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Colortronic CTT 250, Operating Instructions Manual

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Colortronic CTT 250 Operating Instructions Manual Download Page 13

Assembly

Compare the connected loads with those of the mains supply. Danger of injury through electrical
shock!

When using lifting gear, please observe the pertaining regulations. Caution: Danger of accidents!

Do not modify, add other equipment or change the design of the equipment without the approval
of the manufacturer. Caution: Danger of accidents!

Attachments not supplied by Colortronic must be manufactured in accordance with safety regula-
tion EN 294. Danger of accidents!

The equipment may only be operated when all the associated components are properly connec-
ted up and in accordance with the relevant regulations. This avoids injury and damage to equip-
ment!

Operate the device only if all its components are grounded. Danger: accident through electrical
shock!

Please note for installation that the equipment is top-heavy. Danger exists that it may topple over!

Take care that the device is not standing on the mains cable. This will prevent danger to people
and material!

Operation

Appoint an equipment foreman to be responsible for the equipment.

Ensure that the operating personnel are provided 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 against
unauthorized activation. Caution: Danger of accidents!

Repair work may be carried out by trained personnel only. Caution: Danger of accidents!

Never operate the equipment when partially dismantled! Danger! Limbs may be caught in machi-
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 plastics. Any other or additional use is
contrary to specifications.

This equipment is not suitable for food processing.

The safety instructions of the connected machines must be followed.

Please note that sound levels exceeding 85 db(A) may in the long term damage your health. Use
the appropriate ear muffs. This avoids impairment of hearing!

Please note that the drying cells, drying hoppers and air pipings grow hot during use. Avoid tou-
ching any of these parts! Danger: Injury through burns!

Never operate the dryer without side panels. Danger: Limbs may be caught in machinery! Injury
through burns!

64.10-0260GB05

06/03

CTT 250

Safety instructions 2-3

Summary of Contents for CTT 250

Page 1: ...Operating Instructions Dehumidified air dryer CTT 250 with Siemens S7 control unit 64 10 0260GB05 06 03 Colortronic GmbH...

Page 2: ...rating instructions 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...

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 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 hopper values 3 11 3 5 3 1 Enteri...

Page 5: ...ctional description 6 1 6 1 General Information 6 2 6 2 Drying Hopper Optional 6 3 6 2 1 Hopper heaters optional 6 3 6 3 Connection to a Pneumatic Conveying System Optional 6 4 6 4 Return Air Cooler O...

Page 6: ..._ _ _ _ _ _ _ _ o Currently not available will be delivered at a later date 12 Accessories 12 1 o Spare parts list Drying Hoppers TT 25 TT 6400 o Entering values on the OP 7 17 o Flap control with Fu...

Page 7: ...ation 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 0260GB05 06 03 CTT 250 General...

Page 8: ...ious injury 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 instructi...

Page 9: ...ompressed air pipes on the equipment should be de pressurised before starting maintenance work Caution Danger of hot surface Before starting any work wait until all parts have been cooled down suffi c...

Page 10: ...tructions 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...

Page 11: ...ect 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 language is p...

Page 12: ...rk on the 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 p...

Page 13: ...e provided 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 sec...

Page 14: ...lters should 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...

Page 15: ...pers are always completely filled and that the retention period is re spected if continual removal is taking place Note that too large amounts taken from the drying hopper lead to insufficient drying...

Page 16: ...ote 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 Make sure that any condensate penetrat...

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: ...lower 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...

Page 19: ...and 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 stat...

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: ...er 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 Pres...

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: ...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 temperatu...

Page 25: ...ith 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...

Page 26: ...re 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 there...

Page 27: ...with 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 displ...

Page 28: ...cted 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 E...

Page 29: ...lling 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 resi...

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: ...uested 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 T...

Page 32: ...SHIFT 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...

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: ...the 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 w...

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: ...ect 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 0260GB...

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: ...mes 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 every case...

Page 39: ...is not 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...

Page 40: ...text G 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...

Page 41: ...essages 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 message...

Page 42: ...c service 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 give...

Page 43: ...ature Limiter 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...

Page 44: ...bypass 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 pos...

Page 45: ...ure Measurement 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 hop...

Page 46: ...terial temperature 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 va...

Page 47: ...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 sufficiently protecte...

Page 48: ...el or lu bricant 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: ...dust build up Clean air filter of the suction box All electrical and mechanical connections should be checked to see if they fit securely Annually Dewpoint should be checked only by Colortronic servi...

Page 50: ...n unin tentionally If there is a return air cooler installed switch off its coolant circuit Clogged filters substantially reduce the amount of circulating air and lead to a production lag of your drye...

Page 51: ...the inside of the return air filter hou sing Use non fibrous cleaning cloths or an industrial type vacuum cleaner Blow compressed air from the inside out through the clogged filter cartridge or re pl...

Page 52: ...ilter A off the nozzle Blow compressed air through the clogged air filter from the inside out or replace the air filter Install the cleaned new air filter A Mount the back panel F Never operate the dr...

Page 53: ...pty When disposing of drying agents observe all official rules Since used drying agents may contain impurities from the dried materi als treat them as special waste It is not possible for Colortronic...

Page 54: ...upt the mains supply so that the device cannot be switched on unin tentionally If there is a return air cooler installed switch off its coolant circuit F Clean the drying hopper each time you are chan...

Page 55: ...wards if in use remove be fore the single conveyor Clean the drying hopper Close the hopper lid and close the toggle type faste ners A if in use re mount the single conveyor F Remove any granules rema...

Page 56: ...dles Clean the drying hopper Close the cleaning opening of the drying hopper Turn the handle A until the cleaning opening is locked and then close the handle if in use re mount the single conveyor F R...

Page 57: ...trol 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 so...

Page 58: ...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 59: ...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 60: ...ddressed to the operators of the equipment This functional description assumes general familiarity with drying equip ment It should be verified that the operators do indeed have the appropriate skills...

Page 61: ...generated simultaneously If a malfunction occurs in the drying cycle during the program run regeneration is not interrupted but continues until the program end has been reached This guarantees that on...

Page 62: ...into the drying hopper continuous drying process New moist material is conducted into the upper opening of the drying hopper and slowly reaches the material outlet at the lower end On its way from the...

Page 63: ...ith one or three suction tu bes can be supplied as well optional These suction boxes are developped specifically for this type of hopper The loading of the conveying line with materi al is adjusted by...

Page 64: ...rating 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 of the...

Page 65: ...transport Plugs must be removed before assembly Packing materials should be disposed of according to environmental laws or reused The dryer or the compact unit is delivered on a pallet The dryer shou...

Page 66: ...dition 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 0...

Page 67: ...cessary for installation The dryer must be installed on a level surface and must not be exposed to excessive humidity The maximum permissible ambient temperature is 45 C 113 F To facilitate servicing...

Page 68: ...tions 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 taking plac...

Page 69: ...st not under any circumstances return to the dryer 8 2 Connection of Return Air Cooler Optional F A return air cooler must be employed if the return air temperature is hig her than 65 C 149 F The retu...

Page 70: ...uthorized by Colortronic Other persons are not permitted to carry through the electrical connection The main switch must be freely accessible Ground the equipment against electrostatic charging F Regu...

Page 71: ...stem overpressure Check the compressed air in the factory duct work system Set the air pressure at 5 6 bar system over pressure Open the panel by means of the provided switch cabinet key Attach the co...

Page 72: ...rols max for all heating elements safety temperature limiter for all heaters Optional Equipment Dew point display Return air cooler for processing high temperatures Pre air filter Special color Specia...

Page 73: ...Dimension Sheet 64 10 0260GB05 06 03 CTT 250 Technical Data 9 2 Dimensions and data without obligation Dimensions in mm Specifications may be subject to alterations 3152 1100 2224 1830...

Page 74: ...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 quest 64 10 0260...

Page 75: ...Hose clamp 4 96118 Flexible pipe 7 85651 Heating element 9 kW 230 400 V 82354 Heating element 9 kW 266 460 V 8 07340 Sealing 9 Blower only on request 10 Blower only on request 14 98171 Filter unit 15...

Page 76: ...s ID number Description 5 S82966 Pneumatic thruster 6 S38457 Push piston valve stem 11 S82962 Valve 12 85774 Maintenance unit 13 S82965 Approach switch 64 10 0260GB05 06 03 CTT 250 Spare parts list 10...

Page 77: ...10 1 Switching Cabinet and Operating Unit Observe spare parts list in the electrical manual 10 2 Drying Hopper Observe chapter accessories 64 10 0260GB05 06 03 CTT 250 Spare parts list 10 4...

Page 78: ...e personnel and trained personnel authorized by Colortronic Other persons are not permitted to modify or repair the equipment o Connection diagram no _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o Currently not av...

Page 79: ...s TT 25 TT 6400 o Entering values on the OP 7 17 o Flap control with Fuzzy Logic o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...

Page 80: ...Accessories Spare parts list Drying Hoppers TT 25 TT 6400 GB01 01 03 Colortronic GmbH...

Page 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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...

Page 86: ...Accessories Entering values on the OP 7 17 Colortronic GmbH 02 01GB...

Page 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...Accessories Flap control with Fuzzy Logic Colortronic GmbH 10 00GB...

Page 93: ...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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