PPE FX-D4 Series User manual

FX-D4 SERIES DESICCANT DEHUMIDIFIER

Installation, Operation, and Maintenance Manual

Plastic Process Equipment, Inc.

8303 Corporate Park Drive

Macedonia, OH 44056

Phone: (216) 367-7000

Fax: (216) 367-7022

E-Mail: pp[email protected]

For further information visit us on the web at http://www.ppe.com

Table of Contents

1 INTRODUCTION

1-1 FX SERIES DESICCANT DEHUMIDIFIER INTROCUCTION ......................................................4

1-2 PRINCIPLES OF OPERATION ...............................................................................................4

1-3 FX-D4 SERIES DESICCANT DEHUMIDIFIER SPECIFICATION .................................................5

1-4 FRONT PANEL CONTROLS ..................................................................................................6

2 INSTALLATION

2-1 INSPECTION UPON RECEIPT...............................................................................................8

2-2 PLACING THE EQUIPMENT.................................................................................................8

2-3 ELECTRICAL CONNECTIONS ...............................................................................................8

2-4 DUCK WORK CONNECTIONS..............................................................................................9

2-5 WATER CONNECTINS.........................................................................................................9

3 OPERATION

3-1 INITIAL STARTUP..............................................................................................................11

3-2 VERIFYING FAN ROTATION ..............................................................................................11

3-3 SET THE PROCESS OULET TEMPERATURE ........................................................................13

3-4 REGENERATION TEMPERATURE ......................................................................................13

3-5 DESICCANT ROTOR ROTATION ........................................................................................13

3-6 THERMAL PROBE.............................................................................................................14

3-7 HMI+PCB SETUP AND OPERATION...................................................................................14

4 MAINTENANCE

4-1 DESICCANT ROTOR ..........................................................................................................20

4-2 DESICCANT ROTOR SEALS................................................................................................21

4-3 DESICCANT ROTOR SHELL................................................................................................22

4-4 DESICCANT ROTOR DRIVE MOTOR ..................................................................................23

4-5 FILTERS ............................................................................................................................23

4-6 MAINTENANCE RECORD FORM .......................................................................................24

5 TROUBLESHOOTING

5-1 TROUBLESHOOTING INDEX .............................................................................................26

6 TECHNICAL INFORMATION

6-1 WIRING, MODEL: FX-50/100/180 (230V/3￠/60HZ)........................................................28

6-2 WIRING, MODEL: FX-100/180/300/400 (460V/3￠/60HZ) ..............................................32

6-3 EXPLOSION VIEW (FX SERIES) ..........................................................................................37

INTRODUCTION

1-1 FX SERIES DESICCANT DEHUMIDIFIER INTROCUCTION

Congratulations on your purchase of the PPE FX Series Desiccant Dehumidifier from Plastic Process

Equipment, Inc. The FX Series Desiccant Dehumidifier offers the finest in resin drying technology,

however, this machine can only provide maximum service if properly installed, operated, and maintained.

This manual is provided to familiarize you with the dehumidifier Instructions are provided to install,

operate and maintain your dehumidifier. Ultimate satisfaction depends on the quality of installation and a

thorough understanding of the equipment. The FX Series Desiccant Dehumidifier is built around tested

engineering principles and has passed a thorough inspection for quality of workmanship and function.

There are many models in the FX Series Desiccant Dehumidifier line, some differences may exist between

the pictures in this manual and your specific dehumidifier.

1-2 PRINCIPLES OF OPERATION

The function of the FX Series Desiccant Dehumidify is to continuously remove vapor state moisture from

an air stream. This is accomplished by using a rotating desiccant media and three separate air streams.

Figure 1-1 illustrates the three air streams.

The first air stream passes the moisture laden air from the drying hopper through the desiccant media. After

processed air has been exposed to the desiccant media, the air is returned to the drying hopper. As the

desiccant media adsorbs moisture from the process stream, it is rotated out of the process stream into the

reactivation stream. This second air stream is heated to drive moisture out of the desiccant media, and

prepare it for more adsorption. The desiccant media then rotates out of the reactivation air stream into the

purge air stream. The purge stream consists of a small portion of the process outlet air that cools the

desiccant media. Once cooled, the desiccant media rotates back into the process stream to begin adsorption

again. This cycle is done on a continuous basis, providing a constant drying process. The FX Series

Desiccant Dehumidifiers are designed with the process and reactivation air streams flowing in opposite

directions. This counter flow design maximizes the energy efficiency of the equipment.

Figure 1-1. Air streams

1-3 FX-D4 SERIES DESICCANT DEHUMIDIFIER SPECIFICATION

MODEL NO. FX-050 FX-100 FX-180 FX-300 FX-400

Air Flow CMH 50 100 180 300 400

Dewpoint °C -40° -40° -40° -40° -40°

Drying Blower KW 0.4 0.75 2.2 3.4 5.5

Drying Heater KW 4 6 12 15 18

Regen. Blower KW 0.18 0.18 0.4 0.75 0.75

Regen. Heater KW 2.5 4 5 8.5 8.5

Processing Heater Honeycomb Rotor

Process inlet inch 2 2.5 2.5 3 3

Process Outlet inch 2 2.5 2.5 3 3

Cooling Water Flow Ltr/min 5 15 30 40 50

Water Connect inch 3/4 1 1 1 1

Power Supply 3Ø，220~460VAC，50/60Hz

Total Power KW 7.08 10.93 19.6 27.65 30

DIMENSIONS

L mm 770 910 910 1045 1045

W mm 680 880 880 930 930

H mm 1280 1630 1630 1930 1930

1-4 FRONT PANEL CONTROLS

The front panel of the FX Series Dehumidifier contains all controls and indicators necessary for

dehumidifier operation. For a description of the controls and indications, refer to Figure 1-2 and the

following list:

1. Power On indicator – This black switch turned to “on” when power has been supplied to the

dehumidifier. This does not indicate that the unit is turned on. This only indicates that power is

available to the dehumidifier.

2. System On indicator – This panel screen light illuminates when the Power switch is in the ON

position. This indicates that the unit is turned on.

3. Faults indicator – This panel screen showed red light illuminates on “STATUS” when the bed

failure alarm occurs, or a failure of motor protection circuit breaker. A bed failure alarm will occur if

the desiccant rotor does not rotate at least once every ten minutes.

4. Audible Alarm – The audible alarm will sound to indicate a fault on “STATUS”.

5. Dew point Display – This indicator displays the current process outlet dew point.

NOTE

Dew point Set point is for reference only; dew pointer is strictly display, not control.

6. Process Temperature (Dry temp) – This indicator/controller displays the temperature selected by

the Temperature Indication selector, and controls the process outlet temperature. The PV of the

display shows the currently selected process variable. The SV of the display shows the process outlet

temperature set point. For flexible tubing and water flow requirements see chart below:

7. Regeneration Temperature (Desiccant temp)– This selector controls the temperature displayed on

the Temperature Controller. The PV of the display shows the currently selected process

variable. The SV of the display shows the process outlet temperature set point. (Default value

180 °C /356 °F)

8. Power switch – This switch controls power to the dehumidifier.

Figure 1-2. Front Panel Controls and Indicators

INSTALLATION

2-1 INSPECTION UPON RECEIPT

Thoroughly inspect the dehumidifier to ensure no damage has occurred during shipping. Inspect both the

inside and outside of the dehumidifier. If any damage is found, a claim should be filed with the shipping

company immediately. Please notify Plastic Process Equipment immediately so we may provide whatever

assistance we can.

Check dehumidifier external surfaces for damage.

Ensure the desiccant rotor is tightly secured in place.

Ensure the drive chain is in good contact with the desiccant rotor, tensioner arm, and drive

pulley.

Ensure the top and bottom desiccant rotor seals are in good contact with the desiccant rotor.

Check all electrical connections to ensure they are tight.

2-2 PLACING THE EQUIPMENT

The dehumidifier should be carefully located and set in place on a level surface. If mounting the

dehumidifier on a machine or stand, the dehumidifier must be adequately supported. At a minimum,

support is required below the caster mounting plates. Dehumidifier maintenance and service will require

access to all sides of the dehumidifier. If the unit is machine or stand mounted, leave enough room on all

sides to open all dehumidifier access doors.

2-3 ELECTRICAL CONNECTIONS

Ensure the supply power requirements are in accordance with the dehumidifier

nameplate data. Serious damage to the dehumidifier motor and control systems

can occur if incorrect power is supplied to the dehumidifier.

Install electrical connections in accordance with all applicable federal, state, and local regulations. Good

electrical practices should be followed to achieve the best installation possible. Refer to the electrical

schematic provided with this manual before installing any electrical connections. If a disconnect switch is

not furnished with your dehumidifier, one should be installed adjacent to the dehumidifier for safety and

ease of servicing. Electrical wiring to the equipment must be adequately sized for the minimum amperage

shown on the unit nameplate.

2-4 DUCK WORK CONNECTIONS

NOTE

All supply and return air ductwork and hose connections for the dehumidifier must

be air and vapor tight. Failure to achieve air and vapor tight connections may

impact dehumidifier performance.

The most common type of ductwork used with resin drying equipment is flexible hose that is both

temperature and moisture resistant. Moisture resistance is extremely important for proper dehumidifier

performance. Even though the dehumidifier is removing moisture from the hopper return air, the air will

not be dry when it reaches the process if moisture enters the dry supply air stream through leaks in the

ductwork. Air ducts must be properly sized to keep pressure losses at a minimum. Pressure loss must not

exceed the designed static capacity. Connect the process inlet and process outlet hoses to the appropriate

connections on the back of the dehumidifier cabinet. Refer to Figure 2-1 for hose connection

locations.

Figure 2-1. Hose Connections

2-5 WATER CONNECTINS

Water should be supplied to the unit to achieve the rated performance. Connections ports for the inlet

air-cooling coil are located on the rear of the dehumidifier assembly. When facing the rear of the

dehumidifier the connections are located in the lower left hand corner of the rear panel. The connections

are male NPT. Water Temperature should be between 40 & 80° F. For flow requirements refer to the

table on the following page.

Model

Male NPT connection

Iced water capacity

Iced water flow LPM/GPM

FX-50

1/2"

1500Kcal/H/10℃/50°F

10/2.6

FX-100

1”

3000Kcal/H/10℃/50°F

20/5.2

FX-180

1”

6000Kcal/H/10℃/50°F

30/7.8

FX-300

1”

9000Kcal/H/10℃/50°F

50/13

FX-400

1”

14000Kcal/H/10℃/50°F

60/16

FX-700

1”

27000Kcal/H/10℃/50°F

100/26

FX-1000

1”

42000Kcal/H/10℃/50°F

140/37

Water connections, rear of unit Water lines inside of unit

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