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IMS APD 1-9 User manual

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1

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© Copyright 2014 IMS Company. All rights reserved. An ISO 9001:2008 Registered Quality Company
1
PORTABLE, DUAL
DESICCANT BED DRYERS
Model APD 1-9/HDP 1-9
INSTRUCTION MANUAL
Telephone: (440) 543-1615
Fax: (440) 543-1069
Email: sales@imscompany.com
Website: www.imscompany.com
December 2014
IMS Company
10373 Stafford Road
Chagrin Falls, OH 44023-5296
DRI-AIR INDUSTRIES, INC.
OPERATING MANUAL - APD 1-9, HPD 1-9 PORTABLE DRYERS
Revision 10/8/02 Page 3
CONTENTS
DRYER OPERATION/FEATURES---------------------------4
AIR FLOW SCHEMATIC FOR APD 1-9 DRYERS------- 6
AIR FLOW SCHEMATIC FOR HPD 1-9 DRYERS ------7
(HIGH PERFORMANCE MODEL SHOW)
DRYER CYCLE DIAGRAM ------------------------------------8
PLC STANDARD ELECTRICS -------------------------------9
INSTALLATION PROCEDURE ----------------------------- 10
Electrical Connection ------------------------------------- 10
Check for correct motor rotation ----------------------- 10
Compressed Air Connection---------------------------- 10
START-UP PROCEDURE ----------------------------------- 11
Standard Electrics----------------------------------------- 11
To Set Temperature: -------------------------------------- 11
Microprocessor Control ---------------------------------- 12
CLOSED LOOP LOADING SYSTEM --------------------- 13
ReceiverInstallation -------------------------------------- 13
Vacuum Check --------------------------------------------- 14
Adjustment of Sensors ----------------------------------- 14
Material Flow Adjustment-------------------------------- 15
BASIC TROUBLE SHOOTING for
CLOSED LOOP LOADING SYSTEM --------------------- 16
Material will not feed. ------------------------------------- 16
CLL MAINTENANCE------------------------------------------ 16
DailyMaintenance:---------------------------------------- 16
MonthlyMaintenance: ------------------------------------ 16
DRYER OPERATION-TROUBLE SHOOTING --------- 17
DRYER OPERATION-DETAILED DIAGNOSIS -------- 18
DRI-AIR ROTARY ZONE VALVE--------------------------- 19
PARTS LISTS
ARID-X 18 - 35 APD 1-4 and HPD 1-4--------------- 20
ARID-X 50 - 100 APD 5-9 and HPD 5-9 ------------- 21
DRI-AIR INDUSTRIES, INC.
OPERATING MANUAL - APD 1-9, HPD 1-9 PORTABLE DRYERS
Revision 10/8/02
Page 4
The ARID-X dryer series is a dual bed design that provides a
constant supply of dry air to the material hopper. 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 cycle is depicted Page 8.
The airflow design of the ARID-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 6.
HP4-X Design
Our patented HP4-X design incorporates 4 desiccant beds
where two are stacked, one over the other. This nearly
doubles the amount of desiccant available for drying the
process air stream, and because of the tower design, the
dryer is able to regenerate the desiccant in the same time as
our ARID-X series. This allows the dryer to operate in very
high humidity conditions without affecting the process air dew
point. In fact, this design produces dew point levels of – 40’ to
-80’ C for faster more complete drying of your material. Please
see the Air FLow Diagram on Page 7.
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
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.
DRYER OPERATION/
FEATURES
DRI-AIR INDUSTRIES, INC.
OPERATING MANUAL - APD 1-9, HPD 1-9 PORTABLE DRYERS
Revision 10/8/02 Page 5
Closed Loop Loading System
Dri-Air’s closed loop loading system utilizes a dedicated
blower, small receiver, filtration system and desiccated air to
move the material from the dryer hopper to the molding
machine. This eliminates the possibility that your material will
be contaminated with moisture as with some other material
transfer systems, helping to eliminate defects resulting from
moisture contamination. Please refer to the Closed Loop
Loader System section of this manual for the proper
installation and maintenance.
Dryer Controls
The ARID-X series can be supplied with the standard PLC
Control Module or the advanced Microprocessor Control
Module, while the HP4-X series is only available with the
Microprocessor Control Module.
The PLC Control module includes a PLC control board,
display board, temperature controller and touch pad that is
programmed for the drying cycle described above. The
controller, display board and touch pad indicate the machine
status, alarms, set points and allow you to enter operational
settings for the dryer. These are explained in more detail later
in this manual.
The Microprocessor Control Module is one of the most
sophisticated yet operator friendly controls on the market. It
has many more features than the PLC control module that
provide the operator with more control and operational
flexibility with the dryer. These features and the operating
instructions are covered in detail in the Microprocessor
Control Instruction Manual included with your dryer.
DRYER OPERATION/
FEATURES (Cont.)
DRI-AIR INDUSTRIES, INC.
OPERATING MANUAL - APD 1-9, HPD 1-9 PORTABLE DRYERS
Revision 10/8/02
Page 6
AIR FLOW SCHEMATIC
FOR APD 1-9 DRYERS
XX
VORTEX BLOWER
4-WAY ZONE
VALVE
FILTER
VENT
SAFETY THERMAL
SAFETY THERMAL
REGENERATION
AND PROCESS
HEATER
TO HOPPER
PROCESS HEATER
(APD 5-9)
CONTROL
THERMOCOUPLE
H2
CONTROL
THERMOCOUPLE
L1
CONTROL
THERMOCOUPLE
L2
CONTROL
THERMOCOUPLE
H1
DRI-AIR INDUSTRIES, INC.
OPERATING MANUAL - APD 1-9, HPD 1-9 PORTABLE DRYERS
Revision 10/8/02 Page 7
AIR FLOW SCHEMATIC
FOR HPD 1-9 DRYERS
XX
VORTEX BLOWER
4-WAY ZONE
VALVE
FILTER
VENT
CONTROL
THERMOCOUPLE *
M2
CONTROL
THERMOCOUPLE *
M1
SAFETY THERMAL
SAFETY THERMAL
SAFETY THERMAL
REGENERATION
AND PROCESS
HEATER
REGENERATION
AND PROCESS
HEATER
TO HOPPER
PROCESS HEATER
(HPD 5-9)
SECONDARY
REGENERATION
HEATER
CONTROL
THERMOCOUPLE
H1
CONTROL
THERMOCOUPLE
H2
CONTROL
THERMOCOUPLE
L2
CONTROL
THERMOCOUPLE
L1
* - CONTROL THERMOCOUPLE
FOR PLC CONTROL ONLY
DRI-AIR INDUSTRIES, INC.
OPERATING MANUAL - APD 1-9, HPD 1-9 PORTABLE DRYERS
Revision 10/8/02
Page 8
Dryer Cycle
Diagram
Desicant Beds
Zo ne 1 He a ting
Zone 2 Cooling
Zo ne 2 He a ting
Zone 1 Cooling
Va lve Shifts
Valve Shifts
DRYER CYCLE
DIAGRAM
XX
DRI-AIR INDUSTRIES, INC.
OPERATING MANUAL - APD 1-9, HPD 1-9 PORTABLE DRYERS
Revision 10/8/02 Page 9
The control package includes a PLC controller which is
programmed for the drying cycle previously discussed. The
display board indicates the machine status, heater operation
and alarms. See section on start up for details.
Below are descriptions of the inputs and outputs of the PLC
which are used for trouble shooting. A lit LED indicates the
input or output is actuated. All inputs are 12 volts AC and all
outputs are 110 volts AC and 15 v DC to the heater relays.
Refer to the electrical schematic for more detail.
PLC STANDARD
ELECTRICS
XX
S2
J12
D16
C11
C20
C14
C15C13
D20
D15
D12
D10D14
D9D13
D8D11
J5
Jp7
J2
11
J118
J11
J11A
U7
U5
U9
U2
U2A
S1
R36
OSC1
OSC3
OSC2
Rn7
OSC1
R11
R12
R13
R14
+
+
+
++
C18
C13
C16
D16
C12
Rn5
Rn6
INPUTS
Rn7
OUTPUTS
R37
R38
Tb1
R1
R2
R3
R4
R5
R6
Jp1
Jp2
Jp3
Jp4
Jp6
Jp5
Br1+ +C18
C17
C22
C23
L1
L2
Z1
C2
R7
R8
C11 C0
C1
C2
C3
C2
U3
U4 U6
C8
U11
C15 D8
D9
D0 D1 D2 D3 D4 D5 D6 D7
D10
D11
D12
D13
D14
D15
C4
C5
C6
C7
C9
C19 J5
R2
OSC1
OSC3
OSC2
J2
U8
U9
U1
C1
0
1
2
3
5
6
7
4U2
Jp7
Rn4
Rn3
U5
U18
C14
Tb2
S
mal l
PLC03
REV E
8 UNUSED
8A UNUSED
9 UNUSED
9A UNUSED
10 ALARM (OPTIONAL)
11 HIGH TEMP. ALARM (OPTIONAL)
12 UNUSED
13 MAIN CONTACTOR/TEMP CONTROL
14 ZONE VALVE
PROCESS HEATER
ARID-X 50-100
Z1 TOP HEATER
Z2 TOP HEATER
TEMP
SAFETY
MAIN
HI TEMP
POWER
DISPLAY BOARD - P/N 83401
THERMOCOUPLE BOARD
MOTHER BOARD
PORT
DRI-AIR INDUSTRIES
EXPANDER BD REV C
SS4
AL2
CR1
M2
AL1
SS1
SS2
110 VAC
FROM XFORMER
T1
50
14
UNUSED
NON H.P.
50-300
#9TEMP.CONTSIGNAL
SAFETY
7DAYTIMER
HI TEMP. ALARM SIGNAL
UNUSED
UNUSED UNUSED
GROUND
L1
L2
QT9
QT8QT7QT6QT5
OL1
7DAYTIMER
H.P ONLY 50-100 PROCESS TUBE
C1
0
1
2
3
4
5
6
7
C13C14C15C16C17
Ch5 Ch4 Ch3 Ch2PWR Ch1 Ch0
C3 C4
U1 U10
C2
C21
TC rev B
Rgain
C20 C19
C18
C9
J2
JP2
JP3
DegC
X10
OSC1
JP1
ANALOG
TC
C8
J1
C7
C6
C1
C10 C11
C5
1
1
1
2
2
2
3
3
C12
-
+
-
+
-
+
-
+
-
+
-
+
-
+
H2
H1
M2
M1
L2
L1
UNUSED
SS3
SS5
-
+-
+-
+
+
+
-
-
Z1 BOTTOM HEATER
Z2 BOTTOM HEATER
UNUSED
UNUSED
50-300
NON H.P.
TC1
TC1
JUMP
UNUSED
8
9
10
11
P/N 84100
DRI-AIR INDUSTRIES, INC.
OPERATING MANUAL - APD 1-9, HPD 1-9 PORTABLE DRYERS
Revision 10/8/02
Page 10
For all Dri-Air models except ARID-X 10, AHM-1, & PDII
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.
«use approved wire and fastening means «
Wire incoming power to the top of the disconnect as shown in
the diagrams below.
NOTE:
When 3 wire supplies are used in place of 4 wire supplies,
a control transformer is required.
3 PHASE DRYER INSTALLATION
CHECK FOR CORRECT MOTOR ROTATION
BEFORE RUNNING DRYER
To check motor rotation.......
Leave the electrical cabinet door open so the blower can be
observed. Turn on the power to the dryer and press the ON/
START touch pad and then immediately press the OFF/STOP
touch pad. Observe the cooling fan on the top of the blower
motor and verify the fan is turning clockwise. If the motor is
not turning clockwise, switch any two adjacent supply wires.
Compressed Air Connection:
Compressed air is only required for dryers which have the
closed loop loader as part of the system. For those units:
CONNECT COMPRESSED AIR TO INLET ON FRAME
UNDER DRYER. The closed loop system includes a
regulator that is set to the proper pressure and an automatic
drain water separator. Maximum incoming pressure not to
exceed 145 psi (1.0 mpa).
The unit is now ready for operation.
INSTALLATION
PROCEDURE
XX