Dri-Air Industries FM Series User manual

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Contents
FM DRYERS...................................................................................................................2
INSTALLATION PROCEDURE.......................................................................................5
QUICK START-UP GUIDE..............................................................................................6
DRYER OPERATION TROUBLE SHOOTING................................................................6
PART LIST......................................................................................................................8
SMART TOUCH CONTROLS GUIDE...........................................................................10
MAIN OPERATING SCREEN: ......................................................................................10
SYSTEM SETUP SCREEN:..........................................................................................11
7 DAY TIMER:...............................................................................................................11
FACTORY SETTINGS:.................................................................................................12
SETBACK (option) ........................................................................................................13
LOADER RECEIVER (option).......................................................................................15
RECIPE MENU: ............................................................................................................16
DIAGNOSTICS SCREEN:.............................................................................................17
INPUTS:........................................................................................................................17
OUTPUTS:....................................................................................................................18
TEMPS:.........................................................................................................................18
TREND GRAPHS:.........................................................................................................19
EVENT LOG:.................................................................................................................20
ALARMS: ......................................................................................................................21
DIGITAL KEYPAD SCREEN:........................................................................................22
ALPHA-NUMERIC KEYPAD:........................................................................................23
TROUBLESHOOTING:.................................................................................................24
Hopper Ban
STC SMART TOUCH CONTROLS –HP4-X 25/35 FM
OPERATING MANUAL

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FM DRYERS
FEATURES:
The FM series dryers are the traditional dryer and hopper where the dryer is on the floor
positioned next to the molding machine and the hopper is mounted on top of the molding
machine. They are ideal where floor space is limited and material changes are infrequent. The
FM dryer series utilize the HP4-X four bed design that provides a constant supply of dry air to
the material hopper.
A FM can also be used with a hopper bank to provide hot, dry air to a hopper bank where the air
will then be heated up by each hopper’s booster heater.
HP4-X 4 Bed Design
While one bed is removing moisture from the process air the other is regenerating by heating
the desiccant to a high temperature. Once the regenerated bed cools down, the Zone Valve
switches the airflow, and the newly regenerated bed is used to desiccate the process air stream.
The saturated bed is now regenerated in the same manner, completing the regeneration cycle
The airflow design of the HP4-X dryers makes the regeneration cycle more efficient because we
utilize a small amount of the desiccated process air rather than ambient air to regenerate the
desiccant bed. This reduces the impact of the high moisture content of the ambient air, which
would contaminate the desiccant bed, and allows the dryer to attain a lower dew point. Please
see the Air Flow Schematic on Page 4.
Dryer process operating temperatures are 140 degrees F (minimum) to 325 degrees F
(maximum) with an accuracy of +/- 3 degrees. When the drying temperature is 275 degrees F
or higher, it is necessary to install a water-cooled heat exchanger on the return hose of the dryer
to ensure maximum dryer efficiency. If you do not have a heat exchanger and will be operating
275 degrees F or higher, please contact the factory for heat exchanger pricing.
Hopper Design
Dri-Air’s “all stainless” hopper design utilizes a stainless-steel inner shell surrounded by a
stainless-steel jacketed insulation layer. The easily removable stainless steel spreader cone

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promotes proper material flow to ensure that the material is dried efficiently and no dried
material is left at the hopper bottom that needs to be fed out prior to operating. You must ensure
that your hopper is adequately sized for your usage rate and is kept filled, to ensure that you
have sufficient time to dry the material.
STC Smart Touch Controls
The FM series are supplied with the Smart Touch Control (STC).
The new STC (Smart Touch Control) was introduced for optimum operation of the dryer and is
as user friendly as possible. The easy-to-see, menu driven HMI allows access to all operating
parameters and enables the operator to navigate through all settings and data. All data and fault
conditions are shown on the display in a format that is easy to understand and stored for
retention and reports
As with earlier designs, the STC is driven by thermocouples strategically located in the towers,
hoses to the hoppers, and other locations to properly control the operation of the dryer. Other
inputs monitor the performance of the dryer for safe and efficient operation.
Please refer to the STC controls section following the dryer operation.

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INSTALLATION PROCEDURE
Electrical Connection:
Open electrical access door on the front of the machine by turning the disconnect off and
turning the lower clamping screw 1/2 turn counterclockwise. Locate the disconnect by following
the operating handle down to the electrical panel.
Insert the incoming power cable or conduit through the hole provided on the side of the
machine. Wire incoming power to the top of the disconnect as shownin the diagramsbelow.
« use approved
wire and fastening
means «
3 PHASE DRYER INSTALLATION CHECK FOR CORRECT MOTOR ROTATION
BEFORE RUNNING DRYER
In case the blower does not have a cooling fan, remove the 1.5” process hose from top of dryer
and press the “start” button. Air should be blowing out the port on the top of the dryer. If the air
is sucking in on this port, the rotation is backwards can be reversed on the incoming power
leads.

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QUICK START-UP GUIDE
Operating this unit is very simple. Once the dryer is connected to the facility power supply, the
unit can be started by turning the disconnect handle located in the upper right-hand corner of
the electrical panel enclosure to the ON position and pressing the START button on the HMI. To
shut the dryer off, simply push the STOP button on the HMI.
For a more detailed explanation, please refer to the STC control section later in this manual.
DRYER OPERATION TROUBLE SHOOTING
The SmartTouch Controls were designed for quick diagnosis of problems. .The following
steps should be done before proceeding with other diagnostic steps. Alarm codes that
occur on the STC controls are further detailed in the controls section of this manual.
Check the Power Circuit:
1. Incoming fuses or circuit breaker
2. Check secondary fuses or circuit breakers.
3. Is power supplied to the unit?
4. Check heater continuity using a volt ohmmeter.
Compressed Air:
For those models that require compressed air.
5. Is compressed air connected with at least 60 PSI
6. Check water separator and drain if necessary
7. Pressure gage should read 60 PSI
Air Flow Circuit:
8. Ensure zone valve position is correct. Remove the hoses from the top of the desiccant
towers and compare the airflow to that in the provided airflow diagram in this manual.
9. Make sure that all hoses are connected, not crushed, and free from obstructions.
10. Inspect filter and make sure cover is tight and the filter is clean and in good condition.

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Control Circuit:
11. Using the PLC motherboard indicator lights as a guide for the dryer regeneration
cycle, check that all inputs/outputs are proper for the part of the regeneration cycle
that the machine is in.
12. Monitor the PLC output lights to ensure the corresponding LED on the power solid
state relay is illuminated and there is an output voltage to the heater.
Operating Conditions:
13. Check the process temperature. It should not be set below 140° F (60° C) because
the unit will go into high temp alarm.
If the temp exceeds the set point check the following:
1. Remove the hose from the top of the hopper to check air flow. There should be air flow
out of the hopper with a suction on the hose. If there is little or no flow, check the inlet
hose.
2. Inspect the filter to make sure that it is clean and not affecting the air flow.
3. Check to see if one of the solid-state relays has failed on. Using an ammeter or
voltmeter on the output to the heater, see if there is power when the LED is not lit
which will indicate a failed relay.
4. Check the valve position.
The Dri-Air valve is designed to provide very little flow restriction and no leakage. It
incorporates high temperature spool for years of trouble-free service. The electrical
controls are built into the end of the valve for long lasting performance.
DO NOT PUT FINGERS INTO VALVE WITH POWER ON
Check all electrical connections to make sure they are tight.
Contact factory with the serial number of the dryer for a replacement valve.

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PART LIST
Voltage
208V
230V
400V
480V
575V
Cone
83342
83373
83982
83374
84235
HP/Middle
82373
82373
83958
82505
84260
Process
82343
82343
84204
82319
84065
Description
Part #
Amount
Valve Zone STC 24V Assembly
Smart touch
89167
1
Blower 25CFM 3PH
86867
1
Sensor RH STC Control for
84936 RH Board Assembly
85374
1
Gasket 6” for 18-35 towers
81028
6
Filter Element 25-35 CFM for
DAC 25-35 CFM Dryers
81055
1
Thermocouple 1/8” x 6” Female
Type J
82174
8
Switch Pressure Ultra Low 1.5”
for STC Blower Rotation
86155
1
Thermocouple 1/8” x 3” Female
Type J
87361
1

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Description
Part #
Amount
Contactor 12A 600V 4P 24VDC
LS
85355
1
Overload .4-.63 Amp
Overload .63-1 Amp
–LS Interchangeable w/ Carlo
Gavazzi
85358
85359
1
Relay SS 40A 480V 2P 15-32
VDC
85364
2
Switch Disconnect 40A (Handle,
Shaft, Switch)
85365
1
Relay 1P DT 24VDC 6A card
wago
89384
1
STC HMI
85089
1
STC PLC
85090
1
Mother Board STC Rev3A
STC/HMI
89030
1
Power Supply 24VDC 30W STC
89259
1
Transformer
85959
1

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SMART TOUCH CONTROLS GUIDE
MAIN OPERATING SCREEN:
The operating screen displays all of the dryer performance information in an easy-to-read format
visible from a long distance. The large STOP/START button is incorporated into the screen rather
than being located remotely.
All common operator inputs are located on
this main screen including starting and
stopping the dryer, closed loop loader
control and temperature changes. The
asterisk (next to the setpoint) indicates the
setback function is turned on. The setpoint
temperature numbers change to red when
the dryer is in setback.
To change the process temperature, press
the SETPOINT number to display the input
screen. Select the new temperature setting
and press ENT.

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SYSTEM SETUP SCREEN:
To enter the setup screen, first tap the main menu button in the top right of the touch screen, then
select the “SETUP” button.
All of the parameters of the dryer are accessed through this screen that is very explanative.
To access the area of interest, simply press the associated button.
System, Alarms, and Factory settings buttons are only accessible through password protected
Log In.
7 DAY TIMER:
The 7-Day Timer allows the user to set one start and one stop time per day.
Before setting the times into the schedule, check to verify the actual time matches the time set
into the dryer as shown in the upper left-hand corner.
If the time is incorrect, press the hours, minutes, or seconds display and make the correction from
the keypad that will be displayed.

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To enter a start or stop time, press the time box on
the day selected and a keypad will be displayed to
make the entry desired. Note that 99 in the hour
field turns off the time for that setting. All times are
displayed in military timewhere the day is 24 hours.
For 8:00 AM set 0800 and for 4:00 PM set 1600,
settable 00:00 to 23:59. Then press Disabled
button to Enable. You may also disable any day
independently with the disabled button.
FACTORY SETTINGS:
Factory settings allow DRI-AIR personnel to
make changes to the basic operating
parameters where necessary. This screen is
password protected and only trained
personnel have access.
Some pages in the setup screen are locked,
and can only be accessed through factory
settings; this includes the “SYSTEM” page,
the “ALARM” page, and the “FACTORY
SETTINGS” page. Note that this alarm page
is separate from the alarms page in the
diagnostic menu.
In addition, switching between Fahrenheit and Celsius can only be done under factory settings.

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SETBACK (OPTION)
Temperature setback allows the dryer to automatically lower the process temperature after a
period of time to keep from over drying the material. Here you can enable or disable the setback
as well as setting setback parameters. The factory set parameters will work for most setback
applications.
Parameter changes require a Log In and password. Password = 1285
An asterisk (*) will be displayed next to the “Hopper Is On” window on the Home Screen when
setback is turned on. The new setpoint temperature will change to red when the setback
activates.
Inhibit Time = Time in minutes that the process temperature will maintain original setpoint
before going into setback. (Settable 10-480 minutes)
Delta Temp = The amount the temperature will setback from setpoint (settable 0-999℉)
Warning: Delta temp cannot be set higher than the High Temp Alarm delta temperature.
Active Delta Temp = The difference between the setpoint temperature and the setback
thermocouple temperature. The setback thermocouple temperature must be equal or less than
the setpoint temperature minus the Active Delta Temp before the setback will activate. (Settable
0-999℉)

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Restore Temp = The temperature that the setback thermocouple must drop down to or below
for it to come out setback and revert to the original setpoint. (Settable 0-999℉)
Factory default settings will work fine for most temperature setback applications.

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LOADER RECEIVER (OPTION)
For those dryers with the closed-loop loader option to load the dried material to the press, this
screen is used to configure the loading cycle.
The FILL TIME is the time in seconds the loader sends material to the receiver and is normally
in the range of 5 to 10 seconds.
The DROP TIME allows the material in the receiver to empty into the sight glass and inhibits the
loader from trying to load again.
The LOADER ALARM CYCLES initiates an alarm if material has not been sent to the receiver
in the set number of tries.
All adjustments are made by pressing on the selected time box which brings up a keypad to
make the change.

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RECIPE MENU:
*
*PDII Pictured
The process temperature can also be set using the RECIPE MENU screen. From the MAIN
OPERATING SCREEN, press the MAIN MENU, then press the RECIPE button to access this
screen.
To change the name of the recipe or any other designation you prefer and the temperature, press
the section to change and a screen will appear to make the changes. The NEXT MENU button is
the second page for this selection.
Press the H1 button next to the desired material and the temperature setpoint of that material will
be activated. H2 represented only in PDII models.

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DIAGNOSTICS SCREEN:
To enter the diagnostics screen,first tap the main menu button in the top right of the touch screen,
and then select the “DIAGNOSTICS” button.
All diagnostic information about the dryer is in thisscreen, this includes temperature data, alarms,
and event logs.
To access the area of interest, simply press the associated button.
INPUTS:
The inputs screen displays different sources of inputs, in this screen you can independently tell
whether or not an input is on or off, as well as switching between auto and manual mode.
This screen also displays an Hour Meter (Not resettable) and a Preventive Maintenance (PM)
Meter (Which is resettable).

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OUTPUTS:
The outputs screen displays different sources of outputs, in this screen you can independently
tell which output sources are on or off. You can also switch from Auto to Manual mode to test
output operation.
TEMPS:
The temps screen is used to display all of the thermocouple temperatures to trouble shoot a
problem. The current status of the regeneration cycle is displayed in the lower right of the display.
We will use this screen while assisting in determining where to look to solve a problem. Heater
outputs are also displayed by a small LED to the left of each heater’s temperature readout.

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TREND GRAPHS:
To read the temperature data in a trend graph, select the “Trend Graphs” button to get data on
the dryer’s temperature and dew points over a period of time. To record data, press write csv, to
check older data use the “<< PAGE” and “PAGE>>” buttons, to check different data sheets use
the “NEXT >” button to navigate. The Live Data button will refresh the data on the right to what
the readings are at that moment. Write CSV will write a CSV file to an SD card; this is how you
can send a file to Dri-Air Industries. Note: the Write CSV button will only write a CSV file for the
data on the current screen, if you want other tracked data to be written to an SD card you will
need to press the Write CSV file on those screens as well.

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EVENT LOG:
All alarms and events are stored to assist in trouble shooting a problem. They are stored in
sequence with the latest one first followed by past alarms and events. To make access easier,
you can select the day’s events using the arrow keys on the right. All events over 7 days are
cleared out with a first in, first out sequence. Alarms and events are stored in two different menus,
looking at the picture above, the bottom most red button is the alarm page and the button directly
above it is the event log page. Write CSV will write a CSV file to an SD card; this is how you can
send a file to Dri-Air Industries. Note: the Write CSV button will only write a CSV file for the data
on the current screen, if you want other tracked data to be written to an SD card you will need to
press the Write CSV file on those screens as well.