Colortronic CTT 1600 Instrucciones de operaciones

Operating InstructionsDehumidified Air DryerCTT 1600with Siemens S7 control unit64.10-0233GB05 11/02Colortronic GmbH

2. Safety instructionsVersion: 64.10-0127GB03 11/02»These safety instructions apply to all persons within the range of action of theequipment.Please i

2.1. For your safetyGeneralThe operating personnel of this equipment must be at least 16 years old.Please read these operating instructions carefully

Take care that the device is not standing on the mains cable. This will prevent danger to peopleand material!The drying cells must be filled with dryi

MaintenanceBefore starting maintenance work, appoint a supervisor.Inform the responsible personnel before maintenance work on the system is started. C

2.2. For the safety of the devicesNever change settings without carefully assessing the consequences.Use only original Colortronic spare parts.Observe

Observe that the drying cells must be filled with drying agent before setting-up the dryer (onlyCTT 1600, CTT 2400). This will prevent damage of mater

3. Start-upVersion: 64.10-0233GB05 11/02»This chapter is directed at the operators of the equipment.This chapter assumes general skills in dealing wit

3.1. Control systemThe control system is switched on at the main switch. The control system is operated via a”selection window” and the keyboard of th

3.1.2. Flow chart1 Indicator lamp2 Valve system3 Drying chamber4 Drying blower5 Return air filter6 Drying hopper7 Drying heater8 Regeneration heater9

3.2. Switching on the dryerSwitch on the system by means of the main switch.&The control system carries through a self-test; after that, the name

Technical service:Service departmentTelephone: (0 61 75) 7 92-2 22Telefax: (0 61 75) 7 92-1 19Email [email protected] parts departmentTele

3.3. Viewing the software-versionPress the “±”-key.&Lamp test: all LED’s must light up.The software-version will be displayed (optional).3.4. Pass

LoginPress the key “F2".Enter the password.Press the ENTER key.&If the password has been entered correctly, the corresponding passwordlevel i

3.5. Basic parametersPress the ”F1"-key.3.5.1. Turning the devices on/offSelect ”Main menu”.Acknowledge with the ENTER-key.orPress the ”F2”-key.D

Hopper X on/off (X = number of the drying hopper)“on” = releasing drying hopper X, “off” = blocking drying hopper XAcknowledge with the ENTER-key.Hopp

3.5.2. Entering dryer valuesSelect ”Dryer”.Acknowledge with the ENTER-key.orPress the ”F3”-key.Regeneration Heater Act.The regenerated heat temperatur

&If the unit operates with a return air cooler (optional):Return air cooler TargetEnter the max. permissible return air temperature (65 °C max.).

3.5.3. Entering hopper valuesSelect ”Hopper”.Acknowledge with the ENTER-key.orPress the ”F4”-key.Hopper entry X Target(X = number of the drying hopper

&If the unit operates with motor flaps (optional):Granules Xtarget:_%=_°C(X = number of the drying hopper)Enter the material temperature at which

3.5.4. Observing processing statusSelect ”Status”.Acknowledge with the ENTER-key.orPress the ”K1”-key.&The current operation status of individual

3.5.5. Setting date and time&This function is password protected.Press the “K3"-key.Enter the password if requested.DatePress the SHIFT key.B

Colortronic GmbH retains all rights to change the information in these operatinginstructions at any time without notice.We assume no liability for any

3.5.6. Viewing/changing language and contrast&This function is password protected.Press the “K4"-key.Enter the password if requested.Contrast

3.5.7. Changing parametersSelect ”Parameters”.Acknowledge with the ENTER-key.orPress the SHIFT-key and the ”K1”-key.Run on timedrying blower-- 300 sec

3.5.8. Setting the timerSelect ”Timer”.Acknowledge with the ENTER-key.orPress the SHIFT-key and the ”F1”-key.XX ON 00:00 OFF 00:00 (XX = day Mo-Su)Ent

3.6. Starting continuous operationWhen you have carried through all basic settings, you can start with continuous operation.FMake sure that hoppers wh

3.7. Viewing system runtimeSelect ”System runtime”.Acknowledge with the ENTER-key.orPress the SHIFT-key and the ”F2”-key.System runtimePLC #.## hr.-bl

3.8. Switching the dryer offSelect ”Main menu”.Acknowledge with the ENTER-key.orPress the ”F2”-key.Select ”Dryer off”.Acknowledge with the ENTER-key.L

4. Error and error correctionVersion: 64.10-8248GB01 04/02»This chapter is directed at the operators of the equipment.This chapter assumes general ski

&Alarm messages are displayed in plain language on the screen of theoperator device.The display of alarm messages in the operator device can only

ViewPress the ”F2"-key.All alarm messages with their numbers (see Texts), date, time and the supplement ”K”, ”G”, or ”Q”are displayed.&”K” =

NumberPress the ”F2"-key.Total messagesThe number of all alarm messages is displayed.Waiting messagesThe number of current alarm messages is disp

TABLE OF CONTENTS1. General Information (Version: 64.10-8248GB01 04/02) ...1-11.1. Warnings and symbols ...

OverflowPress the ”F2"-key.&If there are more current alarm messages than can be saved, a warningmessage (= residual buffer reached) may be g

TextPress the ”F3"-key.All possible alarm messages are displayed with their numbers (see Viewing).For viewing the possible alarm messages, press

Temperature Measurement Regeneration Heater DefectiveCheck the cables and the sensor.Check the power supply.Short circuit check.Excess Temperature Reg

Temperature Measurement Drying Heater DefectiveCheck cables and sensor.Check the power supply.Short circuit check.Excess Temperature Drying HeaterThe

Temperature Measurement Granules Defective Hopper X(X = number of the drying hopper)Check cables and sensor.Check the power supply.Short circuit check

5. MaintenanceVersion: 64.10-0233GB05 11/02»This chapter is intended for persons with skills in electrical and mechanicalareas due to their training,

FPlease observe the maintenance schedule.Before starting maintenance work, clean the equipment of oil, fuel or lu-bricants.Ensure that materials and i

5.1. Maintenance intervals5 hours after firstputting into operation: Check drying agent in the drying cells, if necessary fil uplDaily: Check warning

5.2. Cleaning/renewing the air filtersPress the ”F2”-key.Select ”Dryer off”.Acknowledge with the ENTER-key.LWait until the blowers have stopped turnin

Return air filter/Regeneration air filterLoosen the securing nut on the filter housing and remove the housing lid.Remove the return air filter/regener

5. Maintenance (Version: 64.10-0233GB05 11/02) ...5-15.1. Maintenance intervals ...5-35

Filter of the electrical cabinetRemove the lid of the filter.Remove the filter mat.Blow through the filter mat with compressed air from inside to outs

5.3. Tensioning the V-beltsPress the ”F2”-key.Select ”Dryer off”.Acknowledge with the ENTER-key.LWait until the blowers have stopped turning.Switch of

”Regeneration” BlowerRemove the protective grid of the blower (pos. 3).Loosen the nut (pos. 1).Loosen and remove the screw (pos. 2).Slide motor with c

”Drying” BlowerRemove the protective grid of the blower (pos. 7).Loosen the nut (pos. 10).Loosen the screw (pos. 11).Replacement: Remove defective V-b

High-pressure blowers with frequency converter operationFBlowers work without V-belts!5.4. Disposing of the drying agentEnsure that drying cells are e

5.6. Changing the battery of the control system»This work may be carried through only by qualified personnel trained in thefield of electrical enginee

LStore backup batteries in a dry and cool place.Backup batteries can be stored for approx. 5 years.If backup batteries are not treated properly, they

5.6.1. Resetting the control values»This electrical work is intended to be carried out only by trained personnel.&After changing the battery or th

6. Functional descriptionVersion: 64.10-0233GB01 11/02»This functional description is intended for all operating personnel of theequipment.Prerequisit

6.1. DryerThe dryer operates with dehumidified air, i.e. the air is not only heated but also dehumidified befo-re flowing into the drying hopper. This

10. Spare parts list (Version: 64.10-0233GB05 11/02) ...10-110.1. Switching Cabinet and Operating Unit ...

6.2. Drying hopper (optional)The material is dried in the drying hopper. The dehumidified air is forced through the material inthe hopper, collecting

6.3. Return air cooler (optional)FA return air cooler is generally required in cases in which the return airtemperature is over 65 °C.A return air coo

6.4. Hopper heaters (optional)If differing drying temperatures are required in the different drying hoppers, hopper heaters mustbe installed on the dr

7. Transport, Assembly and StorageVersion: 64.10-8248GB01 04/02»This chapter is intended for all operating personnel of the equipment.Personnel using

7.1. Transport and Packing»Please ensure adequate carrying capacity of the lifting equipment.Note that the dryer system is top-heavy. Risc of toppling

with a workshop craneCheck if the eyelets are installed on the dryer housing.If this condition is met, fasten the transport cables to the eyelets.If t

7.2. Assembly»Please ensure adequate carrying capacity of the lifting equipment.Check the carrying capacity of the point of installation, particularly

8. Assembly instructionsVersion: 64.10-0233GB05 11/02»These installation instructions are intended for persons with skills in electri-cal and mechanic

8.1. Mounting of the suction device for regeneration exhaust airWhen plastics are dried which produce hazardous gases, environmentally sound disposal

8.2. Filling up the drying cellsLAt delivery the drying cells are not filled with drying agent.FBefore filling up check that the screw connection (B)

1. General InformationVersion: 64.10-8248GB01 04/02»These operating instructions are addressed to all users of the device.These operating instructions

8.3. Connection of the air coolers (optional)FA return air cooler is generally required in cases in which the return airtemperature is over 65 °C.The

8.4. Electrical connection»Observe the rules of the local electricity board.Check that the supply voltage and the power frequency are in accordancewit

9. Technical DataVersion: 64.10-0233GB05 11/02Basic Equipment·Centrally monitored PLC S7 drying control system with operator panel OP 7·Central temper

Dimension sheet64.10-0233GB05 11/02CTT 1600Technical Data 9-2All dimensions are in mm. Subject to alteration.2OOO34506OO215OVR

10. Spare parts listVersion: 64.10-0233GB05 11/02»This spare parts list is intended to be used only by trained personnel.Other persons are not permitt

12 99716 Ball bearing16 05190 Valve stem86363 Spindle motor 24 V64.10-0233GB05 11/02CTT 1600Spare parts list 10-212,16

39 31536 Sealing72 16517 Motor flap (optional)86379 Motor88952 Sealing100 83986 Moisture sensor86387 Sensor PT 100 (12 m)64.10-0233GB05 11/02CTT 1600S

4 S89532 Blower HRD 1/594211 V-belt5 83970 Blower HRD 7/1231924 Acoustic cover83963 V-belt33 31516 Drying cell96196 Drying agent96143 Tension ring2842

Control27892 Front panel with flow chart83468 CPU 315 (S7)83809 Battery83811 OP 784156 Fan84157 FilterHopper heatersCable set heating95828 Tubular hea

11. Electrical manualVersion: 64.10-0133GB01 10/97»This electrical manual is intended to be used only by Colortronic servicepersonnel and trained pers

1.1. Warnings and symbolsThe following warnings and symbols are used in these operating instructions:»This symbol indicates danger to life! Fatal or s

12. AccessoriesVersion: 64.10-0134GB01 10/97¨Entering values on the OP7/17¨Flap control with Fuzzy-Logic¨Elektror High-pressure blower with frequency

AccessoriesEntering values on the OP7/17Colortronic GmbH02/01GB

1OP7, OP1709/96 3.3 Entering ValuesIn input fields, values can be entered on the OP and transferred to the PLC.To do this, proceed as follows:Step Pro

2 OP7, OP17 09/96 3.3.1 Entering Numerical ValuesIn fields that allow the operator to enter a numerical val

3OP7, OP1709/96 3.3.2 Entering Alphanumeric ValuesWith the input of alphanumeric values, digits and letters are mixed.For the numerical components of

4 OP7, OP17 09/96 If the characters available on the keypad are not sufficient for the alphanu-meric input,

5OP7, OP1709/96 3.3.3 Entering Symbolic ValuesWhen you enter a symbolic value, text is displayed instead of the value. If afield has to be filled by

AccessoriesFlap controlwith Fuzzy-LogicColortronic GmbH10/00GB

FObserve that the hopper is not switched off after the flap has closed.Turning hopper off: see chapter “start-up, turning the devices on/off”.Control

1.2. Explanations and informationVarious terms and designations are used in these operating instructions to ensure clarity. There-fore please note tha