Manual DFD Desiccant Flex Dryer Lab-Dry

Transcription

1 Manual DFD Desiccant Flex Dryer Lab-Dry Serial No... ISO GB LT no.: Rev. N00 Date:

2 SIEMENS asdasdasdasd asdasdasdasd ON SIMAT EK PANEL OFF Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 2 of 47 DFD600 - DFD1700 DFD300 - DFD450 DFD DFD R1945

3 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 3 of 47 DRYING UNIT DFD (Desiccant Flex Dryer) Pos. Designation 1 Inlet slide valve desiccant bed 1 2 Inlet slide valve desiccant bed 2 3 Outlet slide valve desiccant bed 1 4 Outlet slide valve desiccant bed 2 5 Fresh air valve 6 Thermostat regeneration air, desiccant bed 1 7 Thermostat regeneration air, desiccant bed 2 8 Dry air blower 9 Regeneration blower 10 Return air cooler 11 Regeneration air cooler 12 Return air filter 13 Regeneration filter 14 Thermostat for dry air 15 Thermostat for regeneration air 16 Desiccant bed 1 17 Desiccant bed 2 18 Heating element for regeneration, desiccant bed 1 19 Heating element for regeneration, desiccant bed 2 20 Air outlet pipe 21 Control cabinet 22 PLC control 23 Operator panel DRYING HOPPERS DH Pos. Designation 24 Dry air heating element 25 Drying hopper DH 26 Air distributor

4 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 4 of CONTENTS 2.0 GENERAL INFORMATION Application Restrictions Design Relevant standards, instructions and directives Operating principles Certificates TECHNICAL DATA Technical specifications Identification plate Dimensioned drawings Capacity table Safety measures Noise level INSTALLATION/OPERATION Packaging and transport Installation External power supply Internal connections Operating the system Operating - LAB DRY ACCESSORIES Additive trap MAINTENANCE Maintaining the DFD dryer Replacement of return air filter (12)/regeneration filter (13) TROUBLESHOOTING Self-monitoring system The DFD dryer does not start Error codes Checking the resistance of the regeneration heating elements (in ohms) REPAIRS Replacement of heating elements DFD and Replacement valve gaskets... 46

5 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 5 of GENERAL INFORMATION 2.1 Application The Desiccant Flex Dryer (DFD) is a central desiccant dryer designed for continuous drying of granular plastic materials to a final moisture content of 0.02% or lower, depending on the material involved. The DFD dryer is able to supply dry air with a dew point down to 40ºC or lower to one or more insulated Drying Hoppers (DH hoppers) according to requirement. The DFD dryer has been designed for drying hygroscopic raw materials, non-hygroscopic raw materials and regrinds in the temperature range from 60 to 200ºC with a temperature deviation of ±5ºC or better 2.2 Restrictions None within the field of application. As the DFD dryer operates on ambient, dehumidified air the residual humidity will always depend on the relative air humidity. The DFD dryer may only be used for the purposes specified. The DFD dryer cannot be used for powders or liquids, nor for living creatures. A qualified operator, following the correct procedures must operate the DFD dryer. The DFD dryer may not be used in areas where there is any danger of explosion. 2.3 Design DFD (Desiccant Flex Dryer) The central Desiccant Flex Dryer (DFD) operates in a closed system and is fitted with two desiccant beds (16) and (17) to dehumidify the air before use. One of the desiccant beds will always be operative in the drying cycle while the other bed will be regenerating or in stand-by mode ready for activation into the drying cycle. The DFD dryer operates on the adsorption drying principle, i.e. the water molecules pass a water adsorbent agent (the desiccant) which adsorbs the water molecules and releases them again during regeneration. The desiccant used in the DFD dryer is called a molecular sieve. It has a large surface to which the water molecules can affix. The water is removed from the desiccant by heating (regeneration). The adsorption and regeneration processes take place without chemical transformation of the desiccant, which therefore has a long life. Deterioration of the desiccant is caused solely by soiling of the surface of the desiccant with oil, dust etc. An efficient dust filter which can easily be cleaned and replaced therefore protects the desiccant in the DFD dryer. Additive trap (optional): To prevent additives from soiling the desiccant beds an additive trap can be placed between the drying hopper(s) (25) and the return air filter (12). Desiccant bed assembly (16) (17): Consists of two identical desiccant beds (16) and (17). One of the desiccant beds will always be operative in the drying cycle while the other bed will be regenerating or in stand-by mode ready for activation into the drying cycle.

6 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 6 of 47 Valves for desiccant beds (1) (2) (3) (4): Two parallel-mounted, pneumatically activated valves have been fitted at the inlet and outlet, respectively to the desiccant beds. Valves are changed over automatically monitored by the control. Return air filter (12): Consists of a filter system, which is placed in a specially designed box. The filter separates dust from the return air before it is re-circulated through the desiccant bed system. Return air cooler (10): Reduces the drying air temperature before it is re-circulated through the desiccant bed to ensure optimal adsorption of humidity. Regeneration air cooler (11): Is connected in the final phase of the regeneration cycle to cool the desiccant bed in a closed system maintaining a dew-point temperature below 40ºC. Heating elements for regeneration (18) (19): Consisting of a number of heating elements fitted above the desiccant beds (16)(17) for heating the regeneration air above 300ºC. Regeneration filter (13): Removes dust from the ambient air taken in for regeneration of the desiccant Control (22) The control is located inside the control cabinet. The regeneration cycle is controlled automatically via march of the temperature. This ensures an optimal regeneration of the drying agent at the lowest possible energy consumption. 2.4 Relevant standards, instructions and directives We refer to accordance agreement attached. 2.5 Operating principles Drying The dry air passes the dry air heating element (24) and via an air distributor (26) it is sent into the bottom of the drying hoppers (25) and forced up through the humid plastic material to pick up water molecules from the material. The air, which is now humid, is fed back to the DFD dryer and filtered in the return air filter (12). The dry air pipes and hose must be connected before DFD started, otherwise there is a risk of damaging the drying hopper.the air supply must not be shut off. The humid air temperature is lowered in the return air cooler (10) to improve adsorption of humidity in the molecular sieves. The dry air blower (8) ensures that the airflow is maintained in the drying cycle. Moisture is adsorbed by the air passing through the desiccant beds (16) or (17) before, via the heating element (24), it is fed back to the drying hopper (25) (See R2734).

7 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 7 of 47 D F D D F D D F D D F D R Regeneration Regeneration of the molecular sieve occurs in a separate cycle using heated, ambient air that afterwards is re-circulated in a closed system. By it, the drying air reaches a dew point of 40ºC. The moisture adsorbed in the desiccant bed is evaporated by increasing the inlet air temperature to 300ºC. In the last phase the molecular sieve is cooled down to be ready for new moisture adsorption. This occurs in the following phases: Regeneration phase 1 Ambient air passes through the regeneration filter (13) and is sent on to the heating element (18) or (19) to increase the inlet air temperature to 300ºC. The moisture adsorbed is evaporated and is forced into the ambient air via the outlet pipe (20) of the regeneration air (See R2732). D F D D F D D F D D F D R2732

8 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 8 of 47 Regeneration phase 2 When the outlet air temperature reaches 170ºC the heating element (18) or (19) is disengaged. The air is cooled down in an open system for 10 minutes(see R2732). Then through the air cooler (11) the air is re-circulated in a closed system until a final temperature of 50ºC (is selectable) has been obtained (See R2733). D F D D F D D F D D F D R3733 Regeneration phase 3 Now the regeneration blower stops, and the desiccant bed is now in stand-by position. The cooling down phase still occurs in a closed system to prevent the molecular sieve from adsorbing humidity from the ambient air. Intervals of regeneration To save energy the machine is pre-programmed to regenerate the molecular sieve only when it is necessary.

9 SIEMENS asdasdasdasd asdasdasdasd ON SIMAT EK PANEL OFF Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 9 of 47 DFD600 - DFD1700 DFD300 - DFD450 DFD DFD R1945

10 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 10 of Certificates ISO certificate

11 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 11 of TECHNICAL DATA 3.1 Technical specifications The DFD dryer is supplied in the following voltage variants: Supply voltage: 3x380/400/415/440/460/480, 50/60Hz Technical specifications DFD Supply of compressed air [bar] Installed power [kw] 9, Power consumption, average Heating element regeneration Dew point temperature better than [kw] [kw] 2x3,5 3x3,5 6x3,5 9x3,5 12x3,5 [ C] Air flow, approx [m 3 /h] Net weight [kg] We reserve the right to make changes to the specifications without notice. 3.2 Identification plate The identification number consists of a code (A), a type number (B) and a serial number (C). A) The first digit (A) of the code identify the year in which the machine was manufactured. Example: 16= 2016 B) The digits in the middle (B) of the code identify the machine. The type number consists of two/three digits characterizing the machine type: DFD 300: 125 DFD 450: 124 DFD 600: 01 DFD 1000: 56 DFD 1500: 78 DFD 1700: 104

12 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 12 of 47 (C) The serial number is a four/five-digit number referring to the individual manufacturing number of the machine. T e l: F a x : w w w.la b o te k.c o m Strøbjergvej 29 D K F re d e rik s s u n d D e n m a rk T y p e : D e s i. F le x D ry e r, D F D V o lt: 3 x M o d e l n o : A m p : - S e ria l n o : P re fu s e : 5 0 A m p D a te : k W : 2 1 k W D ia g ra m : H z : 5 0 H z A R2731 B C

13 I I Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 13 of Dimensioned drawings The dimensions of the DFD dryer are shown below. We reserve the right to make changes to the dimension without notice. DFD J K DFD J K R1947 DFD I Height J Width K Depth Measurements in mm.

14 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 14 of Capacity table The size of the desiccant dryer can be determined on the basis of the table below. Desiccant dryers: Capacity table kg/h Raw Materials Recommended Drying time [h] Recommended Drying temp. [ C] DFD 300 [kg/h] DFD 450 [kg/h] DFD 600 [kg/h] DFD 1000 [kg/h] DFD 1500 [kg/h] DFD 1700 [kg/h] ABS PA PA PC 2, PE 1* PE 2** PETG 4, PETP PETP 5*** PI PMMA POM PPO PSU PUR PVC SAN SB * Drying only, not heating ** Depends on the content of (carbon black) The above capacity table states recommended values only, based on the drying of the specific materials down to a final moisture content of 0.02% which, however, will vary depending on type of material (e.g % for high-temperature PETP***). The capacities are based on a general bulk density of 0.7 with the exception of the PE and PET materials, which are based on bulk densities of 0.55 and 0.85 respectively. The original moisture content of the individual material plus contents of hydrophilic material additives can prolong the drying time and hence reduce the specified capacities.

15 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 15 of Safety measures DFD dryer The two heating element pipes on the DFD are fitted with an over temperature protection, which disengages the heating elements in case the temperature exceeds a preset critical value. If the over temperature protection has been activated it is very important to establish what caused the activation, and to correct possible damages before the machine is restarted. In any case the DFD cannot be restarted before the power supply has been disconnected and reclosed using the main switch. After that the DFD is restarted in the usual way via the control panel (see section 4.5) A communication cable between the drying hoppers and the DFD dryer ensures that none of the drying hoppers can be operated if the dry air blower (8) of the DFD dryer is not in service. While in operation the following parts of the machine may cause serious injury: Regeneration air system: Return air pipe: Return air filter: Regeneration blower: Regeneration blower: The outlet pipe (20) for regeneration air may develop extremely high temperatures. A warning of the danger of burns is displayed on the outlet pipe (20). The return air pipe (pos. 27 in fig.r1949) may be hotter than 60ºC. A warning of the danger of burns is displayed on the return air pipe. May be hot. A warning of the danger of burns is displayed on the filter lid. WARNING! READ ALL OPERATING INSTRUCTIONS: Use this motor only in original and/or the nameplate application. Improper installation of motor may result in fire, explosion, electric short or injury. WARNING! Turning off power before connecting or servicing. Ground the floor frame with grounding cord, green ground screw or wire. Insulate any unused lead wires individually. Terminal cover must be in place during operation of the motor. Failure to comply may result in serious injury.

16 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 16 of 47 Regeneration blower: Regeneration blower: Regeneration blower: WARNING! Before connecting the motor to a power source be sure the voltage supplied is the same as that specified on the nameplate of the blower. Using a power source with voltage more or less than the nameplate rating is harmful to the motor. WARNING! MOTOR CONTAINS NO EXPLOSIVE PROTECTION: If the motor is used in hazardous or explosive locations, it will result in serious injury to the user as well as damage to the motor. WARNING! Intake filter is required to prevent material from entering the blower. Regeneration blower: WARNING! Do not touch blower; high surface temperature. Risk of burn. Cooling water system: Handling: Cooling water system: The cooling water system is ensured against overload by means of a pressure control valve which is located just before the return air cooler (10). The pressure control valve has been adjusted to a maximum pressure of 6 bar, and should not be connected to operating a cooling water system operating a pressure higher than approx. 5 bar. By forklift or lifting truck.

17 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 17 of 47 R Noise level DFD db(a) ,3 73,3

18 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 18 of INSTALLATION/OPERATION 4.1 Packaging and transport Before supply, the cooling system of the DFD dryer is scoured to prevent any congelifraction during transit. Therefore small amounts of scour may occur in the cooling system. 4.2 Installation When installing the DFD dryer, the minimum space requirement must be taken into consideration. Please note that the below dimension are minimum, and only for control of the machine. For maintenance (example mounting/placement of desiccant bed) will the minimums dimension be 1000mm instead of 500mm). R1950

19 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 19 of 47 If it is desired to connect the air outlet pipe (20) to a duct system it is recommended to do this by using an extractor. Air outlet pipe must not be directly connected to an extraction pipe system since suction will cause that air is drawn through the DFD. Also there may be a risk of the DFD not being able to get rid of the heat which can cause the heating elements to be overheated. 4.3 External power supply The following external standard power supply is required: DFD : Installation of compressed air 1/4 /ø8 (5-8 bar) 5 litre/bar/regeneration DFD : Installation of compressed air 1/4 BSPF (5-8 bar) 5 litre/bar/regeneration DFD : Cooling water inlet 1/2 BSPM DFD : Cooling water inlet 3/4 BSPM DFD : Cooling water outlet 1/2 BSPM DFD : Cooling water outlet 3/4 BSPM Pressure outlet, cooling water [max. 6 bar] Drain must not be blocked. Connection to outlet pipe/angle, customer supply. Connection of power supply Air outlet pipe, regeneration (20) (see diagram for compressed air fig. R1982) (see diagram for compressed air fig. R1982) (see diagram for cooling water fig. R1983) (see diagram for cooling water fig. R1983) (see diagram for cooling water fig. R1983) (see diagram for cooling water fig. R1983) (see diagram for cooling water fig. R1983) (see electrical diagram) Inlet for cooling air, motor for regeneration blower (OBS! must not be covered) Inlet for cooling air, motor for dry air blower (OBS! must not be covered)

20 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 20 of 47 R1982 R1983

21 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 21 of Consumption of cooling water DFD Dryer Minimum pressure [KPa] 1,3 1,3 3, Minimum pressure [bar] 0,013 0,013 0,030 0,22 0,45 0,45 Water consumption at this drop of pressure [l/h] Average heat emission [kw] The water consumption has been calculated on the following conditions: Return air 120 C Regeneration cycle Water temperature, inlet (max.) 20 C Ambient temperature (max.) 35 C 1min. - 90min. The supply pressure needs to be increased if the above conditions cannot be met. Please contact the supplier for an exact calculation. If the temperature of the cooling water available is lower, i.e. below 20ºC, the water consumption can be reduced. The average heat emission will not change. The water consumption is reduced by means of a cooling water regulator (optional). For supplement of accessories, please contact Labotek or it s representive POWER SUPPLY DFD Connected load [kw] 9, x380V Cable size [mm2] 4x2,5 4x6 4x10 4x16 4x25 4x25 50/60Hz Connecting fuse [Amp] x400V Cable size [mm2] 4x2,5 4x6 4x10 4x16 4x25 4x25 50/60Hz Connecting fuse [Amp] x415V Cable size [mm2] 4x2,5 4x6 4x10 4x16 4x25 4x25 50/60Hz Connecting fuse [Amp] x440V Cable size [mm2] 4x2,5 4x6 4x10 4x16 4x25 4x25 50/60Hz Connecting fuse [Amp] Internal connections The male plug on the communication cable on first DH drying hopper is connected to the corresponding female plug on top of the DFD dryer.

22 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 22 of Operating the system 1: Main switch (1) for connection of voltage and emergency stop. Main switch should not be used for on / off function of the machine as this can cause overheating of heating elements. For daily on / off function, use on / off switch on Lab-Dry control. 2: Lab-Dry control (2) for readout of operating status, alarm messages and input of operating parameters Operating - LAB DRY DFD is controlled via the MP-based control unit s colour touch screen (2). The touch screen shows graphically the machine s operating status. The touch screen is activated by touching the screen lightly. LAB-DRY has a standby function in order to prolong screen life. The screen automatically goes to standby 10 minutes after the last touching of the screen. The screen moves out of standby immediately upon touching the screen. DFD is equipped with automatic calculation of drying time, based on the recorded amount of moisture in desiccant beds. The automation ensures minimal energy consumption.

23 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 23 of 47 Attention! LAB-DRY contains control programs for several machine types. It is therefore important the correct machine type is chosen and its icon shows in the lower right hand corner of the screen. For DFD selects program DFD/P5. Selecting a program / machine type carried out at 3-pol. Dip - switch on the rear of the circuit board. Hereafter the display will be referred as DFD.

24 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 24 of 47 Normal operations 4-5 seconds after the machine is turned on, the screen will show the operating menu Operating menu Optional: Actual process air cooler temperature (Out) ( C) Actual process air temperatur Optional: Dew point Actual regeneration temperatur Optional: Actual return air cooler temperature (In) Lock / Unlock Start / Stop Setup menu Alarm info Lock /Unlock-button. The button must be green before any of the other buttons can be operated. A short push on the button will allow operation of the Start/Stop and Alarm buttons. A longer push (minimum 3 seconds) will allow operation of the SET button (indicated by green icon). Start/stop-button: Starts and stop the entire machine. Attention! When the machine is switched off, conveying and heating elements stop immediately. Motors for drying and regeneration will continue to run for 5 min. for cooling the heating elements and then stop SET-menu: In order to change the operating parameters in the Setup menu, the Open/Close button must be depressed a minimum of 3 seconds. Thereafter the Set button will change colour from red to green. Touching the SET button will bring forth the Setup menu. Alarm info: In case of an operating alarm, this button will become visible. A short touch on the button will display the alarm status.

25 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 25 of Setup menu Temp. Process air, alarm Temp. process air, cool er Temp. Return air, cooler Filter alarm ESC Options menu, (password required) Clock/time Regeneration end temp. Options menu: A password is required before admittance to this menu can be gained. Clock-button: Allows setting of the clock and delayed timer start. The green dots on various areas of the menu are activation buttons that allow a change in the parameter of the specific area/machine. On DFD without options installed, there will be green space for parameter selection. ESC: Brings you back to the operating screen.

26 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 26 of Options menu DFD can have various options. A common setup of these options is that after installation, they must be activated via the options menu. The chosen options and their status will thereafter be shown on the operating screen. The options menu is password protected to avoid unauthorized changes. In the password menu, enter the default Password (2404) and press Enter. Thereafter the screen will show the options and general parameters. ESC Back Enter Numerical values to allow entering of 4 digit password. Back: Erases input value Enter: Push enter after entering 4 digit password ESC: Brings you back to the setup screen. The Options menu is divided into two sections with the same icons as are found on the operating screen. Options that can be chosen are marked with colours: Green: option is turned on. Red: option is turned off.

27 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 27 of 47 Section on the left: Five buttons for options, for the Drying system. Section on the right: Four buttons for options, for the total machine. Drying system Total machine Dew point sensor Process air cooler Return air køler Filter alarm Scale 0 C/0 F Drying system: OFF/ON choice of the process air cooler with regulating of the max. process air temperature Remark: Process air Pt100 sensor shall be installed to use this option. Parameter for the max. process air temperature is entered in set-up menu via parameter setting. OFF/ON choice of the return-air cooler with regulating of the max. return-air temperature. Parameter for the return air temperature is entered in set-up menu via parameter setting. OFF/ON choice of the return-air filter alarm. OFF/ON choice of the dewpoint measurement. The optional dewpoint measurement device is activated here and the dewpoint will be shown continuously on the operating screen. Choice of temperature scale, either Celsius or Fahrenheit. Choice is shown on the button. The default value is Celsius.

28 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 28 of 47 Alarm-log External start Language I/O-Status ESC Total machine, DFD Alarm-log. All alarms will be recorded in this log, including the time. Maximum capacity is 10 alarms. Alarm-log can be deleted, however, active alarm states will return. I/O-Status. Shows the status for all inputs, outputs, temperatures and dewpoint. External start: Starts/stops the machine from an external control. After connection to an external control, the DFD must be turned off on the operating screen before the external control can be used. The External Start button will show Red/Green on the operating screen if this feature is activated. When the external start is used the button on the operating screen will turn green. The normal off/on button will be green and have a black circle and line through it. In this operational situation, the machine can not be started and stopped locally. However, there is possibility of changing the parameters locally. It is, however, possible to turn the external start/stop option off at the machine and thereafter operate the machine from the touch screen. Language: LAB-DRY has 3 languages: English, German and Danish. The preferred operating language is chosen by pressing the corresponding flag. The chosen language will be denoted by a black box around the flag. ESC: Brings you back to the setup screen.

29 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 29 of Standard Set-up Process air temperature alarm: The function allows the monitoring of the process air temperature to DH hoppers. If the selected alarm limit temperature is exceeded the blower of dry air and DH hoppers stop. UP/DOWN: These buttons allow access to select the process air temperature alarm set point. ESC: Brings you back to the setup screen.

30 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 30 of Option Set-up Process air cooler: The option allows to regulate the cooling of the process air to DH hoppers. This required implementation of cooler, PT-100 sensor and solenoid valve to apply the option. UP/DOWN: These buttons allow access to select the regulated max. process air temperature. ON/OFF: This button turns the process air cooler on or off. ESC: Brings you back to the setup screen.

31 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 31 of 47 Return air cooler: The option allows to regulate the max. return air temperature from the DH hoppers. This required implementation of cooler and solenoid valve to apply the option. UP/DOWN: These buttons allow access to select the regulated max. return air temperature. ON/OFF: This button turns the return air cooler on or off. ESC: Brings you back to the setup screen.

32 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 32 of 47 Setup menu Clock/Timer LAB-DRY control system has both a real-time clock and delayed start capabilities. The delayed start function allows the machine to be programmed to start at a predetermined time and day. The delayed start timer always shows current time, date and year before programming is started. Up Current date/time Down ESC Start timer The timer menu has buttons in the upper left there a labelled 1-7 indicating the days of the week. 1 = Monday, 2 = Tuesday and so forth. 7 = Sunday and is always coloured red. Under the buttons is shown the entered start time, date, year. Startup time runs with 10 min. interval. UP/DOWN: Adjusts the desired start time. Example: Actual time: Friday 16:00 hours. The machine has been turned off on the operating panel. Desired start: Monday hours. UP/DOWN is depressed until the time shown is Monday on the weekday line and 05:00 on the time line. Starting the timer: Depress the timer symbol. The symbol will change from red to green. The timer function is now activated. When the timer is activated the symbol will appear on the operating screen (blinking). Date/Time: Used to adjust current time and date. Current time is the time shown on the operating menu. Push the button to adjust if the current time/date is not correct. ESC: Bring you back to the setup menu.

33 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 33 of 47 Adjusting current time via the numeric keypad, calendar and clock buttons. Set time Set date ESC Numeric keys 0 to 9. Back: Erases input value. Enter: After password is input, press enter. Set Time: Proceed with the same steps as calendar setting. When the set time button is push the actual current time will be shown and blink. The time can now be changed. When finished, press enter to save. Set Date: When the set date button is pushed, the current time, date will be shown and blink. The date can now be changed. When finished, press enter to save. ESC: Brings you back to clock/time.

34 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 34 of Operating Menu Alarms LAB-DRY has a number of alarms that warn against incorrect functions. All alarms can light external lamps (if mounted). All alarms will reset themselves when the malfunction is corrected. There are two types of alarms: Critical alarm: Non-critical alarm: Shows a blinking red stop sign on the operating panel A critical alarm will stop the machine or part of the machine depending on the alarm type. Show a blinking alarm triangle on the operating panel. A non-critical alarm warns of potential malfunctions. All alarms will continue to show, despite pressing Reset, if the malfunction is not corrected. All alarms have a failure code and a troubleshooting guide. Up Down ESC Troubleshooting UP/DOWN: Choice of alarm. Choose alarm to be reset. Troubleshooting guide: Push and help text will appear in the window. ESC: Brings you back to the operating screen.

35 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 35 of 47 Operating menu Alarm info - Troubleshooting guide The text shows the most common faults and their remedies. ESC ESC: Brings you back to Alarm info.

36 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 36 of Menu system

37 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 37 of Troubleshooting On every error check/restart it is recommended to check: Connection voltage Fuses (6F1-3) Hose connections Cable connections and the settings for the LAB DRY control Machine gives an error message Alarms The machine continually monitors the system to ensure correct functionality. An alarm will show if the machine is not operating properly, the alarm will be shown with a blinking icon on the operating screen. Below please find list of potential alarms. Alarm-no.: Description: Action: 00 Fire protection out Shuts down the machine 01 Motor drying out Shuts down process air + cooler 02 Motor regeneration out Stop regeneration 03 Comp. air guard out Shuts down the machine 04 Filter guard out Message only 05 Phase relay out Shuts down the machine 10 Air forward temp Shuts down process air + cooler 13 Reg. heat too long Message only 14 Sensor Forward/Cool Shuts down process air + cooler 15 Sensor Return/Cool Message only 16 Sensor regenerating Shuts down drying/regeneration 17 Sensor return air - cooler Shuts down process air + cooler

38 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 38 of Compressed air alarm (29) A pressure monitor is fitted as standard. An alarm is factory preset to activate if the pressure drops below 5 bar. DFD DFD R1967

39 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 39 of Control of cooling water via thermostat phial If the machine is supplied with cooling water control with thermostat phial (optional), the temperature of the air, after having passed through the cooler, is factory preset at 25ºC. This temperature ensures optimal conditions for the cooler and minimum water consumption. Warning! If the controller is adjusted at a temperature higher than 25ºC the DFD drying capacity will be reduced and alarm for excess outlet temperature may be activated. 5.0 ACCESSORIES 5.1 Additive trap Additive trap (complete) The additive trap is used to dry containing additive granular material which evaporates during the drying process. The additive trap is fitted in the return air hose between the drying hopper(s) and the DFD to ensure that additives condense in the trap and not in the DFD. The condensed additive material can be drained out from the trap via two ball tap valves (1). Cooling surfaces and grease separators are washed off. The additive trap is fitted as shown in the drawing below. Cooling water in (5) max.5 bar. Cooling water out" (6). R2048 R2049

40 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 40 of Cooling cartridge (2) Even though most of the collected additive can be drained out from the bottom of the additive trap cleaning of the additive trap is necessary at regular intervals. Wash off the cooling cartridge in a vat with hot/boiling soapy water - do not flush using compressed air. It is recommended to have an extra cooling cartridge and grease separator to allow quick replacement without interrupting the production. R Grease separator (3) (4 pcs.) The grease separator is used to collect the condensed additive. The grease separator may be flushed in soapy water using compressed air Coarse filter (4) The coarse filter is used to filter coarse grains which may originate from the DH hoppers.

41 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 41 of MAINTENANCE 6.1 Maintaining the DFD dryer The basic maintenance principle of the DFD dryer is to prevent plastic granules, additives and dust from entering the blowers, coolers, heating elements and the desiccant in the desiccant beds (16) and (17) in particular as this will adversely affect the performance and life of the machine. 1. The return air filter (12) should be cleaned once a week or as necessary. If large quantities of dust laden material have been processed, e.g. regrinds, we recommend cleaning the filter every day. 2. The regeneration filter (13) should be cleaned or replaced once every half a year. 3 The drying unit may be supplied with a dirt trap at cooling water inlet and a water separator at the compressed air inlet (both optional). These should be cleaned once a fortnight. 6.2 Replacement of return air filter (12)/regeneration filter (13) 1. Use the ON / OFF button to switch ON/OFF the machine. The machine will cool down in 5 min. Disconnect the power supply at the main switch (1) 2. Loosen the finger screws (30). 3. Remove the filter cover (31). Warning! The cover may be heated. 4. Unscrew screw nuts (32) and clean the return air filter (12) or regeneration filter (13) using a vacuum cleaner air or replace it if necessary. DFD DFD R1968

42 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 42 of TROUBLESHOOTING WHEN TROUBLESHOOTING/RESTARTING, WE RECOMMENDED THAT YOU CHECK THE: - power supply level - circuit breaker overload - cartridge fuses (F 1-5) - hose connections - cable connections - and the values set on the control. 7.1 Self-monitoring system The DFD dryer has a pre-programmed self-monitoring program in the control system to locate any malfunctions. The self-monitoring program is activated automatically at every restart. Errors are indicated on the display in explanatory text (see section 7.3). 7.2 The DFD dryer does not start Check the phase sequence relay M 301: 1. Green LED must light up. 2. If both the green and red LEDs light up, a phase error has occurred - either the phase sequence is wrong or one or two phases are missing. 3. If there are no numbers or text on the operator panel display, check fuses F1 to F Error codes The control notifies any alarm state with flashing alarm icon in the operating screen. By pressing the alarm icon an error text will appear. All alarms on Lab-Dry has self reset function, when the alarm condition is gone. Error 10 Air forward temperature (Process air temperature) (dry air blower and cooler stops) Check: 1. Return air temperature If the granular plastic material has been over dried (drying time too long) or dried at too high a temperature, the temperature of the return air may have exceeded 50ºC. Check the return air cooler (10). 2. Resistance in the PT100 sensor should be ohms at a temperature of 20ºC.

43 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 43 of 47 Error 04: Filter guard out (Alarm) (Blocked filter) Check: 1. The state of the filter. 2. The state of the vacuum monitor. Error 13: Regeneration time too long > 60 min (Alarm) Check the following before troubleshooting begins: 1. Has the desiccant dryer been inoperative for some time? If so, the desiccant beds may have absorbed enough moisture to activate the alarm. 2. Is the moisture content of the raw material unusually high? 3. Is the ambient temperature higher than 40ºC? This may result in insufficient cooling. 4. Have one or more DH hoppers been open during pre-drying? This will cause false air to enter the system. Error 13: Troubleshooting in case of recurrent error message 13 After start-up, the regeneration sequence in display should be observed (see 4.6.1): Is the regeneration blower running? No Check contactor and blower Yes Is the actual regeneration temperature rising in Regeneration phase 1 (see )? Yes Switched to Regeneration phase 2 (cool down) (see )within 60 min. from startup? Yes Switched to Regeneration phase 3 (standby) (see ) within 90 min.? Yes No No No Check the regeneration heating element, thermostat, and regeneration sensor. Check the regeneration heating element, filter for regeneration, air outlet, renegeration sensor Check the cartridge filter for regeneration, air outlet, regeneration sensor Error 05: Phase relay out (Stop) (Error in electrical system) Check: 1. Phase sequence relay (green LED must light up). 2. Combi-switches.

44 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 44 of Missing water supply/water flow in return air cooler. 7.4 Checking the resistance of the regeneration heating elements (in ohms) Test resistance in each heating element (two per phase). Heating element for regeneration: 3.5 kw Volt Ohm Approx Approx. 60

45 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 45 of REPAIRS 8.1 Replacement of heating elements DFD and Select display 1.2. (section 4.6) Stop the DFD by pressing STOP and leave the automatic cooling of heating elements to act (5 minutes). Disconnect power at the power switch (1). 2. Remove the back/side -plate. 3. Remove the clip (33) at the desiccant beds (16) and (17). 4. Pull out the entire heating element for regeneration (18) or (19) as far as the wires of the heating element pipe reach. 5. Now dismantle the heating elements and mount and wire new heating elements (34) follow the attached electrical diagram. 6. Assemble the DFD in reverse order. DFD DFD R1969

46 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 46 of Replacement valve gaskets DFD Turn the piston rod (35) a half-turn. 2. Unscrew the 4 screw nuts (36) and remove these along with the 4 nut washers (37). 3. Now remove end cover (38) and replace the O-ring (39). 4. Remove the cylinder pipe (40) and replace the O-ring (41). 5. Unscrew the 4 studs (42). 6. Unscrew the piston (43) with piston rod (50). 7. Remove the 3 gaskets at the piston (43). 8. Fit O-ring (44) on the piston. Place slide ring (45) above the O-ring. 9. Fit the control (46) at the second groove of the piston. 10. Remove cover (47) by loosening the screws (48) and fit new cover. 11. Assemble the cylinder in reverse order. R2656 Note! Position the valve plate (49) just above the holes in the two positions.

47 Rev. N00 DFD Desiccant Flex Dryer, Lab-Dry Page 47 of DFD Turn the piston rod (35) a half-turn. 2. Unscrew the 4 screw nuts (36) and remove these along with the 4 nut washers (37). 3. Now remove end cover (38) and replace the O-ring (39). 4. Remove the cylinder pipe (40) and replace the O-ring (41). 5. Unscrew the 4 studs (42). 6. Unscrew the piston (43) with piston rod (50). 7. Remove the 3 gaskets at the piston (43). 8. Fit O-ring (44) on the piston. Place slide ring (45) above the O-ring. 9. Fit the control (46) at the second groove of the piston. 10. Remove cover (47) by loosening the screws (48) and fit new cover. 11. Assemble the cylinder in reverse order. R1984 Note! Position the valve plate (49) just above the holes in the two positions.