Aec AP Series Large Dehumidifying Dryer User Manual

Large AP1+ Control Dehumidifying Dryer Part Number: 882.00202.00 Bulletin Number: XX1-670 Effective: 09/01/05 Write Dow

Large Dehumidifying Dryers Safety 9 ; Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment.

Large Dehumidifying Dryers Appendix 99 7-5 Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [630] 595-106

Large Dehumidifying Dryers Safety 10 employer probably has established a set of safety rules in your workplace. Those rules, this manual, or any oth

Large Dehumidifying Dryers Safety 11 When you need to perform maintenance or repair work on a dehumidifying dryer above floor level, use a solid pl

Large Dehumidifying Dryers Functional Description 12 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides ope

Large Dehumidifying Dryers Functional Description 13 moisture is stripped from the air by a desiccant bed. The dried process air is then re-heated

Large Dehumidifying Dryers Functional Description 14 Once the main air valve and closed loop regeneration valve are in place, the process air blower

Large Dehumidifying Dryers Functional Description 15 Sequence shutdown switch ; NFPA86, UL, AGA & CGA machinery electrical standards (Gas Drye

Large Dehumidifying Dryers Functional Description 16 2-5 Drawings and Diagrams Regen.FilterRegeneration BlowerProcess BlowerOptional After-cooler

Large Dehumidifying Dryers Functional Description 17 PSDifferential Pressure SwitchFilter Check GageEFDust Level IndicatorSlide GateClampDust PanFi

Large Dehumidifying Dryers Functional Description 18 Process Aftercooler The optional aftercooler cools the moist air returning to the dryer from t

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Large Dehumidifying Dryers Functional Description 19 Figure 4: Process Air Dust Collector PSDifferential Pressure SwitchFilter Check GageEFDust Lev

Large Dehumidifying Dryers Functional Description 20 Material Overdrying Protection Material Overdrying Protection is an automatic system used to re

Large Dehumidifying Dryers Functional Description 21 Mechanical Options ; Low temperature operation (120°F to 250°F) ; High temperature operation

Large Dehumidifying Dryers Functional Description 22 2-6 Safety Devices and Interlocks This section includes information on safety devices and pr

Large Dehumidifying Dryers Functional Description 23 In addition to the safety devices listed above, these dehumidifying dryers are equipped with a

Large Dehumidifying Dryers Functional Description 24 Dimensions and Specifications 9 Denotes availability CFM 600 850 1000 1250 1500 2000 2500

Large Dehumidifying Dryers Functional Description 25 Electrical Features CFM Dryer AMP Draw 600 850 1000 1250 1500 2000 2500 3000Standard voltage L

Large Dehumidifying Dryers Mechanical Installation 26 Chapter 3: Mechanical Installation 3-1 Uncrating the Equipment The large dehumidifying drye

Large Dehumidifying Dryers Mechanical Installation 27 ; Make sure all electrical connections are tight. 3-4 Making Gas Line Connections (Gas-Fir

Large Dehumidifying Dryers Mechanical Installation 28 3-5 Checking for Proper Blower Rotation After the electrical connections have been made, che

Large Dehumidifying Dryers ii Shipping Info Unpacking and Inspection You should inspect the large dehumidifying dryer for possible shipping damage.

Large Dehumidifying Dryers Mechanical Installation 29 3-6 Making Dryer/Drying Hopper Process Air Connections When making process air connections

Large Dehumidifying Dryers Mechanical Installation 30 Process Air Heater on Drying Hopper Return air thermocouple location

Large Dehumidifying Dryers Mechanical Installation 31 Drying System with Dust Collector and Process Air Heater on Dryer Return air thermocouple loc

Large Dehumidifying Dryers Mechanical Installation 32 After cooler ModelWater Flow ( GPM )AD600 10AD850 10AD1000 15AD1250 15AD1500 20AD2000 25AD2500

Large Dehumidifying Dryers Mechanical Installation 33 3-8 Using the Drying Hopper Air Trap Our exclusive air trap assembly in the top of the dryi

Large Dehumidifying Dryers Controls 34 Chapter 4: Controls 4-1 Controller Description The AP1+ dryer control system is designed to control ACS c

Large Dehumidifying Dryers Controls 35 4-2 Operating the Dryer To operate the dryer, access the Overview display and press the “Push to Start Dr

Large Dehumidifying Dryers Controls 36 • The drying hoppers process supply air heaters shut down and then the Process air blower(s) shutdown after

Large Dehumidifying Dryers Controls 37 4-3 AP1+ Data Entry Values and text are changed using one of 4 different keypads. • Numbers use the TE

Large Dehumidifying Dryers Controls 38 The appropriate keypad appears when a changeable value is pressed. You are only allowed to change a num

Large Dehumidifying Dryers iii Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping depar

Large Dehumidifying Dryers Controls 39 4-4 Dryer Setup The customer can fine-tune the AP1+ by changing values and turning options on or off. Us

Large Dehumidifying Dryers Controls 40 4-5 Drying Hopper Setup Use the drying hopper setup display to change the following drying hopper specifi

Large Dehumidifying Dryers Controls 41 o In addition to temperature setback, close the optional air damper valve. Air Balance o Requires the opti

Large Dehumidifying Dryers Controls 42 4-6 AP1+ Data Monitoring and Navigation Overview Displays There may be up to 4 overview displays depending

Large Dehumidifying Dryers Controls 43 Drying Hopper Status Displays The drying hopper status displays show detailed information on the operationa

Large Dehumidifying Dryers Controls 44 Drying Hopper Setup Displays The drying hopper setup displays allow the user to change a limited number of

Large Dehumidifying Dryers Controls 45 Material Miser and Air Balance Setup Displays The Material Miser and Air Balance setup display is used to a

Large Dehumidifying Dryers Controls 46 Material Miser – Convey Activated – Set Back Only Material Miser – Convey Activated – Air Damper Only Mat

Large Dehumidifying Dryers Controls 47 Air Balance Enabled Both Material Miser and Air Balance use the return air temperature and cannot both be

Large Dehumidifying Dryers Controls 48 • Press “Open Damper Deviation” to change difference between the return air temperature and return air tempe

Large Dehumidifying Dryers iv Table of Contents CHAPTER 1: SAFETY... 7 1-1 How to Us

Large Dehumidifying Dryers Controls 49 Alarm History Display 1. Use the alarm history display to trouble shoot dryer problems. 2. The alarm h

Large Dehumidifying Dryers Controls 50 Dryer Menu Display 1. Use the dryer menu display to access other displays associat

Large Dehumidifying Dryers Controls 51 The trend colors match the colored line underneath the values description in the main part of the display. T

Large Dehumidifying Dryers Controls 52 LEFT BED REGEN-HEAT H:M– Regeneration in progress, heating active LEFT BED COOLING H:M– Regeneration in

Large Dehumidifying Dryers Controls 53 Dryer Setup Display 1. Press “Temperature FAHRENHEIT” to change the temperature units to Celsius. 2. Pr

Large Dehumidifying Dryers Controls 54 Blow Back Filter Setup Display 1. Press “Process Blowback Filter” to change the enable status of the blowb

Large Dehumidifying Dryers Controls 55 4. Press “Dryer Menu” to return to the dryer menu display. 5. Press “Help” to access the help menu display

Large Dehumidifying Dryers Controls 56 3. Press the “Clear All Days” button to reset all the start and stop times to 00:00 and turn off the auto-st

Large Dehumidifying Dryers Controls 57 4. Press “I/O” status to access the system inputs and outputs status display. 5. Press “DeviceNet” status

Large Dehumidifying Dryers Controls 58 Set Clock 1. Press the time value to change the system time. 2. Press the date value to change the system

Large Dehumidifying Dryers v 3-7 Connecting Aftercooler/Precooler Cooling Water (Optional)... 32 3-8 Using the

Large Dehumidifying Dryers Controls 59 I/O Status • Use the I/O status displays to see what inputs and outputs are active. • A point that

Large Dehumidifying Dryers Controls 60  1 1st Drying Hopper Bank (1 – 8)  2 2nd Drying Hopper Bank (9 - 16)  3 3rd Drying Hopper Bank (17 – 2

Large Dehumidifying Dryers Controls 61 Important, never remove or insert the memory card while the PLC’s busy light is on. Damage to the card and

Large Dehumidifying Dryers Controls 62 4-7 Program Upgrade Procedures The AP1+ PLC and touch screen both use compact flash memory cards for data

Large Dehumidifying Dryers Controls 63 Touch Screen Program Upgrade • Remove and return the exiting memory card to ACS service. • Insert the upg

Large Dehumidifying Dryers Controls 64 4-8 Security The AP1+ dryer control system implements a three tier security model. The first tier is UNS

Large Dehumidifying Dryers Controls 65 A security tier is activated by entry of the proper password. Once activated, that tier will remain active

Large Dehumidifying Dryers Controls 66 Alarm List The following table lists all of the alarms the AP1+ can detect. Alarm Text System Severity P

Large Dehumidifying Dryers Controls 67 MODULE 5 FAIL Regen Critical REGEN BLWR CLS FAIL Regen Critical REGEN BLWR AIR FAIL Regen Critical REGEN

Large Dehumidifying Dryers Controls 68 RIGHT 2 OUT SENSOR Regen Critical RIGHT 2 HI TEMP Regen Non-Critical RIGHT 2 LO TEMP Regen Critical RIGHT

Large Dehumidifying Dryers vi Annex B Information...95 7-3

Large Dehumidifying Dryers Controls 69 DH 7 PH ISO CLS FAIL Process Non-Critical DH 8 PH ISO CLS FAIL Process Non-Critical DH 9 PH ISO CLS FAIL

Large Dehumidifying Dryers Controls 70 DH 5 PH BURN ON Process Critical DH 6 PH BURN ON Process Critical DH 7 PH BURN ON Process Critical DH 8 P

Large Dehumidifying Dryers Controls 71 DH23 PH BURN OUT Process Non-Critical DH24 PH BURN OUT Process Critical E-STOP Process Critical DH 1 AIR

Large Dehumidifying Dryers Controls 72 DH 4 LOOP BREAK Process Non-Critical DH 4 AIR DAMPER FAIL Process Non-Critical DH 4 LOW LEVEL Process Crit

Large Dehumidifying Dryers Controls 73 DH 8 LOOP BREAK Process Non-Critical DH 8 AIR DAMPER FAIL Process Non-Critical DH 8 LOW LEVEL Process Cri

Large Dehumidifying Dryers Controls 74 DH12 LOOP BREAK Process Non-Critical DH12 AIR DAMPER FAIL Process Non-Critical DH12 LOW LEVEL Process Crit

Large Dehumidifying Dryers Controls 75 DH16 LOOP BREAK Process Non-Critical DH16 AIR DAMPER FAIL Process Non-Critical DH16 LOW LEVEL Process Cri

Large Dehumidifying Dryers Controls 76 DH20 LOOP BREAK Process Non-Critical DH20 AIR DAMPER FAIL Process Non-Critical DH20 LOW LEVEL Process Crit

Large Dehumidifying Dryers Controls 77 DH24 LOOP BREAK Process Non-Critical DH24 AIR DAMPER FAIL Process Non-Critical COMM FAULT 1ST BANK Dryer

Large Dehumidifying Dryers Controls 78 Alarm Text Abbreviations The 5.4” touch screen limits the amount of characters that are visible on the alarm

Large Dehumidifying Dryers Safety 7 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operat

Large Dehumidifying Dryers Controls 79 Common Text Descriptions CLS FAIL (Device Failure to Close) Generated when a valve or contactor is command

Large Dehumidifying Dryers Controls 80 4-10 Troubleshooting PLC Faults If a fatal error occurs on the PLC the touch screen will display a speci

Large Dehumidifying Dryers Controls 81 PLC Module Faults DeviceNet7 The first module to the right of the PLC CPU is the DeviceNet master module.

Large Dehumidifying Dryers Controls 82 DeviceNet I/O Faults10 The drying hoppers DeviceNet inputs and outputs reside in the drying hopper control b

Large Dehumidifying Dryers Maintenance 83 Chapter 5: Maintenance 5-1 Maintenance Schedule The checklist below contains a list of items that shou

Large Dehumidifying Dryers Maintenance 84 5-2 Preventative Maintenance Cleaning or Replacing the Process Air Filters Regular filter cleaning will

Large Dehumidifying Dryers Maintenance 85 Use the following procedure to clean or replace the filter cartridges: 1. Turn off and/or lock out elect

Large Dehumidifying Dryers Maintenance 86 5. Remove the restricted filter cartridge from the housing again. The alarm light should stay off when t

Large Dehumidifying Dryers Maintenance 87 5-3 Corrective Maintenance Symptoms of Worn Out Desiccant The moisture adsorption capacity of the desic

Large Dehumidifying Dryers Maintenance 88 6. Inspect the gaskets on each of the covers. Replace if necessary. 7. Re-install the covers. Figur

Large Dehumidifying Dryers Safety 8 Dryer Safety Tags Tag Description Tag Description Read Operation & Installation Manual High Voltage Insi

Large Dehumidifying Dryers Maintenance 89 High Temperature GasketDouble Wall Stainless Steel Heater HousingHeater ElementsHeater Element Mounting P

Large Dehumidifying Dryers Maintenance 90 1. Access the desiccant canisters by removing the panels on the dryer. 2. Remove the Regeneration Heate

Large Dehumidifying Dryers Troubleshooting 91 Chapter 6: Troubleshooting 6-1 Introduction The utmost in safety precautions should be observed at

Large Dehumidifying Dryers Troubleshooting 92 Problem Possible Cause Corrective Action Process heaters are faulty. Replace. Desiccant beds are

Large Dehumidifying Dryers Troubleshooting 93 6-3 Determining Temperature Controller Errors or Sensor Errors Using a Thermocouple If the control

Large Dehumidifying Dryers Appendix 94 Chapter 7: Appendix 7-1 Warranty The manufacturer warrants all equipment manufactured by it to be free fr

Large Dehumidifying Dryers Appendix 95 7-2 Technical Specifications Annex B Information The following design information is provided for your re

Large Dehumidifying Dryers Appendix 96 7-3 Spare Parts List 600CFM600CFM600CFM600CFM600CFM850CFM850CFM850CFM850CFM850CFM1000CFM1000CFM1000CFM1000

Large Dehumidifying Dryers Appendix 97 7-4 LEVEL 3 ( Electrical Components )600CFM600CFM600CFM600CFM600CFM850CFM850CFM850CFM850CFM850CFM1000CFM10

Large Dehumidifying Dryers Appendix 98 8-4 Dryer Identification (Serial Number) Tag (Located on back of Dryer) XXX Series Dr