only be carried through or assigned by
Colortronic service staff or by qualified staff authorized by
Colortronic.
Other persons are not permitted to carry through the
electrical connection.
Observe the rules of the local electricity board.
FRegularly make sure that none of the electrical or screw con-
nections are loose.
The operating voltage is 400 V/50 Hz, 3 AC or 400 V/60 Hz, 3 AC.
Special voltages can be supplied on request.
The connected loads are*:
CTT 30............................................approx. 0.7 kW;
CTT 60...........................................approx. 1.6 kW;
CTT 120...........................................approx. 3.2 kW.
*If hopper heaters are installed, the value of each hopper heater must be
added to these connected loads (max. 9.0 kW).
FBefore connecting the mains plug, make sure that the main
switch is at “0" position.
Connect the mains plug to a mains socket.
The fuse protection must have 16 A.
CTT 30 / CTT 60 / CTT 120
Assembly instructions20