Sterling Clothes Dryer SCD 10 User's Manual
Contents
1. SCD 10 Compressed Air Dryer Part Number 882 00280 00 Bulletin Number DH1 625 1 Effective 04 28 08 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2008 All rights reserved Shipping Info Unpacking and Inspection You should inspect the equipment for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for as2. A high temperature safety system will disable the dryer if the process temperature is too hot The high temperature safety is designed so that if it fails the failure causes a safe condition and the dryer will not run The compressed air continues flowing to cool down the system Airflow monitoring Safety System If the airflow source to the compressed air dryer is below 35 PSI the unit will shut down and not run This is an indication that there is not enough pressure and flow for proper operation of the unit Line Cord Plug 115 1 60 units only The line cord plug allows the operator or maintenance personnel to unplug the dryer from its power source and tag it out This plug may be tagged with any number of approved electrical lockout tags These tags are available at most electrical supply stores Always disconnect power before servicing or moving this unit DANGER At no time should anyone remove the lockout or reconnect the twist plug other than the person who installed the lockout or who unplugged the twist plug 2 6 Drying Hopper Air Trap Refer to the drying hopper Operation and Installation manual for proper operation of the drying hopper 10 CFM Compressed Air DryerChapter 2 Functional Description 9 of 30 2 7 Remote Membrane Dryer for Low Dew point Operation Optional Membrane dryers take a small percentage of the dried gas and direct it back in a sweeping pattern through the module shell This provides a driving
3. 8 8 0 3 6 5 2 2 3 PA11 167 75 4 6 0 7 0 07 2 8 1 3 5 6 2 5 16 3 2 9 PA12 167 75 4 6 0 7 0 07 2 8 1 3 5 6 2 5 16 3 2 9 PA6 176 80 4 6 0 5 0 05 2 8 1 3 5 6 2 5 16 3 2 9 PA6 6 176 80 4 6 0 5 0 05 2 8 1 3 5 6 2 5 16 3 2 9 PA6 6 176 80 4 6 0 5 0 04 2 8 1 3 15 6 2 5 16 3 2 9 GF35 PBT 266 130 3 4 0 25 0 02 4 0 1 8 18 0 3 6 19 0 4 1 PC 248 120 2 4 0 16 0 01 4 6 2 1 19 2 4 2 10 4 4 7 PE Filled 185 85 3 4 0 5 0 02 4 6 2 1 19 2 4 2 110 4 4 7 PE 194 90 1 2 0 05 0 01 7 3 2 14 6 4 15 8 7 1 PEEK 302 150 4 3 5 1 6 7 G 2 7 9 3 6 PEI 302 150 4 0 25 0 01 3 5 1 6 7 G 2 7 9 3 6 PES 302 150 4 0 43 0 02 3 5 1 6 7 G 2 7 9 3 6 PETP 300 392 4 6 0 25 0 002 2 3 1 0 4 6 2 1 15 2 2 3 150 200 PETG 149 65 4 5 0 1 0 04 3 5 1 6 7 8 2 7 9 3 6 PMMA 176 80 2 3 0 25 0 02 5 6 2 5 11 2 5 1 12 6 5 7 POM 212 100 3 4 0 2 0 05 4 6 2 1 9 2 4 2 10 4 4 7 PP 194 90 2 0 1 0 05 7 3 2 14 6 4 15 8 7 1 PPO 212 100 2 3 0 2 0 02 5 6 2 5 11 2 5 1 12 6 5 7 PPS 284 140 3 4 0 1 0 05 4 6 2 1 9 2 42D 10 4 4 7 PS 176 80 1 2 0 05 0 02 7 3 2 14 6 4 15 8 7 1 PSU 302 150 3 4 0 3 0 05 4 6 2 1 19 2 4 2 16 4 7 4 PUR 176 80 3 4 0 4 0 01 4 6 2 1 9 2 4 2 16 4 7 4 PVC 158 70 1 2 0 3 0 10 9 3 4 2 18 6 8 4 141 9 19 SAN 176 80 2 3 0 3 0 03 5 6 2 5 11 2 5 1 25 2 11 4 SB 176 80 2 0 3 0 03 7 3 2 14 6 4 131 5 14 3
4. Parameter up Level Function fe Can be set to RUN or STOP When RUN is selected the control is running When STOP is selected the control is stopped and the Stop indicator lights The default value is I Integral Time I Run Stop r S RUN bei 2 Can be set from 1999 to 9999 This parameter is used to O indicate how many degrees the process temperature will be Alarm Value AL 1 allowed to exceed the set point temperature An alarm output will de energize the heaters The default value is 25 Can be set to ON or OFF This feature is used to automatically set the optimum PID parameters proportional Auto tune At band integral time and derivative time for the set point value by changing the variables that had been modified previously The default value is OFF Can be set from 199 9 to 999 9 This setting is used to offset an error between the set point and the actual temperature The entire input range is shifted by a set figure preprogrammed by Temperature Input the operator The default value is 0 Shift Tns o Can be set from 0 1 to 999 9 This setting controls the amount 5 P in which the manipulated variable MV is proportionate to the deviated value or controller error The default value is 8 0 5 Proportional Band zZ Can be set from 0 to 3999 Setting this feature gives the control an action that is proportionate to
5. a different mode of operation be sure selector switches are correctly positioned Locking selector switches should be adjusted only by authorized personnel and the keys removed after setting Report unsafe operation unsafe conditions unusual dryer action leakage and improper maintenance immediately Never stand or sit where you could slip or stumble into the dryer while working on it Do not wear loose clothing or jewelry which can be caught while working on a dryer In addition cover or tie back long hair Clean the dryer and surrounding area daily and inspect the machine for loose missing or broken parts Shut off power to the dryer when it is not in use Turn the switch to the off position or unplug it from the power source Never attempt to move the dryer while it is in operation Always allow time for the dryer to cool off before moving it or servicing the fuse or air filter We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 10 CFM Compressed Air Dryer Chapter 1 Safety 7 of 30 Chapter 2 Functional Description 2 1 2 2 2 3 2 4 Models Covered in This Manual This manual provides instructions for installing and operating your 10 cfm compressed air dryer General Description Mini compressed air d
6. ceuvedia banat caane 21 CHAPTER 6 TROUBLESHOOTING cccseeetteeinee 22 10 CFM Compressed Air Dryer ili CHAPTER 7 APPENDIX geesde eege 20 7 1 Returned Material Policy isc curissscstscde todas tacteeneines dies Rho sadhvsadamteannnentaaaaaeene 25 Kee en lee 26 7 3 Technical Speciications i ccescccsncce c8iaseeee Aled Eege seettaeederenteacelsaielvebacls 27 Dryer Operating Parameters AAA 28 DIMENSIONS enis gege heet erh es aenn 29 7 4 Spare Parts List 10 CFM Compressed Air Dryer Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your dryer The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light preventative maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation and preventive maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the dryer We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed befor
7. the time integral of the control error By using this setting proportional action is used in combination with integral action to offset the control error and the set point will begin to match the control temperature PV or process value The default value is 233 Derivative Time d Can be set from 0 to 3999 Setting the derivative control provides the controller with the ability to correct for a future error in the previously set process output The default value is 40 10 CFM Compressed Air DryerChapter 2 Functional Description 13 of 30 2 9 Restoring Factory Default Settings If the preset parameters on the controller have been tampered with and it no longer properly controls temperature and displays dew point you can restore the controllers to the factory setup Contact the Service department for detailed instructions 10 CFM Compressed Air DryerChapter 2 Functional Description 14 of 30 Chapter 3 Installation 3 1 Uncrating the Equipment The 10 cfm compressed air dryer has a handle at the top of the cabinet to use for lifting For hopper mount configurations be sure to support the hopper when lifting and placing the dryer Use caution and observe safety rules when lifting and placing your dryer Be sure it is securely attached and additional bracing is used if necessary 3 2 Connecting a Hopper Mount Dryer to a Hopper When mounting the dryer to an existing hopper use the adapter and the self tappi
8. 30 7 2 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 262 641 8610 Fax 262 641 8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8610 Emergencies after 55m CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most of our products www acscustomerservice com Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST fax 262 641 8653 Our products are sold by a world wide network of independent sales representatives Contact our sales department for the name of the sales representative nearest you Contracting Department Call 262 641 8610 Monday Friday 8am 5pm CST Let us install your system The Contracting Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non
9. TPE 230 110 3 4 4 6 2 1 19 2 4 2 16 4 7 4 TPU 194 90 2 3 0 4 0 02 5 6 2 5 11 2 5 1 on Performance may vary based on initial quality of the compressed air supply to the dryer 10 CFM Compressed Air Dryer Chapter 7 Appendix 28 of 30 Dimensions 13 4 339 12 25 GU 10 CFM Compressed Air Dryer Chapter 7 Appendix 305 15 7 Cy 398 29 of 30 7 4 Spare Parts List Parts not included in this list must be replaced by the factory Part No Quantity Description 35452 1 Filter Regulator 725 00002 00 1 Fuse 110 volt 725 00001 00 1 Fuse 220 1 50 725 00001 00 2 Fuse 230 1 60 CT92241 1 Hopper Mounting CLDMP CT94233 1 Hopper Mounting Gasket 10 CFM Compressed Air Dryer Chapter 7 Appendix 30 of 30
10. ad cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable Carefully test the condition of lifting cables chains ropes slings and hooks before using them to lift a load Be sure that all on current carrying parts of electrical apparatus electrical enclosures and the dryer frame are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes which apply When you have completed the repair or maintenance procedure check your work remove your tools rigging and handling equipment Do not restore power to the dryer until all persons are clear of the area Do not start and run the dryer until you are sure all parts are functioning properly 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Becoming familiar with materials inspection and maintenance and total user responsibility will assist you in learning potential areas in need of observation for danger Each individual must take responsibility for observing t
11. an be mounted to any flat surface with two screws Use Figure 5 as a reference for this installation 1 Remove the large particle filter including the close nipple from the inlet of the compressed air dryer 2 Attach the large particle filter including the close nipple to the membrane drying kit Note The membrane drying kit must have the large particle and the coalescing filters in place and functioning properly to ensure full drying capabilities of the membrane Both filters must be checked and cleaned regularly 3 Attach the 1 4 NPT elbow to the inlet of the compressed air dryer 4 Run the 3 8 hose between the outlet of the membrane drying kit and the inlet of the compressed air dryer Use thread sealant on all threaded connections Figure 5 Membrane Dryer Assembly FILTER REGULATOR AND NIPPLE COMPRESSED AIR DRYER MEMBRANE DRYER KIT 3 8 ELBOW FITTIN 1 4 ELBOW FITTING 3 8 POLY TUBING 10 CFM Compressed Air Dryer Chapter 3 Installation 18 of 30 Chapter 4 Operation 4 2 Before beginning dryer operation make sure that there is a good compressed air connection and that the main power is securely plugged in Check the process hose and hopper exhaust filter for tight connections Check all companion equipment such as the drying hopper verify that the loading system is ready for operation The dryer will not run if a fault condition exists Investigate the cause of any f
12. aults DANGER Always turn the dryer off before servicing Do not attempt to check the alarms on the controller located within the unit enclosure unless you are a qualified electrician Auto tuning the Dryer Although the controller is calibrated at the factory the unit should be auto tuned prior to dryer start up Use the following procedure to auto tune the dryer 1 Press the Level button one time to enter the Adjustment level 2 Press the Mode Key one time The PV display will read At 3 Press the Up Arrow button to change the value to ON 4 Press the Level button to begin auto tuning and return to the Operation level The unit will automatically auto tune While this process is taking place the SV display will blink the set point value When the SV display stops blinking the auto tune process is finished Note It is recommended that the unit be auto tuned when the pressure and airflow of the compressed air have been adjusted and the dryer is running close to process temperature set point Setting the Alarm Value The Alarm Value setting determines how many degrees the process temperature is allowed to exceed the set point temperature before the high temperature alarm is triggered and the heater turned off Use the following procedure to set the alarm value 1 Press the Mode button two times to select the Alarm Value 1 parameter The PV display will read AL 1 2 Use the Up Arrow and Down Arrow button
13. e commencing with operation of the dryer These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the dryer safely and efficiently The Maintenance chapter is intended to ensure that your dryer provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situati
14. ergy savings Make sure that hoses are not kinked or collapsed Use the following procedure to connect a floor mount dryer to a hopper 1 Using the clamps provided clamp a hose adaptor onto the dryer and the hopper See Figure 4 Note Depending on the drying hopper model the clamp and hose adapter may not be required Connect the dryer hose with the hose clamp directly to the process air inlet of the drying hopper 2 Install an exhaust filter to the drying hopper outlet return line 3 Drying hopper air inlet and outlet locations vary but always connect hoses so the dry process air from the dryer enters the bottom of the drying hopper and flows out the top Figure 4 Floor Mount Configuration r 5 N 10 CFM Compressed Air Dryer Chapter 3 Installation 16 of 30 3 4 Making Electrical Connections The serial tag lists voltage phase and amp draw information Line voltage must be within plus or minus ten percent of the voltage listed on the serial tag or damage may occur Never supply any voltage other than what the dryer is configured for Fulfill all national state and local safety and electrical code requirements A qualified electrician should make all electrical connections Connect main power to the dryer Install a fused disconnect with a lockout feature in the power main leading to the dryer The power drop must include a ground wire Make sure all electrical connecti
15. force to remove the moisture with the minimum purge required The moisture vent membrane dryer consists of thousands of hollow fiber membranes made of tough temperature and pressure resistant plastic The inside surface of these hollow fibers is coated with an ultra thin layer of a second plastic that actually separates the water vapor from the air This second coating allows air to pass through it over 20 000 times easier than it allows water to pass As a result moisture is expelled rapidly with very little air loss Two stage drying provides the option of using the moisture vent directly at the point of use in combination with refrigerated air dryer As a single stage unit the dryer provides consistent performance from 60 F to 20 F outlet dew point When combined with a refrigerated air dryer the moisture vent system will suppress or reduce the inlet pressure dew point to below 40 F with very low sweep requirements Figure 1 Remote Mount Membrane Dryer Airflow Schematic Humid Air SS Dry Air Dry Air 10 CFM Compressed Air DryerChapter 2 Functional Description 10 of 30 2 8 Microprocessor Controls The 10 cfm compressed air dryer uses a microprocessor based PID temperature controller for maintaining process air temperature The controller is a modular self con
16. he controller is turned on Process set point is out of acceptable range Function set for degrees Celsius C set point at degrees Fahrenheit F Restore temperature controller to factory pre sets Verify correct Celsius or Fahrenheit settings 10 CFM Compressed Air Dryer No setting change possible on temperature controller Process thermocouple not in airflow The internal mechanism is not inserted properly into the housing Verify that the thermocouple is properly installed in the inlet tube Properly insert the internal mechanism into the housing The power supply is not connected to its terminals properly Properly connect the power supply to the power supply terminals No power is supplied or the supplied power is not within the specified range Supply a voltage of 85 to 125 VAC to the power supply terminals of the controller or 220 240 V for higher voltage units Chapter 6 Troubleshooting 23 of 30 Problem 10 CFM Compressed Air Dryer Alarm light is on and unit has no air pressure Possible Cause Possible Remedy Disconnect switch or Control Power switch not set to ON Control Power fuse blown The key protection switch is set to ON Compressed air source is no longer sufficiently above 35 psi Regulator is set below 35 psi Chapter 6 Troubleshooting Check control power fuse for continuity Turn disconnect switch and contro
17. he prescribed safety rules as outlined All caution warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor 10 CFM Compressed Air Dryer Chapter 1 Safety 6 of 30 1 4 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personal injury or equipment damage when installing operating or maintaining this dryer use good judgment and follow these safe practices M M M M Never place your hands or any part of your body in any dangerous location Never operate service or adjust the dryer without appropriate training and first reading and understanding this manual Never try to pull material out of the dryer with your hands while it is running Before you start the dryer remove all objects tools nuts bolts clamps bars from the hopper area If your dryer has been inoperative or unattended check all settings before starting the unit At the beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly Keep all safety guards in place and in good repair Never attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment When changing control settings to perform
18. l power switch ON Set the key protection switch to OFF Check compressed air source for proper functioning Check regulator for proper functioning 24 of 30 Chapter 7 Appendix 7 1 Returned Material Policy Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMS number will be assigned for the equipment to be returned Reason for requesting the return must be given All returned material purchased from the manufacturer is subject to 15 75 00 minimum restocking charge All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMS number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion if the item is found to be defective in materials or workmanship Purchased components are covered under their specific warranty terms 10 CFM Compressed Air Dryer Chapter 7 Appendix 25 of
19. loor mount configuration Membrane compressed air dryer for low dew point operation 220 1 50 operation 230 1 60 operation 10 CFM Compressed Air DryerChapter 2 Functional Description 8 of 30 2 5 Safety Features This section includes information on safety devices and procedures that are inherent to the 10 cfm compressed air dryer This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment Safety Circuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial Council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards into the design of the dryer however it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices High Temperature Safety System
20. lter cleaning is essential to keep the dryer operating at peak efficiency Use the following procedure to clean or replace the process air filter or the membrane dryer coalescing filter 1 Turn off and lock out electrical power to the dryer 2 Remove the clear bowl at the bottom of the filter See Figure 6 3 Discard the contents of the clear filter bowl 4 Visually inspect the filter element 5 If needed clean the filter element with compressed air or replace it Caution Do not clean or wash the filter with water 6 Replace the clear bowl Figure 6 Large Particle Filter S 10 CFM Compressed Air Dryer Chapter 5 Maintenance 21 of 30 5 3 Replacing the Fuse Outside of the Cabinet Note If the compressed air dryer does not start when the ON OFF switch is in the ON position check the main power supply to ensure that it is properly installed If the main power supply is correct check the fuse This is located on the front of the driver cabinet Use the following procedure to check and if needed replace the fuse 1 2 Bos OV Ee Make sure that the main power to the dryer is shut off and locked out Locate the fuse holder that houses the fuse for the dryer see picture below for fuse holder location Using a standard flat head screwdriver remove the insert that holds the fuse from the fuse holder Separate the insert from the fuse Using a multimeter check for contin
21. mperature controller set point to a value of 100 Fahrenheit Allow at least one minute of run time so that the compressed air continues to flow through the unit and cool down the heating components Turn the On Off switch to Off If needed empty the drying hopper For maintenance or a long term shutdown open the electrical disconnects at the dryer and at the power drop 10 CFM Compressed Air Dryer Chapter 4 Operation 20 of 30 Chapter 5 Maintenance 5 2 This dryer is designed to be virtually maintenance free This unit is factory sealed Any service required on this unit must be performed by factory personnel at the manufacturer s facility WARNING The 10 cfm compressed air dryer is sealed at the factory Removing this seal and opening the box that houses the dryer will void your warranty Please contact the manufacturer for assistance Preventative Maintenance Schedule Weekly Inspect all filters for wear and replace clean if dirty or worn Check to make sure that all hose connections are air tight Monthly Lock out electrical power and inspect the main power supply for integrity Cleaning and Replacing the Filters The 10 cfm compressed air dryer uses a large particle air filter in the process air system to clean the compressed air before it enters the drying cabinet The optional remote mount membrane dryer assembly features a coalescing filter in addition to the large particle air filter Regular fi
22. ng screws that are provided with the unit to mount the dryer to the inlet of the hopper The adapter is pre drilled with three holes that are used to mount it to the hopper Note In some cases depending on the drying hopper model an adapter may not be required If an adapter is not required attach the dryer to the hopper with the clamps provided and install the exhaust filter to the drying hopper outlet return line Use the following procedure to mount the dryer to a hopper using an adapter See Figure 3 1 Mark the holes in the inlet tube of the hopper for drilling 2 Use a 9 64 drill bit to pre drill for the 8 32 screws that are provided 3 Spread silicone adhesive over the area where the adapter will mount to the hopper inlet tubing 4 Place the adapter onto the tubing and install the three screws to hold it in place Allow sufficient time for the silicon to cure before you operate the dryer 5 Attach the dryer to the hopper with the clamps provided 6 Install an exhaust filter to the drying hopper outlet return line Figure 3 Typical Hopper Mount Configuration 10 CFM Compressed Air Dryer Chapter 3 Installation 15 of 30 3 3 Connecting a Floor Mount Dryer to a Hopper Optional Use high temperature flexible dryer hose or rigid tubing to connect the dryer to the drying hopper Keep the delivery hose to the drying hopper as short as possible to minimize heat loss We strongly recommend insulated hose for maximum en
23. on or practice that if not avoided may result in minor or moderate injury or in property damage 10 CFM Compressed Air Dryer Chapter 1 Safety 5 of 30 1 2 General Safety Regulations Read and follow the instructions in this manual before installing operating or maintaining any equipment Additional copies are available from the manufacturer Install operate and maintain this equipment according to applicable work and safety codes for your location This includes OSHA CE NEC CSA SPI and many other local national and international regulations Only qualified persons should work on or with this equipment Work only with approved tools and devices Before removing adjusting or replacing parts on a machine remember to turn off all air and electric supplies and all accessory equipment at the machine You must also disconnect and lock out electrical and pneumatic power and attach warning tags to the disconnect switch and air shut off valve When you need to perform maintenance or repair work on a dryer above floor level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk on your dryer use it The work platform should have secure footing and a place for tools and parts Do not climb on dryers machines or work from ladders If you need to repair a large component use appropriate handling equipment Before you use handling equipment portable A frames electric boom trucks fork trucks overhe
24. ons are tight Note Due to variances in 220 240 V connections customers must supply the plug for these dryer models 3 5 Making Compressed Air Connections The compressed air supply must be regulated to 80 PSI 5 5 bars Low air pressure will create poor drying performance If the pressure in the system drops below 35 PSI the alarm light will activate and the process heater and solenoid valve will shut off Note For maximum drying efficiency we recommend a refrigerated compressed air connection Not using refrigerated compressed air to provide pre conditioned compressed air to this unit will affect drying performance and material drying capabilities To achieve the lowest possible dew points an optional remote mount membrane dryer assembly is available See Section 2 7 on page 10 for more information about the remote mount membrane dryer assembly Connect a minimum of 3 8 9 mm air line to the top of the filter regulator Compressed air must be clean dry and free of oil A shut off is recommended for your in plant air supply In line filters can handle small amounts of moisture in line desiccant filters or packed beds of granular absorbing polymer can remove oil mist and condensed oil 10 CFM Compressed Air Dryer Chapter 3 Installation 17 of 30 3 6 Installing the Remote Mount Membrane Dryer Optional The membrane drying kit can be mounted anywhere near the compressed air dryer The kit is pre assembled with a bracket that c
25. parameter values in set up modes Up Arrow button The Up Arrow button is used to increase the set point temperature during operation It also increases the parameter values in set up modes AL1 Alarm 1 indicator The Alarm 1 indicator lights when the process temperature exceeds the set point temperature by more than the alarm deviation value Alarm output de energizes the heaters Heaters re energize when the temperature falls within the acceptable range AL2 Alarm 2 indicator The Alarm 2 indicator is not used HB Heater Burnout indicator Optional The Heater Burnout indicator lights when a heater burnout is detected The heater burnout alarm remains On by setting the heater burnout latch To reset turn the power supply off and then on or set the heater burnout alarm vale to 0 0A OTT Output 1 indicator The Output 1 indicator lights when the controller signals the process heaters to be energized OT2 Output 2 indicator The Output 2 indicator is not used STOP Stop indicator CMW Communications indicator The Stop indicator lights when the controller has been stopped The Communications indicator is not used 10 CFM Compressed Air Dryer Chapter 2 Functional Description 12 of 30 MANU Manual Mode Key Lights when the auto manual mode is set to manual mode Lights when the setting change protect is ON Understanding the Controller s Parameters Set
26. ryers are designed to generate heated dehumidified air at carefully controlled temperatures for use in plastic drying systems Drying systems are sized to meet specific requirements stated by the purchaser at the time of purchase Moisture removal from hygroscopic moisture attracting plastic pellets is an essential step in the manufacture of high quality plastic products This dehumidifying dryer is used to generate very low dew point air heated to a controlled temperature for drying plastic pellets and regrind Many variables were considered in the selection of your drying system including type of materials residence time throughput of the extruder or injection molding machine Should your operating environment change the manufacturer can advise you on necessary equipment and process time and temperature modifications required for your system Typical Features and Components Electrical solenoid valve Compressed air filter regulator and gauge Drying temperature range of 120 F to 400 F Display of process temperature set point and actual settings Process thermocouple located in the process air stream just before the hopper inlet Nema control enclosure a Fusing b Power On light c IEC process heater contactor d Solid state relay e Alarm light f High temperature safety system g Airflow detection system Options Options can tailor your dryer to meet the exact requirements of the drying task being performed F
27. s to change the value 3 Press the Mode button to accept the value and begin operation Note The factory default valve for this setting is 25 10 CFM Compressed Air Dryer Chapter 4 Operation 19 of 30 4 3 Start up Use the following procedure to start the dryer 1 Turn on the disconnect switch in the power drop close the slide gate at the bottom of the drying hopper Close the slide gate at the bottom of the drying hopper Fill the drying hopper with material Turn the ON OFF switch to ON to energize the display panel and turn on the solenoid and the heater Use the Up Arrow and Down Arrow buttons to set the process set point on the temperature controller Note Consult the resin manufacturer for the recommended drying temperature 6 Press the Mode button one time to make sure the controller s Run Stop parameter is set to RUN Use the Up Arrow or Down Arrow button to change the value to RUN Press the Mode button to begin operation After the proper pre drying time for the initial hopper fill has elapsed fully open the drying hopper slide gate Note To allow proper residence time during continuous processing maintain the material level in the hopper at the midpoint of the air trap assembly 4 4 Shut down Use the following procedure to shut down the dryer 1 When processing is complete close the hopper slide gate and shut down any in line companion equipment Lower the process te
28. sistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have Kl Compressed air dryer M Bill of lading M Packing list Kl Operating and Installation packet Kl Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately at 262 641 8610 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department 10 CFM Compressed Air Dryer ii Table of Contents CHAPTER T SAFETY cscceceicsccectscccetstecensestccceveestsarvacctecesconsvececs 5 1 1 How to Use This Manual siccc d cccascees che ccateeny Ae SEENEN EE de 5 Safety Symbols Used in this Manual 5 1 2 General Safety Regulations E 6 T 37 Responsipility seata Eeer 6 T A Warnings and W e TEE 7 CHAPTER 2 FUNCTIONAL DESCRIPTION sccseeeeeees 8 2 1 Models Covered in This Manual s cccsccics ccesiese ets eete eesti 8 2 2 General DESC EE 8 2 3 Typical Features and Components ENEE 8 2 4 Op ONS EE 8 Se GE ee ee 9 Safety Circuit SIANO ANOS EE 9 High Temperature Safety Sys
29. tained unit that you can remove from the mounting housing All parameters except for the process air set point are factory set and adjusted Normally no field adjustment to the internal controls is necessary Figure 2 Microprocessor Controller Tamperalure unit Mo 1 display Operalion Indicators 10 CFM Compressed Air DryerChapter 2 Functional Description 11 of 30 Identifying the Controller s Buttons and Indicators Button or Indicator Function PV display SV display During normal operation the PV numeric LED indicator displays the process temperature at the To Process thermocouple It also lists parameters during set up and error messages if any errors occur During normal operation the SV numeric LED indicator displays the set point temperature selected for the dryer The dryer then maintains this set point temperature This LED indicator also displays parameter and preset function values during configuration set up Temperature Unit display Level button Q Sl This LED indicator displays the temperature units F or C that the dryer is configured to use The Level button is used to enter set up There are two set up levels available Operation and Adjustment Mode button The Mode button is used to scroll through paramenters in set up modes Down Arrow button The Down Arrow button is used to decrease the set point temperature during operation It also decreases the
30. tem AA 9 Airflow monitoring Safety EE 9 Line Cord Plug 115 1 60 units only cccaccziasedicvegsieldbesidienen kcaetdeuet dee daans RAAEE EE 9 2 6 Drying Hopper Air Trap geste geEh A eege SEENEN desta san eecteranaseagietentadtae deeerevtsanadees 9 2 7 Remote Membrane Dryer for Low Dewpoint Operation Optional 10 2 8 leegen EE 11 Identifying the Controller s Buttons ANC Indicators sssssannsnnaeeeennnnnnnnneeeeennaaa 12 Understanding the Controller s Parameierg 13 2 9 Restoring Factory Default Gettings AAR 14 CHAPTER 3 INSTALLATION ccssccsseeeeesseesseeeeeeeeeeeneeees 15 3 1 Uncrating the e len EE 15 3 2 Connecting a Hopper Mount Dryer to a HOPPel cceeeeeceeeeeeeeeeeeseteeeeeeenaeeeteeeaes 15 3 3 Connecting a Floor Mount Dryer to a Hopper 0 0 2 eeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeesseeeeeeeeeas 16 3 4 Making Electrical Connections AAA 16 3 5 Making Compressed Air Connections AEN 17 3 6 Installing the Remote Mount Membrane Dryer Optional 18 CHAPTER 4 OPERATION sisccieccscecssasestlsticeveticacesrevsceeeeseadiedes 19 4 1 Autotuning the Dryer EE 19 4 2 Setting the ALARM AIG soi ege e E EE 19 e En GD EEN 20 4 4 SRU OWI BEE 20 CHAPTER 5 MAINTENANCE ctcccsceeessssessseeeeeseeeesneeees 21 5 1 Preventative Maintenance Gchechule AAA 21 5 2 Cleaning and Replacing the Filters AEN 21 5 3 Replacing the Process Heaters sec sceree esa Aces ead a cael as cebed ascnanpagueedcataceiev
31. uity between the two ends of the fuse If there is no continuity replace the fuse See Spare Parts List for fuse part number Insert new fuse into the fuse holder Using a standard flat head screwdriver turn the fuse into the installed position within the fuse holder Fuse Holder 10 CFM Compressed Air Dryer Chapter 5 Maintenance 22 of 30 Chapter 6 Troubleshooting The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the unit turned off power disconnected and with the machine tagged as out of service Problem Loss or reduction in drying capacity Material in drying hopper cakes or meltdown occurs Possible Cause Material being dried differs from material specified at the time of purchase Possible Remedy Drying systems are designed for the material that was originally specified Different materials may need a longer residence time or a different drying temperature Break in flex hose to drying hopper Process temperature set too high due to operator error Inspect for air leaks replace as needed Check resin manufacturer s data sheet for proper drying temperature Make sure plant personnel are aware of the correct process temperature set point High temperature alarm not set properly Reset high temperature alarm Nothing displays when t
32. union installations Sterling Inc 2900 S 160 Street New Berlin WI 53151 www sterlco com 10 CFM Compressed Air Dryer Chapter 7 Appendix 26 of 30 7 3 Technical Specifications Average dew point 10 F 23 C Average dew point with optional membrane dryer 40 F 40 C Heating capabilities up to 400 F Large particle compressed air filter Exhaust air cartridge filter 1 16 DIN PID temperature controller High process temperature alarm light Automatic shutoff system to monitor compressed air supply Full load amps 12 5 115V 6 25 240V 1 5 2 2 5 or 3 OD process air outlet specify Approximate weight 25 lbs 11 3 kg 10 CFM Compressed Air Dryer Chapter 7 Appendix 27 of 30 Dryer Operating Parameters Material Drying Drying Drying Hopper Capacity lbs hr kg hr Temp F time in Initial Final 0 4 cu ft 10 8 cu ft 0 9 cu ft C hours moisture moisture 11 liter 22 liter 25 liter content content drying drying drying H20 in H 0in hopper hopper hopper ABS 176 80 2 3 0 45 0 15 5 6 2 5 11 2 5 1 12 6 5 7 ASA 212 100 3 4 6 2 1 19 2 4 2 10 4 4 7 CA 176 80 2 3 0 7 0 15 5 6 2 5 11 2 5 1 12 6 5 7 CP 167 75 2 3 1 0 0 15 5 6 2 5 11 2 5 1 12 6 5 7 EVA 176 80 2 3 5 6 2 5 11 2 5 1 19 0 4 1 Ionomere 194 90 3 5 4 0 1
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