Colortronic CTT 1600 Operating Instructions Manual Download Page 46

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Please observe the maintenance schedule.

Before starting maintenance work, clean the equipment of oil, fuel 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 parts.

Keep record of all maintenance and repair procedures.

64.10-0233GB05

11/02

CTT 1600

Maintenance 5-2

Summary of Contents for CTT 1600

Page 1: ...Operating Instructions Dehumidified Air Dryer CTT 1600 with Siemens S7 control unit 64 10 0233GB05 11 02 Colortronic GmbH...

Page 2: ...10 0233GB05 11 02 CTT 1600 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 Co...

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: ...chart 3 3 3 2 Switching on the dryer 3 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 Enterin...

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

Page 6: ...ently not available will be delivered 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...

Page 7: ...48GB01 04 02 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 8248GB01 04 02 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: ...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 10: ...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 11: ...ork is carried out on these com ponents Caution Danger to life through electrical shock Compile detailed operating instructions based on these Operating instructions for the sequence of procedures to...

Page 12: ...nery Electric shock In case of malfunction shut down the equipment immediately Have malfunctions corrected im mediately Danger of accidents The machine is intended only for the drying of granulated pl...

Page 13: ...e equipment should only be started when the the main switch is off and the blower has stopped This avoids injury and damage to equipment Check the v belts of the blower only when the main switch is sw...

Page 14: ...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 15: ...CTT 1600 CTT 2400 This will prevent damage of material Check 5 hours after first putting into operation that the drying cells are sufficently filled with drying agent only CTT 1600 CTT 2400 This will...

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: ...wer 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 li...

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: ...e data entered into the 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...

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: ...d operation internal operation with timer 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 opera...

Page 23: ...per X off blocking drying hopper X Acknowledge with the ENTER key Hopper heater X on off X number of the hopper heater on switch on hopper heater X off switch off hopper heater X Acknowledge with the...

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: ...the ENTER key Return air cooler Act The current return air temperature will be displayed The cooling effect of the return air cooler is highly dependent on the cooler circuit The lower the value chos...

Page 26: ...g with supplementary heating Acknowledge with the ENTER key Hopper entry X Act X number of the drying hopper The current temperature at the feed opening of hopper flap X will be displayed If there is...

Page 27: ...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 X is displayed in...

Page 28: ...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 29: ...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 30: ...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 31: ...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 32: ...ching off time Acknowledge with the ENTER key Example Fr ON 08 00 OFF 23 59 Sa ON 00 00 OFF 23 59 Su ON 20 00 OFF 08 00 Mo ON 00 00 OFF 00 00 The dryer starts on Friday at 08 00 in the morning runs th...

Page 33: ...the materials in the hoppers After first filling do not process the material until after the dwelling time If a return air cooler is installed switch on the coolant circuit of the return air cooler Ma...

Page 34: ...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 0233GB0...

Page 35: ...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 36: ...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 37: ...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 38: ...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 39: ...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 40: ...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 41: ...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 42: ...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 43: ...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 44: ...perature Granules Hopper X X number of the drying hopper The material temperature is too high Check the heater Check the throttle valve Valve Error Hopper X X number of the drying hopper The throttle...

Page 45: ...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 46: ...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 47: ...Check V belt tension of blower Every three months Clean filter of the regeneration blower depending on amount of dust collected Every six months Exchange return air filter depending on amount of dust...

Page 48: ...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 49: ...ter housing Use lint free cleaning rags Re install the cleaned new return air filter regeneration air filter Mount the lid and fasten the securing nut Close the panel F Never operate the dryer without...

Page 50: ...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 51: ...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 Order number V belts regeneration blower ID...

Page 52: ...s 4 Replacement Remove defective V belts pos 5 put on new ones Re tensioning Adjust belt tension by means of screw pos 2 in accordance with the information plate Tighten the nuts on threaded bolt pos...

Page 53: ...os 32 put on new ones Re tensioning Adjust belt tension by means of screw pos 11 in accordance with the informa tion plate Tighten the nut pos 10 again Mount the protective grid of the blower pos 7 Mo...

Page 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...end has been reached This guarantees that 2 regenerated drying cells are always available The air inside the switch cabinet is cooled by a cooling appliance for the protection of temperatu re sensiti...

Page 60: ...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 61: ...lue chosen for the return air temperature the better the efficiency of the drying cells The dryer is automatically switched off if temperature exceeds 80 C Return air temperature is continuously monit...

Page 62: ...via the dryer The supplementary heating system is then automatically switched off 6 6 Connection to a pneumatic conveying system optional The dryer operates most effectively in conjunction with a pne...

Page 63: ...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 64: ...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 65: ...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 66: ...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 67: ...safety 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 wo...

Page 68: ...air must be provided The throughput of the regeneration blower may not be changed It must be taken into consideration when installing a disposal system e g exhaust system that regeneration exhaust ai...

Page 69: ...nd the tin plate A Fill the drying cell with drying agent up to the nozzle see filling level Mount the tin plate and the tension ring A F Check 4 5 hours after first putting into operation the filling...

Page 70: ...network Observe the water flow with connection to water mains network The coolant circuit must be di mensioned acccordingly Remove the side panel of the dryer Connect the coolant intake line and cool...

Page 71: ...n The main 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 Re...

Page 72: ...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 voltage Printe...

Page 73: ...Dimension sheet 64 10 0233GB05 11 02 CTT 1600 Technical Data 9 2 All dimensions are in mm Subject to alteration 2OOO 3450 6OO 215O V R...

Page 74: ...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 75: ...12 99716 Ball bearing 16 05190 Valve stem 86363 Spindle motor 24 V 64 10 0233GB05 11 02 CTT 1600 Spare parts list 10 2 12 16...

Page 76: ...39 31536 Sealing 72 16517 Motor flap optional 86379 Motor 88952 Sealing 100 83986 Moisture sensor 86387 Sensor PT 100 12 m 64 10 0233GB05 11 02 CTT 1600 Spare parts list 10 3 39 100 72...

Page 77: ...ll 96196 Drying agent 96143 Tension ring 28420 Sealing ring 85533 Tension ring 36 86356 Filter cartridge 61 88226 Filter cartridge 64 21027 Sealing 65 07050 Sealing 66 27899 Heating head 85322 Silicon...

Page 78: ...Sealing 16517 Motor flap NW80 complete 88952 Sealing 86376 Motor operator 24 V AD DC 50 60 Hz 18232 Air control flap 88952 Sealing 84492 Thermometer CTT 1600 93687 Fine mesh filter with filter mat com...

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: ...with Fuzzy Logic Elektror High pressure blower with frequency converter operation Elektror High pressure blower _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...

Page 81: ...Accessories Entering values on the OP 7 17 Colortronic GmbH 02 01GB...

Page 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...Accessories Flap control with Fuzzy Logic Colortronic GmbH 10 00GB...

Page 88: ...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...

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