Colortronic CTT 1200 Operating Instructions Manual Download Page 9

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When disposing of drying agents / batteries / oil, observe all official rules.

Caution: High noise pollution!
For all work on the equipment, hearing protection should be worn.
Avoids impairment of hearing!

Caution: Danger of crushing!
Disconnect

the

equipment

from

mains

supply

before

starting

mainenance procedures. All compressed air pipes on the equipment
should be depressurised before starting maintenance work.

Caution: Danger of hot surface!
Before starting any work wait until all parts have been cooled down suffi-
ciently. Avoid touching any of these parts!

Caution: Danger of skidding!
Remove any granules remaining on the ground.

Caution: Danger to life through electrical shock!
Observe that the control system is still under voltage even when the main
switch is switched off.

64.10-8248GB02

05/03

Dehumidified Air Dryer

General Information 1-3

Summary of Contents for CTT 1200

Page 1: ...Operating Instructions Dehumidified Air Dryer CTT 1200 with Siemens S7 control unit 64 10 8279GB02 05 03 Colortronic GmbH...

Page 2: ...GB02 05 03 CTT 1200 2 Colortronic GmbH Otto Hahn Stra e 10 14 D 61381 Friedrichsdorf Telephone 0 61 75 7 92 0 Telefax 0 61 75 7 92 1 79 Email info colortronic de Http www colortronic com USA Colortron...

Page 3: ...out notice We assume no liability for any errors or direct or indirect damage resulting in con text with these operating instructions Copying translation or publication in any form except for personal...

Page 4: ...4 3 2 1 Operation statuses 3 4 3 3 Viewing the software version 3 5 3 4 Passwords 3 5 3 5 Basic parameters 3 7 3 5 1 Turning the devices on off 3 7 3 5 2 Entering dryer values 3 9 3 5 3 Entering hoppe...

Page 5: ...6 3 6 3 Return air cooler optional 6 4 6 4 Pre air cooler optional 6 4 6 5 Hopper heaters optional 6 5 6 6 Automatic motor flaps optional 6 5 6 7 Connection to a pneumatic conveying system optional 6...

Page 6: ...ed at a later date 12 Accessories Version 64 10 0134GB01 10 97 12 1 o Entering values on the OP 7 17 o Flap control with Fuzzy Logic o Elektror High pressure blower with frequency converter operation...

Page 7: ...48GB02 05 03 These operating instructions are addressed to all users of the device These operating instructions must be used by every person charged with work on the unit 64 10 8248GB02 05 03 Dehumidi...

Page 8: ...ury is possible if the corresponding instructions regulations or warnings are not observed F This symbol indicates that extensive damage to equipment is possible if the corresponding instructions regu...

Page 9: ...d air pipes on the equipment should be depressurised before starting maintenance work Caution Danger of hot surface Before starting any work wait until all parts have been cooled down suffi ciently Av...

Page 10: ...s must be compiled by the operator of the equipment Equipment foreman When several operating personnel work on one machine the equipment foreman coordinates the sequences The equipment foreman must be...

Page 11: ...the direct and indirect hazards connected with the equipment These operating instructions are to be used by all persons assigned activities connected with the equipment Knowledge of the English langua...

Page 12: ...he equipment is to be carried out by persons whose qualifications are specified in the pertaining chapters of the operating instructions Improper operation results in danger of acci dents The proper w...

Page 13: ...ded detailed instruction in the operation of the equipment Improper operation results in danger of accidents When the main switch is switched off for reasons pertaining to safety it must be secured ag...

Page 14: ...ould only be cleaned replaced when the the main switch is off and the blower has stopped This avoids injury and damage to equipment Any maintenance work on the equipment should only be started when th...

Page 15: ...e drying instructions of the material manufacturer Take care that the drying hoppers are always completely filled and that the retention period is re spected if continual removal is taking place Note...

Page 16: ...operators have the rele vant skills F Note down all set values of the control system Make sure that the cooling appliance is connected to the mains socket in the electrical cabinet if present optional...

Page 17: ...enu If you want to work on several submenu items in succession you can select the individual items directly by means of the arrow keys 3 1 1 Key assignment F1 key Leads to the table of contents ENTER...

Page 18: ...ower 5 Return air filter 6 Drying hopper 7 Drying heater 8 Regeneration heater 9 Regeneration blower 10 Regeneration air filter Indicator lamp messages Green continous light in process Red continous l...

Page 19: ...nd the operation status of the unit are displayed F Unblock the control system Keep the ACK key pressed until the LEDs of the keys K1 K4 light up 3 2 1 Operation statuses The following operation statu...

Page 20: ...he control system Important data can then be entered or modified only after the password has been entered If you make no entries for more than 10 minutes the access is blocked and you have to re enter...

Page 21: ...ady been entered Press the ESC key Logout Press the key F3 Only data for which no password is necessary password level 0 can now be entered into the control system or modified Press the key Edit Press...

Page 22: ...r operation at OP7 see chapter timer external operation with timer if present off operation without timer Acknowledge with the ENTER key The timer is only operating when the dryer is switched on Press...

Page 23: ...want to enable the dry ing hopper Enter OFF if you want to disable the drying hopper Press the ENTER key Hopper heater on off Press the SHIFT key Using the arrow keys enter ON if you want to switch o...

Page 24: ...will be displayed Press the key If the unit is operates with dew point controlled changeover point with dew point display optional Dew point max Enter the maximum permissible worst allowed dew point...

Page 25: ...th the ENTER key Return Pre air cooler Act The current air temperature will be displayed The cooling effect of the pre air cooler is highly dependent on the cooler circuit The lower the value chosen f...

Page 26: ...ture for the drying hopper when operating with supplementary heating Acknowledge with the ENTER key Hopper entry Act The current temperature at the feed opening of hopper flap will be displayed If the...

Page 27: ...the ENTER key This value is entered in percent of the temperature on the hopper inlet The material temperature calculated by the control system for closing the flap on the drying hopper is displayed i...

Page 28: ...ted Press the SHIFT key and the F3 key Enter the password if requested Hopper Enter the drying hopper number Acknowledge with the ENTER key Name TT Enter the drying hopper name Acknowledge with the EN...

Page 29: ...ling time of the material within the drying hopper in minutes Acknowledge with the ENTER key F Observe the indicated dwelling time When the drying hopper is released the dwelling time starts The resid...

Page 30: ...moved in moved out error moved in The upper drying cells are within the drying circuit the lower ones are regenerated moved out The upper drying cells are regenerated the lower ones are within the dry...

Page 31: ...ested Date Press the SHIFT key By means of the arrow keys select the desired week day By means of the arrow keys select the shown date Press the SHIFT key Enter the desired date Press the ENTER key Ti...

Page 32: ...HIFT key By means of the arrow keys select the adjustment which suits you best Press the ENTER key Depending on the outside temperature the brightness of the screen may vary Language Press the SHIFT k...

Page 33: ...and the K1 key Run on time drying blower 300 sec Standard setting 300 seconds changes only after contacting Colortronic Service Press the key Parameters F The values in this menu may only be changed...

Page 34: ...he switching off time Acknowledge with the ENTER key Example Timer ON OFF fr 08 00 23 59 sa 00 00 23 59 su 20 00 08 00 mo 00 00 00 00 The dryer starts on Friday at 08 00 in the morning runs through wi...

Page 35: ...s After first filling do not process the material until after the dwelling time If a return air cooler optional is installed switch on the coolant circuit If a pre air cooler optional is installed swi...

Page 36: ...ct System runtime Acknowledge with the ENTER key or Press the SHIFT key and the F2 key System runtime PLC h r blwr h m blwr h The runtime of the blowers and the PLC SPS is shown in hours 64 10 8279GB0...

Page 37: ...ct Dryer off Acknowledge with the ENTER key L Wait until the regeneration phase is finished and the blower has come to a standstill Switch off the dryer at the main switch Disconnect the power supply...

Page 38: ...er assumes general skills in dealing with drying systems and SPS PLC control units This chapter assumes that the start up description has been read and un derstood It should be ensured in each and eve...

Page 39: ...yet eli minated the flashing changes to steady light If a cooling appliance is present If the temperature inside the switch box is higher than 50 C the lamp alarm temperature inside switch box goes on...

Page 40: ...going the resent for the failure has gone Q reset the display of the alarm message in the operator device has been erased by pressing the ACK key Press the ESC key Print Optional This function is pas...

Page 41: ...The number of current alarm messages is displayed Press the ESC key Delete Press the F3 key This function is password protected Colortronic service Press the ENTER key for deleting the messages Press...

Page 42: ...e Overflow warning On Off Press the SHIFT key By means of the arrow keys select on if a warning message is to be given By means of the arrow keys select off if no warning message is to be given Press...

Page 43: ...imiter has been Activated Check the safety temperature limiter of the drying regeneration or hopper heater respectively Filter Door is Open The side panels to the air filters are open Assemble side pa...

Page 44: ...flap does not close or closes too slowly Check the bypass flap Error Valve Block The valve block has not reached the proper position The main switch is placed in the off position Check the position o...

Page 45: ...surement Heater Defective Hopper X X number of the drying hopper Check cables and sensor Check the power supply Short circuit check Excess Temperature Heater Hopper X X number of the drying hopper The...

Page 46: ...emperature is too high Check the heater Check the throttle valve Valve Error Hopper X X number of the drying hopper The throttle valve does not close or closes too slowly Check the throttle valve Temp...

Page 47: ...hich is in proper working order and load sus pension devices with sufficient carrying capacity Do not stand or work under suspended loads Ensure that the electric motors switch cabinets are sufficient...

Page 48: ...l or lu bricants Ensure that materials and incidentals required for operation as well as spare parts are disposed of properly and in an environmentally sound manner Use only original Colortronic spare...

Page 49: ...Clean filter of the regeneration blower depending on amount of dust collected Every six months Exchange return air filter depending on amount of dust collected Exchange filter of the electrical cabine...

Page 50: ...the dryer at the main switch Disconnect the power supply F Open the upper panel by means of the provided switch cabinet key Clogged filters reduce the volume of circulating air to a substantial de gre...

Page 51: ...using Use lint free clea ning rags Re install the cleaned new return air filter Mount the lid and fasten the securing nut Close the panel F Never operate the dryer without return air filter The dryer...

Page 52: ...outside or renew the filter Re install the cleaned new filter Replace the circular grid Fasten the two wing nuts on Replace the regeneration air filter housing and the lid of the regeneration air filt...

Page 53: ...with compressed air from inside to outside or renew the filter mat Clean the filter housing Use lint free cleaning rags Re install the cleaned new filter mat Replace the lid of the filter F Never oper...

Page 54: ...key L Wait until the blowers have stopped turning Switch off the dryer at the main switch Disconnect the power supply F Open the upper panel by means of the provided switch cabinet key 64 10 8255GB01...

Page 55: ...tion 4 Remove defective V belts position 5 put on new ones F Attention should be given to exact alignment of the V belt pulleys Adjust belt tension by screw position 2 in accordance with the informati...

Page 56: ...put on new ones F Attention should be given to exact alignment of the V belt pulleys Adjust belt tension using nuts on threaded bolt position 3 in accordance with the information sticker Mount the pro...

Page 57: ...isposed of in accordance with all official regula tions Used drying agents are to be disposed of as hazardous waste as it may be contaminated with foreign substances from the materials dried in the sy...

Page 58: ...rol box key which is part of the supply Open the front door of the CPU Pull the backup battery with cable out of the compartment Plug the connector of the new backup battery into the corresponding soc...

Page 59: ...years If backup batteries are not treated properly they can ignite explode and cause severe burning Order number battery ID 83809 Batteries must be disposed of in keeping with the relevant national e...

Page 60: ...is part of the supply Turn the key to the STOP position Turn the key to the MRES position Hold the key in this position until the STOP LED comes on for the second time and remains on this takes 3 sec...

Page 61: ...s intended for all operating personnel of the equipment Prerequisite for this functional description is general knowledge of dryers and SPS PLC systems Ensure in each case that the operating personnel...

Page 62: ...as been reached This guarantees that 3 regenerated drying cells are always available The air inside the switch cabinet is cooled by a cooling appliance for the protection of temperatu re sensitive com...

Page 63: ...material must also be continuously fed into the drying hopper The new moist material is fed into the drying hopper from the top and slowly moves downward toward the material suction box As the materi...

Page 64: ...ed only when nee ded If the return air temperature exceeds the set value e g due to interruption in the cooling wa ter supply or soiling an alarm message is given The return air cooler can be connecte...

Page 65: ...via the dryer The supplementary heating system is then automatically switched off 6 7 Connection to a pneumatic conveying system optional The dryer operates most effectively in conjunction with a pne...

Page 66: ...the operating conditions and safety regulations and their implementation Ensure in each case that the operating personnel are sufficiently informed Please inform all persons within the range of action...

Page 67: ...g transport Plugs must be removed before assembly Packing materials should be disposed of according to environmental laws or reused Only use for transport of the equipment a suitable lifting device e...

Page 68: ...is met fasten the transport cables to the eyelets If this condition is not met mount the eyelets and then fasten the transport cables to the eyelets Disassemble the eyelets after set up 64 10 8248GB01...

Page 69: ...ke sure that the air filters can be changed without problems The rear of the dryer can be placed against a wall To conserve energy keep the distances between dryer hopper and processing machine as sho...

Page 70: ...regulations with regard to lifting gear handling All installation work must be carried out with the equipment disconnected from electrical power and compressed air supply L For installation work taki...

Page 71: ...any circumstances 8 2 Connection of the air coolers optional F A return air cooler is generally required in cases in which the return air temperature is over 65 C The return air cooler can be connecte...

Page 72: ...ain switch must be freely accessible Ground the equipment against electrostatic charging L Observe that the control system is still under voltage even when the mains switch is switched off F Regularly...

Page 73: ...clock or timer Optical alarm indication Function control with flow diagram Optional Equipment Dew point display Return air cooler for high processing temperatures Pre air filter Special color Special...

Page 74: ...Dimension sheet 64 10 8250GB01 05 03 CTT 1200 Technical Data 9 2 222O mm 87 4 274O mm 108 2OOO mm 79 630 mm 25 Dimensions in mm Specifications may be subject to alterations...

Page 75: ...are parts list is intended to be used only by trained personnel Other persons are not permitted to modify or repair the equipment ID numbers for units with special voltage for ex blowers only on re qu...

Page 76: ...TB 160 250 C dry optional 3 86363 Spindle motor 24 V 4 20952 Drying cell complete 96196 Drying agent 5 05190 Valve stem complete 85682 Micro switch 6 84467 High pressure blower HRD 60 5 5 3 kW 400 V 5...

Page 77: ...n air cooler is in use 9 83986 Moisture sensor 10 92717 High pressure blower HRD 14 4T 1 6 kW 400 V 50 Hz reg 86355 V belt 97762 Silicon hose 95819 Pull button 11 96395 Fine mesh filter with filter ma...

Page 78: ...lenoid valve 24 V 84503 Temperature converter 86036 Filter cartridge temperature proof if a return air cooler is in use 10 1 Switching Cabinet and Operating Unit Observe spare parts list in the electr...

Page 79: ...ic service personnel and trained personnel authorized by Colortronic Other persons are not permitted to modify or repair the equipment Connection diagram no _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Currently n...

Page 80: ...r with frequency converter operation Elektror High pressure blower Spare parts list drying hoppers TT 25 TT 6400 Manual Moeller 05 00 AWB 8230 1340D file 2 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...

Page 81: ...Dehumidified Air Dryer Accessories 12 2...

Page 82: ...64 10 0134GB01 10 97 Dehumidified Air Dryer Accessories 12 3...

Page 83: ...Accessories Entering values on the OP 7 17 Colortronic GmbH 02 01GB...

Page 84: ...alues refer to section 3 3 1 S inputs of alphanumeric values refer to section 3 3 2 S inputs of symbolic values refer to section 3 3 3 4 Confirm your input with You can cancel any incorrect input by p...

Page 85: ...o left justified When input begins the old value does not disappear from the display completely but its bit pattern is overwritten one character at a time You move the cursor in this type of field by...

Page 86: ...activated Shift Lock mode with and A to F characters can be entered directly with activated Shift Lock mode using numeric keys 1 to 6 If you want to enter digits again after the letters Shift Lock mo...

Page 87: ...ress in succession 1 A 8 2 Press Shift LED is on The extended character set is available SHIFT 3 Scroll with the arrow keys through the extended character set 4 Select O and using the arrow key move r...

Page 88: ...alue from a list of options To do so proceed as follows Step Procedure 1 In the input field press Shift LED is on The list of options with its configured symbolic inputs is activated SHIFT 2 Select th...

Page 89: ...Accessories Flap control with Fuzzy Logic Colortronic GmbH 10 00GB...

Page 90: ...rning hopper off see chapter start up turning the devices on off Control unit flap Switch position 0 Quick closing flap closes quick 1 Slow closing flap closes controlled 2 Automatic control flap oper...

Page 91: ...Accessories Spare parts list Drying Hoppers TT 25 TT 6400 GB01 01 03 Colortronic GmbH...

Page 92: ...tions are for Please fill in personally Serial number Year of manufacture Date of delivery Number of delivery Date of commissioning Location Group of machines Colortronic GmbH Otto Hahn Stra e 10 14 6...

Page 93: ...thout notice We assume no liability for any errors or direct or indirect damage resulting in con text with these operating instructions Copying translation or publication in any form except for person...

Page 94: ...GB01 01 03 TT 25 TT 6400 4 15 D 9 10 11 12 13 14 PT 100 1 2 3 4 5 6 7 17 16 8 18 PT 100 A C B...

Page 95: ...p in use 3 07418 Flow indicator 150 96099 Tension ring 94231 Sealing ring optional if flap in use 4 16517 Motor flap 80 92241 Tension ring 28923 Cable set 4 16522 Motor flap 150 96099 Tension ring 289...

Page 96: ...ion ring 17 94233 Sealing ring optional if flap in use 18 30350 Grounding set Multiplier PT 100 86371 Pt 100 3 m 89846 Pt 100 6 m 93303 PT 100 9 m 86387 PT 100 12 m 83015 PT 100 15 m Drying Hoppers co...

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