Colortronic CTT 1600 User manual

Operating Instructions
Dehumidified Air Dryer
CTT 1600
with Siemens S7 control unit
64.10-0233GB05 11/02
Colortronic GmbH

Technical service:
Service department
Telephone: [phone]
Telefax: (0 61 75) 7 92-1 19
Email [email protected]
Spare parts department
Telephone: [phone]
Telefax: (0 61 75) 7 92-1 08
Edition: 11/02
Order number: 64.10-0233GB05
Order confirmation number:___________
64.10-0233GB05 11/02
CTT 1600
2
Colortronic GmbH
Otto-Hahn-Straße 10-14
D-61381 Friedrichsdorf
Telephone [phone]
Telefax (0 61 75) 7 92-1 79
Email [email protected]
Http://www.colortronic.com
USA
Colortronic, Inc.
155 E., 9th Avenue
Runnemede, NJ 08078
Telephone [phone]
Telefax [phone]
Email [email protected]
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 retains all rights to change the information in these operating
instructions at any time without notice.
We assume no liability for any errors or direct or indirect damage resulting in con-
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.
64.10-0233GB05 11/02
CTT 1600
3

TABLE OF CONTENTS
1. General Information (Version: 64.10-8248GB01 04/02) ..................1-1
1.1. Warnings and symbols ............................................1-2
1.2. Explanations and information .......................................1-3
1.3. Legal basis ......................................................1-3
1.4. Fields of applications..............................................1-3
1.5. Notes on Usage ..................................................1-3
2. Safety instructions (Version: 64.10-0127GB03 11/02) ...................2-1
2.1. For your safety...................................................2-2
2.2. For the safety of the devices........................................2-5
3. Start-up (Version: 64.10-0233GB05 11/02) ............................3-1
3.1. Control system ...................................................3-2
3.1.1. Key assignment.........................................3-2
3.1.2. Flow chart .............................................3-3
3.2. Switching on the dryer.............................................3-4
3.2.1. Operation statuses ......................................3-4
3.3. Viewing the software-version .......................................3-5
3.4. Passwords ......................................................3-5
3.5. Basic parameters.................................................3-7
3.5.1. Turning the devices on/off ................................3-7
3.5.2. Entering dryer values ....................................3-9
3.5.3. Entering hopper values..................................3-11
3.5.4. Observing processing status .............................3-13
3.5.5. Setting date and time ...................................3-14
3.5.6. Viewing/changing language and contrast ...................3-15
3.5.7. Changing parameters ...................................3-16
3.5.8. Setting the timer .......................................3-17
3.6. Starting continuous operation ......................................3-18
3.7. Viewing system runtime ..........................................3-19
3.8. Switching the dryer off............................................3-20
4. Error and error correction (Version: 64.10-8248GB01 04/02) .............4-1
64.10-0233GB05 11/02
CTT 1600
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5. Maintenance (Version: 64.10-0233GB05 11/02) ........................5-1
5.1. Maintenance intervals .............................................5-3
5.2. Cleaning/renewing the air filters .....................................5-4
5.3. Tensioning the V-belts.............................................5-7
5.4. Disposing of the drying agent ......................................5-10
5.5. Servicing the accessories .........................................5-10
5.6. Changing the battery of the control system ...........................5-11
5.6.1. Resetting the control values ..............................5-13
6. Functional description (Version: 64.10-0233GB01 11/02)................6-1
6.1. Dryer...........................................................6-2
6.2. Drying hopper (optional) ...........................................6-3
6.3. Return air cooler (optional) .........................................6-4
6.4. Hopper heaters (optional) ..........................................6-5
6.5. Automatic motor flaps (optional).....................................6-5
6.6. Connection to a pneumatic conveying system (optional) .................6-5
7. Transport, Assembly and Storage (Version: 64.10-8248GB01 04/02) ......7-1
7.1. Transport and Packing ............................................7-2
7.2. Assembly .......................................................7-4
7.3. Storage.........................................................7-4
8. Assembly instructions (Version: 64.10-0233GB05 11/02)................8-1
8.1. Mounting of the suction device for regeneration exhaust air ..............8-2
8.2. Filling up the drying cells...........................................8-3
8.3. Connection of the air coolers (optional) ...............................8-4
8.4. Electrical connection ..............................................8-5
9. Technical Data (Version: 64.10-0233GB05 11/02) ......................9-1
5
CTT 1600
64.10-0233GB05 11/02

10. Spare parts list (Version: 64.10-0233GB05 11/02) ....................10-1
10.1. Switching Cabinet and Operating Unit ..............................10-5
11. Electrical manual (Version: 64.10-0133GB01 10/97)...................11-1
oConnection diagram no.: ________________
oCurrently not available; will be delivered at a later date!
12. Accessories (Version: 64.10-0134GB01 10/97) .......................12-1
oEntering values on the OP7/17
oFlap control with Fuzzy-Logic
oElektror High-pressure blower with frequency converter operation
oElektror High-pressure blower
o_____________________________
o_____________________________
64.10-0233GB05 11/02
CTT 1600
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1. General Information
Version: 64.10-8248GB01 04/02
»These operating instructions are addressed to all users of the device.
These operating instructions must be used by every person charged with
work on the unit.
64.10-8248GB01 04/02
Dehumidified Air Dryer
General Information 1-1

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 warnings are not observed.
LThis symbol indicates that serious injury is possible if the corresponding
instructions, regulations or warnings are not observed.
FThis symbol indicates that extensive damage to equipment is possible if
the corresponding instructions, regulations or warnings are not obser-
ved.
&This symbol indicates information important for becoming familiar with
the equipment, i.e. technical correlations.
$This symbol indicates that a technical term is explained at this point.
64.10-8248GB01 04/02
Dehumidified Air Dryer
General Information 1-2

1.2. Explanations and information
Various terms and designations are used in these operating instructions to ensure clarity. There-
fore please note that the terms used in the text stand for the corresponding explanations listed be-
low.
•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 responsibility or ac-
cording to instructions.
•Operator
The ”operator” of the equipment (production manager, foreman, etc.) is the person responsible for
all production sequences. The operator instructs the operating personnel of what is to be done.
•Operating instructions
The ”operating instructions” describe the interaction of the equipment, production sequences or
methods. The operating instructions must be compiled by the operator of the equipment.
•Equipment foreman
When several operating personnel work on one machine, the ”equipment foreman” coordinates
the sequences. The equipment foreman must be appointed by the operator.
•Trained personnel
”Trained personnel” are persons who, due to their training, are authorized to carry out the required
work.
1.3. Legal basis
See “Manufacturer’s Certificate” resp. “Certificate of Conformity”.
1.4. Fields of applications
For the drying of thermoplastic granules and regrind before processing in order to remove all re-
maining moisture from the granules both inside and out, independent of climate or ambient air
conditions.
1.5. Notes on Usage
•Experienced operators can begin directly with the chapter on “Start-up” if the unit has been pro-
perly installed.
•If the unit has not been installed yet, observe the instructions in the chapter on “Assembly Instruc-
tions” and “Transport, Assembly and Storage”.
64.10-8248GB01 04/02
Dehumidified Air Dryer
General Information 1-3

2. Safety instructions
Version: 64.10-0127GB03 11/02
»These safety instructions apply to all persons within the range of action of the
equipment.
Please inform all persons within the range of action of the equipment of the
direct and indirect hazards connected with the equipment.
These operating instructions are to be used by all persons assigned activities
connected with the equipment.
Knowledge of the English language is prerequisite.
Ensure in each case that the operating personnel are familiar with the opera-
ting instructions and the function of the equipment.
64.10-0127GB03 11/02
Dehumidified Air Dryer
Safety instructions 2-1

2.1. For your safety
General
The operating personnel of this equipment must be at least 16 years old.
Please read these operating instructions carefully before taking into operation for the first time.
Contact us should questions arise. This avoids injury and damage to equipment!
These operating instructions must be kept available at all times at the place of operation of the
equipment. Improper operation results in danger of accidents!
Please note that, for reasons of clarity, not all conceivable cases regarding operation or mainten-
ance of the equipment can be covered in these operating instructions.
Please observe all safety instructions and warnings on the equipment. This avoids injury and da-
mage to equipment!
All work on the equipment is to be carried out by persons whose qualifications are specified in the
pertaining chapters of the operating instructions. Improper operation results in danger of acci-
dents!
The proper working clothes are to be worn during any work on the equipment. This avoids injury!
The local regulations and requirements pertaining to this equipment must be observed.
Disconnect electrical components from the mains supply before work is carried out on these com-
ponents Caution: Danger to life through electrical shock!
Compile detailed operating instructions based on these Operating instructions for the sequence
of procedures to be carried out on this equipment. Improper operation results in danger of acci-
dents!
Observe that the control system is still under voltage even when the main switch is switched off.
Caution: Danger to life through electrical shock!
Assembly
Compare the connected loads with those of the mains supply. Danger of injury through electrical
shock!
When using lifting gear, please observe the pertaining regulations. Caution: Danger of accidents!
Do not modify, add other equipment or change the design of the equipment without the approval
of the manufacturer. Caution: Danger of accidents!
Attachments not supplied by Colortronic must be manufactured in accordance with safety regula-
tion EN 294. Danger of accidents!
The equipment may only be operated when all the associated components are properly connec-
ted up and in accordance with the relevant regulations. This avoids injury and damage to equip-
ment!
Operate the device only if all its components are grounded. Danger: accident through electrical
shock!
Please note for installation that the equipment is top-heavy. Danger exists that it may topple over!
64.10-0127GB03 11/02
Dehumidified Air Dryer
Safety instructions 2-2

Take care that the device is not standing on the mains cable. This will prevent danger to people
and material!
The drying cells must be filled with drying agent before setting-up the dryer (only CTT 1600,
CTT 2400). This will prevent damage of material!
Check 5 hours after first putting into operation that the drying cells are sufficiently filled with drying
agent (only CTT 1600, CTT 2400). This will prevent damage of material!
Operation
Appoint an equipment foreman to be responsible for the equipment.
Ensure that the operating personnel are provided detailed instruction in the operation of the
equipment. Improper operation results in danger of accidents!
When the main switch is switched off for reasons pertaining to safety, it must be secured against
unauthorized activation. Caution: Danger of accidents!
Repair work may be carried out by trained personnel only. Caution: Danger of accidents!
Never operate the equipment when partially dismantled! Danger! Limbs may be caught in machi-
nery! Electric shock!
In case of malfunction, shut down the equipment immediately. Have malfunctions corrected im-
mediately. Danger of accidents!
The machine is intended only for the drying of granulated plastics. Any other or additional use is
contrary to specifications.
This equipment is not suitable for food processing.
The safety instructions of the connected machines must be followed.
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!
Please note that the drying cells, drying hoppers and air pipings grow hot during use. Avoid tou-
ching any of these parts! Danger: Injury through burns!
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 that the regenera-
tion exhaust air is disposed of without polluting the environment. This will prevent danger to peo-
ple and material!
Operate the dryer only if there is at least one drying hopper operating. This will prevent damage of
material!
64.10-0127GB03 11/02
Dehumidified Air Dryer
Safety instructions 2-3

Maintenance
Before starting maintenance work, appoint a supervisor.
Inform the responsible personnel before maintenance work on the system is started. Caution:
Danger of accidents!
Disconnect the equipment from mains supply before starting maintenance procedures to ensure
that it cannot be switched on unintentionally. Caution: 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!
Depressurise all compressed air piping before starting maintenance work. Danger of accidents!
The air filters should only be cleaned/replaced when the the main switch is off and the blower has
stopped. This avoids injury and damage to equipment!
Any maintenance work on the equipment should only be started when the the main switch is off
and the blower has stopped. This avoids injury and damage to equipment!
Check the v-belts of the blower only when the main switch is switched off and the blowers have
stopped. Caution: Danger of accidents!
Open drying hoppers only if they are completely empty. Danger of accidents!
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!
Before starting maintenance work wait until the drying cells, drying hoppers and air pipings have
been cooled down sufficiently. Avoid touching any of these parts! 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!
64.10-0127GB03 11/02
Dehumidified Air Dryer
Safety instructions 2-4

2.2. 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 connections are loo-
se.
Never readjust sensors without exactly knowing their functions.
Please ensure that the permitted storage temperature lies between -20 and +55 °C
(-4 to +131 °F).
Please ensure that the permitted operation temperature lies between 0 and +45 °C
(32 to +113 °F).
Check the direction of rotation of the blowers after the electrical connections have been made
(see rotational direction arrow).
Clean the drying hoppers before the first filling.
Note the instructions of the material manufacturer for the maximum drying temperature.
Note the drying instructions of the material manufacturer.
Take care that the drying hoppers are always completely filled and that the retention period is re-
spected if continual removal is taking place.
Note that too large amounts taken from the drying hopper lead to insufficient drying of the materi-
al.
Close the air stop valves of drying hoppers which are empty or have not been used.
Note down all data which you have entered into the control system.
The password is to be entrusted to authorised personnel only.
Please note that the temperature of the dryer heating system must always be set lower than that of
the supplementary heaters.
When you dispose of drying agents, observe all official rules.
Note that drying cells are replaced or refilled by Colortronic only if they are empty.
The material level may not fall below 40 % in the drying hopper, when material is continuously re-
moved from the drying hopper, but no material is continuously fed into the drying hopper (batch
drying). Close the throttle valves.
Read the operating manuals of the connected devices.
64.10-0127GB03 11/02
Dehumidified Air Dryer
Safety instructions 2-5

Observe that the drying cells must be filled with drying agent before setting-up the dryer (only
CTT 1600, CTT 2400). This will prevent damage of material!
Check 5 hours after first putting into operation that the drying cells are sufficently filled with drying
agent (only CTT 1600, CTT 2400). This will prevent damage of material!
64.10-0127GB03 11/02
Dehumidified Air Dryer
Safety instructions 2-6

3. Start-up
Version: 64.10-0233GB05 11/02
»This chapter is directed at the operators of the equipment.
This chapter assumes general skills in dealing with drying systems and SPS
(PLC) control units.
This chapter assumes that the functional description has been read and un-
derstood.
It should be ensured in each and every case that the operators have the rele-
vant skills.
FNote down all set values of the control system.
Make sure that the cooling appliance is connected to the mains socket in
the electrical cabinet (if present, optional).
Make sure that any condensate penetrating from the cooling appliance
(optional) does not get inside the dryer or the control box.
&If the inside temperature of the switch cabinet is above +50°C, the dryer
is switched off after 30 minutes if it is operated with a cooling appliance
(optional).
64.10-0233GB05 11/02
CTT 1600
Start-up 3-1

3.1. Control system
The control system is switched on at the main switch. The control system is operated via a
”selection window” and the keyboard of the operator panel.
The facility’s control system is factory-programmed. Nevertheless, you have to set specific
values (basic parameters) which are dependent on the processed material, for instance.
The values entered are stored in the control system and remain so, even after the unit is switched
off or in the event of a power cut. All messages are displayed in plain text.
In describing this start-up, we have assumed that the various sub-menus are selected from the
”table of contents”.
This structure of the description has been selected since, in most cases, you will only work on one
item in the ”submenu”.
If you want to work on several ”submenu” items in succession, you can select the individual items
directly by means of the arrow keys.
3.1.1. Key assignment
F1-key: Leads to the table of contents.
ENTER-key: Confirms the entries.
ESC-key: Goes back one step in the menu.
ACK-key: Activates an alarm message; to unblock the control system.
Arrow keys: Move the cursor bar;
switch the appliances on or off in combination with the SHIFT key;
for scrolling forward or backward in a menu.
SHIFT-key: Switches on the secondary functions of the keys,
when the SHIFT-key has been pushed, the LED “SHIFT” is on.
HELP-key: Viewing additional texts,
when additional texts can be viewed the LED “HELP” is on.
LED “ALARM”: flashes in case of an error;
is on if the error has been acknowledged but not yet
eliminated; is off if there are no errors
&LED = light emitting diode
An additional alarm device (horn or lamp) can be connected (optional).
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CTT 1600
Start-up 3-2

3.1.2. Flow chart
1 Indicator lamp
2 Valve system
3 Drying chamber
4 Drying blower
5 Return air filter
6 Drying hopper
7 Drying heater
8 Regeneration heater
9 Regeneration blower
10 Regeneration air filter
Indicator lamp messages:
Green continous light: in process
Red continous light: alarm
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CTT 1600
Start-up 3-3
3
3
10 9 8
21
2
45 6 7

3.2. Switching on the dryer
Switch on the system by means of the main switch.
&The control system carries through a self-test; after that, the name of the
dryer and the operation status of the unit are displayed.
FUnblock the control system:
Keep the ACK key pressed until the LEDs of the keys K1 - K4 light up.
3.2.1. Operation statuses
The following operation statuses can be displayed:
•system is off
•system is on
•blower runs on
•valve block
•regeneration will be finished in x min.
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CTT 1600
Start-up 3-4

3.3. Viewing the software-version
Press the “±”-key.
&Lamp test: all LED’s must light up.
The software-version will be displayed (optional).
3.4. Passwords
The entry of a password prevents unauthorised persons from having access to the data entered
into the control system. Important data can then be entered or modified only after the password
has been entered.
If you make no entries for more than 10 minutes, the access is blocked and you have to re-enter
the password.
•password level 6: 79 21 54
FTell the password only to authorised persons.
Press the ”Shift”-key and the ”K4”-key.
Press3xthe“â” key.
Press the ”F3”-key.
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Start-up 3-5