Sterling SMD SERIES Dehumidifier User Manual
Contents
1. LX Ge SMD Series Dehumidifying Dryers Page 49 wey After each cleaning e Inspect the filter element Briefly hold a light bulb behind the element and look for any fatigued paper or residual dirt Inspect for holes and tears by looking though the filter toward a bright light Check for damaged gaskets or dented metal parts Do not re use a damaged filter e Check the gasket for damage A damaged gasket allows contaminants into the process Replace as needed 8 3 Servicing the Dew Point Monitor The accuracy of the dew point monitor on mini dryer systems depends on proper operation of the dew point sensor and the control board The dew point sensor is in the process air stream and is therefore susceptible to contamination Dew point sensor life depends on e Air temperature and flow passing over the sensor e The amount of fines dust in the process air Once every six months the dryer operator should monitor the initial dew point sensor readings and establish a periodic replacement schedule as needed CAUTION Do not attempt to check the continuity or resistance of the dew point sensor The sensor will be destroyed 8 4 Replacing the Process Heater The SMD Series dehumidifying dryers utilize a single phase Calrod type heater element This heater element is mounted in the center compartment Although the replacement procedure is the same for each heater the wattage varies by model voltage temperature range2. eres STS EES S ele ale ee very wee By By By By By By By By By By By By By Inspectall fiters for T P dora ql worn Pp TT LE LLL LLL LL S LL LL o o Check to make sure that all hose conections are air tight a ee ee ee ee ee ee Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Lock out electrical power and inspect electrical wiring for integrity Lock out electrical power and check heater elements for continuity using an ohmmeter Check dew point and temperature tracking with an external dew point monitor and pyrometer Photocopy this page for your maintenance records p Page 52 SMD Series Dehumidifying Dryers Wm Troubleshooting 9 Process heaters are faulty Ensen tor eo heaters Replace if required Solid state temperature Replace controller faulty Make sure that plant personnel Process temperature was are aware of the proper adjusted in error by plant temperature set point Post an personnel appropriate sign next to the controller Process heaters are faulty Drying systems are designed for the material which was originally specified Different materials may need a longer residence time or a different drying temperature Break in flex hose to drying Inspect for air leaks replace as hopper needed Insufficient power to PLC Check power supply and power PLC Regeneratio
3. If your main concern is loss of productivity remember this Production is always affected in a negative way following an accident The following are some of the reasons which can affect your production e Loss of a skilled operator temporarily or permanently e Breakdown of shop morale e Costly damage to equipment e Down time An effective safety program 1s responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections 1n addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation 2 6 Operator Responsibility Page 16 The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the dryer and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workp
4. ES 30 AAN Operation and Installation Manual SMD Series Dehumidifying Dryers Important Read Carefully Before Attempting to Install or Operate Equipment Part No A0570029 Revision NEW Bulletin No SM1 620 Write down your dehumidifying dryer serial numbers here for future reference Performance figures stated in this manual are based on a standard atmosphere of 59 F 15 C at 29 92 Hg 1 014 millibars at sea level using 60 hz power Altitude is an important consideration when specifying dehumidifying dryers Sterling can advise you on proper selection and sizing of systems for your operating environment Sterling is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice Copyright Sterling Sterling Material Processing 2003 All rights reserved Effective 8 21 2003 Part No A0570029 Revision NEW Bulletin No SM1 620 p Page 2 SMD Series Dehumidifying Dryers Wm Table of Contents we General Information 1 ceci esee eese eene anna nau 9 1 1 Models Covered Jc t 9 1 2 E guUDMSn FUNCION MET 9 1 3 Necessary P eeu pui DNE UT 9 1 4 etc gars ifo mici MU EIC TETTE T E eosueces 10 1 5 eue EU EL T m 10 1 6 iia dra aee SUC QE 12 1 7 obecityirig a Drying SS Ifi ssrt ENEE ini aE dta aue Sm aa 13 Sall Wu esse Is RERERSPIREFRRER
5. Rubber Bumper for the bottom of Dryer A0568023 Swivel Casters without Brakes Pe Swivel Casters with Brakes p Page 58 SMD Series Dehumidifying Dryers Wm Technical Assistance 12 12 1 Contact Information for Technical Assistance MATERIAL PROCESSING we Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 414 354 0970 Fax 414 354 6421 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to Sterling 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 Sterling parts needs and is dedicated to providing excellent customer service MATERIAL PRESS Service Department Call toll free 8am 5pm CST 800 657 4679 or call 414 354 0970 Emergencies after 59m CST call 847 439 5655 Sterling has a qualified service department ready to help Service contracts are available for most Sterling products dy MATERIAL PROCESSING dy Sales Department Call 414 354 0970 Monday Friday 8am 5pm CST Sterling products are sold by a world wide network of independent sales representatives Contact our Sales Department for the
6. 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 overhead 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 non current carrying parts of electrical apparatus electrical component 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 ZZ SMD Series Dehumidifying Dryers Wm 2 8 Safety 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 correctly BEFORE you turn the dryer over to the operator for production verify all
7. ccccccccseccceeceeeeceeaeeeseceseceseeeeseeeeseeeesees 38 5 11 Setting the Redundant Safety Controller cc cccccecceeceeeeeseeeeeeeeeeeseeeeeeeeeeeeaeeeens 38 5 12 Restoring the WATLOW Redundant Safety Controller to Factory Setup 38 SMD Series Dehumidifying Dryers Page 3 Table of Contents 10 11 12 13 Page 4 Control OPCratiOn 1ccccccccecceccencencesseneeseesensensenseecnenaeeaeneees 41 6 1 Controller iru PRU eevee as evade 41 Without Optional Alarm Horn amp Reset Button seeeeeeseeeeeeeeeeee 41 6 2 Controler OporaUGi t T mm m T 42 With Optional Alarm Horn amp Reset Button seseseeseseeeeeereenn 42 6 3 Alarmi Display Messages c 44 Startup Shutdown and Operation 45 1 1 Pre Start p CNECKS MNT 45 1 2 Starting Up the DIY P EE 45 1 3 Shutting Down the Dryer cccccccssceceessecceececceseecseeeceeueessseecsegeessaeeeeseseessaeeessags 46 MN ENAN euis oxatua E EAE RENE ME 47 8 1 NOS NSS E 47 8 2 Servicing Process Air Filters cccccccsecceseeeceeeeeeeeeceeeeceeeesseceseueesaeeeseeeeseeeesaeeeseeeees 47 8 3 Servicing the Dew Point Monitor ccccecccseeceeeeeeeececeeeesaeceseeeeseeeeseeeeseeeeseeeseneeees 50 8 4 Replacing the Process Heattel cccccccssccsecc
8. etc WARNING HAZARDOUS ELECTRICAL CURRENT PRESENT Disconnect and lock out power before you replace cS heater elements p Page 50 SMD Series Dehumidifying Dryers Wm Figure 12 Process Heater Location and Disassembly Undo 6 10 32 Butto Head Screws using 1 8 Allen Wrench 1 Wide x 1 8 Thick High Temperature Gasket H m 2 4 40 screws Hi Temperature Snap Switch Procedures 1 Remove the four 4 10 32 button head screws securing the process heater access cover using a 1 8 Allen wrench 2 Sketch the heater wiring configuration so you can properly re wire the heater 3 Remove the wires to the heater plate assembly being removed or replaced 4 Remove the two 2 4 40 screws securing the heater plate assembly and slide out the assembly 5 Remove the heater from the mounting plate by removing the large brass nuts and washers 6 Re install the heater and heater plate assemblies in reverse order 7 Install new heater gaskets and securely tighten all fasteners CAUTION Heater loops should not touch each other Hot spots lead to premature heater failure 8 Reinstall the wires based on the sketch you made earlier ai SMD Series Dehumidifying Dryers Page 51 Wm uu Preventive Maintenance Checklist Sterling SMD Dehumidifying Dryers System model
9. Limit 2 High Set Alarm 2 Low Limit 1 Set Alarm 2 High Set Limit 3 Low High Set Set Limit 3 High Set Alarm 3 Low Set Alarm 3 High Set 0 no lockout 1 Programming and Setup Page Locked 2 Limit Mode Parameter s _ sSSeettingrange Default Sterling setting SEn SensoTpe o3 Oo inearization CF Temperature Units ss Fahrenheit Celsius F SdEC Temp Decimal Places 0 00 0 y I SEn INFOSENSEE Yes NO No Bl remeron eee ef 1 00 to 10 00V 1 00V 1 00 to 10 00V 5 00 V CAL Calibration Offset 999 00999 0 FtrE IputFiter Off DiSP Cont both OFF Ot Outpt1Funcion Limt2 2 hyS1__ Limit1 Hysteresis 00to9990 10 Ot Output2Funcion Off Process Alarm Limit 2 OFF LSd j Output2Sides Both higp low Boh None Process Value Limit 1 Low Set Limit 1 High Set Limit 2 Low Set Limit 2 High Set Alarm 2 Low susc DUBPSEIISPISN EOD Set Alarm 2 High Set Limit3Low Process Set Limit 3 High Set Alarm 3 Low Set Alarm 3 High Set LdSP Lower Display Look LOC Lockout Set Points are the only Operation Page parameters accesible 3 Full Lockout s p Page 40 SMD Series Dehumidifying Dryers Wm Control Operation 6 6 1 Controller Operation Without Optional Alarm Horn amp
10. Reset Button 1 Turn the disconnect on the control panel to the ON position Power is applied to the voltage line fuses line side of the control power switch and the temperature controller 2 Turn the control power switch to the ON position Power is applied to the programmable relay and dew point controller Note The relay screen which contains the Alarm Display Messages 1s located inside the controller enclosure For a list of Alarm Display Messages see Section 6 3 on Page 44 WARNING Do not attempt to check the Alarms on the Controller located within the unit enclosure unless you are a qualified electrician 3 Once the control power is on and no fault conditions exist turning the OFF ON START switch to the START position will start the dryer as follows 3 1 The process heater is turned on and controlled by the ESCN controller 3 2 The solenoid valve opens and air flows through the dryer 4 If the OMRON controller faults the optional redundant high temperature safety device opens or the process heater safety switch opens a heater fault is generated HIGH TEMP is displayed on the relay screen The alarm horn and light are activated The process heater and solenoid valve are turned off Turn the OFF ON START switch to the START position to deactivate the alarm light and restart the dryer If the fault condition still exists the dryer will not restart 5 If the pressure in the system drops below 15
11. a mode A 5 Press and __ to set the higher or lower the values of a parameter or turn that function On or Off 6 Press o Level Key once to return to the Process Temperature Setting ai SMD Series Dehumidifying Dryers Page 35 Wm Figure 8 Setting List for Process Temperature Controller E5CN Part No A0555757 Mode Parameter Setting range Default Sterling setting Run Stop Run Stop Rm Alarm value 1 1999 to 9999 0 25 Mode Parameter Settingrange _ Default Sterling setting Adjustment AT execute cancel ON OFF FF t OFF Adjustment Temperature input shift 199 9 to 999 9 00 Adjustment Proportional Band 1 to 999 9 80 2833 0 Adjustment Integral Time 0 to 3999 233 Adjustment Derivative Time to 3999 40 9 Process Air Dew Point Display Optional The Process Air Dew Point meter indicates the current process air delivery moisture content Standard Sterling dryers use a microprocessor based controller for displaying dew point air temperature The controller is a modular self contained unit removable from the mounting housing All parameters are factory set and adjusted normally no field adjustment to the internal controls are necessary Page 36 T SMD Series Dehumidifying Dryers Wm Figure 9 Typical Dew Point Display Monitor O O O LI OUT2 MANU STOP RMT L 1 AT OMRON N
12. liable for any incidental consequential or special damages or expenses The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts Any sales use excise or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty Many types of Sterling equipment carry an additional one year service policy Consult your Sterling sales representative for specific details Sterli Page 61 CU SMD Series Dehumidifying Dryers Wm Notes Page 62 T SMD Series Dehumidifying Dryers Wm Safety Tag Information 13 13 1 SMD Dryer Safety Tags Hot Read Operation and Installation Manual High Voltage Earth Ground Inside Enclosure Protected Earth Lifting Point Ground T SMD Series Dehumidifying Dryers Page 63 PROCESSING 13 2 Dryer Identification Serial Number Tag Located on back of Dryer C SMD Series Dryer Model Number SMD 030 Max Drying Capacity HR Serial Number 060701R Date of Manufacture 06 2003 Over current Protection Device s 4 5A Total Frequency 50 60Hz Compressed air supply None Dryer Mass 400 Ibs 180 KG Electrical Diagrams amp Pneumatic Diagram 5200 W Clinton Ave Mi
13. shifted by a set figure preprogrammed by the operator p Page 34 SMD Series Dehumidifying Dryers Wm Proportional Band Mode P P This setting controls the amount in which the manipulated variable MV is proportionate to the deviated value or controller error Integral Time Mode lI Setting this feature gives the control an action that 1s proportionate to the time integral of the control error By using this setting proportional action 1s 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 Derivative Time Mode d setting the derivative control provides the controller with the ability to correct for a future error in the previously set process output Entering Operating Parameters to Select Modes To enter the display 1 Press the Mode Display key to view the Run Stop amp Alarm Modes A 2 Press and Eva to set the higher or lower the values of the parameter or turn that function On or Off The SV readout displays the different values for the parameter within a mode 3 To switch modes within a level press and hold the fe Level Display key for one 1 second The PV readout will display the different parameters within each mode 4 Use short presses on the Mode Display key to display each parameter within a mode The SV readout displays the different values for the parameter within
14. 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 Sterling s discretion If the item is found to be defective in materials or workmanship and it was manufactured by Sterling purchased components are covered under their specific warranty terms p ZZ SMD Series Dehumidifying Dryers Wm 12 3 Warranty Sterling warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions The Company s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the Company s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the Company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned The Company is not
15. the following sections 3 2 Inthe Event of Shipping Damages Important According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment M Notify the transportation company s local agent if you discover damage M Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to Sterling before the transportation company inspection and authorization M File a claim against 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 M Advise Sterling regarding your wish for assistance and to obtain an RMA return material authorization number Page 22 T SMD Series Dehumidifying Dryers Wm 3 3 If the Shipment is Not Complete Check the packing list The apparent shortage may be intentional Back ordered items are noted on the packing list You should have I SMD Series dryer Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings K IR ERIS Component instruction manuals Re inspect the container and packing material to see 1f you missed any smaller items during unpacking Determine that the item was not inadvert
16. 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 p Page 32 SMD Series Dehumidifying Dryers Wm 5 4 Identifying Temperature Controller Keys Mode Key Press the Mode key to shift the display to the next set of parameters The menu screen displays Down Key x lt Press the Down arrow key to lower the process air set point temperature During setup it lets you decrease the value of the parameter displayed on the set point LED readout P uen Up Key o WS Press the Up arrow key to raise the process air set point temperature During setup it lets you increase the value of the parameter displayed on the set point LED readout 5 5 Setting the Process Air Temperature When setting the process air temperature consult with the resin manufacture for the recommended drying temperature To change the process air temperature set point with the dryer running E ow B Press to raise the set point to the temperature you want Os i B Press to lower the set point to the temperature you want ai SMD Series Dehumidifying Dryers Page 33 Wm 5 6 Restoring the E5CN Temperature Controller to Factory Setup 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 t
17. you are a qualified electrician 3 Once the control power is on and no fault conditions exist turning the Off On Start switch to the START position will start the dryer as follows 3 1 The process heater is turned on and controlled by the ESCN controller Page 42 T SMD Series Dehumidifying Dryers Wm 4 If the OMRON controller faults the optional redundant high temperature safety device opens or the process heater safety switch opens a process heater fault 1s generated HIGH TEMP is displayed on the relay screen The alarm light is activated The process heater regen heater and process regen blower are turned off Pressing the ALARM RESET pushbutton will deactivate the alarm horn and light Turn the Off On Start switch to the START position to restart the dryer If the fault condition still exists the dryer will not restart 5 When no fault conditions exist the display reads SYSTEM NORMAL 6 When a dew point fault is generated by the optional dew point controller the alarm light will activate The alarm light will flash indicating a non critical fault Press Alarm Reset to deactivate the alarm until the next dew point fault occurs 7 The dryer is shut off by turning the control power switch to the OFF position 8 Refer to Schematic drawing A0566087 enclosed in the control enclosure P Stering SMD Series Dehumidifying Dryers Page 43 Wm 6 3 Alarm Display Messages Note The relay scre
18. 2 2 1 Work Rules 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 Obey these specific work rules Read and follow the instructions in this manual before installing operating or maintaining any equipment Additional copies are available from Sterling Only qualified persons should work on or with this equipment Work only with approved tools and devices Disconnect and lock out power while working on this equipment 2 2 Tools and Equipment Needed You ll need the following e Hand tools e Fork lift or overhead lift e Wire conduit and fittings for wiring runs if receptacle 1s not already in place e Mounting bolts with nuts and washers 2 3 Mechanical Installation Dryers may be mounted on a stand or a mezzanine Be sure it 1s securely attached and additional bracing is used if necessary The sections on the following pages explain general installation rules Read manual thoroughly before installing dryer Use approved safety straps or chains to lift the dryer at the marked lifting points Page 14 T SMD Series Dehumidifying Dryers Wm 2 4 Safety Considerations The terms NOTICE CAUTION WARNING and DANGER have specific meanings in this manual See Section 13 for a complete list of specific safety warning information A NOTICE is u
19. 483 1250 Watts Heater Element 208 220 Volts A0566484 1250 Watts Heater Element 230 Volts A0566485 1250 Watts Heater Element 400 Volts A0566486 1250 Watts Heater Element 460 Volts A0566487 1250 Watts Heater Element 575 Volts A0566601 2500 Watts Heater Element 208 220 Volts A0566602 2500 Watts Heater Element 230 Volts A0566603 2500Watts Heater Element 400 Volts A0566604 2500 Watts Heater Element 460 Volts 0566605 2500 Watts Heater Element 575 Volts A0566415 jWasher Gasketforthe Heater Elements MINI DRYER SPARE PARTS LIST SMD30 and SMD60 2 CF OCFM LEVEL 3 Electrical Components a SS Ss 30 6 aos spH poc 220v 60 Hz sPH soc 230v 3PH pocr 400V 50 HZ 3PH asov 3PH 575v 60 Hz 3PH zosv sPH oo 220v 60 Hz sPH eoCFM pov sp f 40V 50 Hz 3PH 600FM asov 3PH oocrM 578v 60 Hz sPH socFm A0567921 A0566096 Mitsubishi Programmable Relay Logic Controller Redundant Temperature Safety Controller LEVEL 3 Mechanical Components PART SIZE A0534059 2 O D by 12 Ft Long Hi Temp Hose A0534060 2 1 2 O D by 12 Ft Long Hi Temp Hose W00015335_ DewPointSensorManifold _ A0548558 Gasketforthe Dew Point Sensor WO00015436 Plastic Nut for the Dew Point Sensor A0568022
20. ERERUEENENEETREEEEEREESRFERENSEREREENNSEERDUNEERMEPEEENE 14 2 1 lod dii 14 2 2 Tools and Equipment Needed cccccccscccseecsseceeeceeeecaecceeeseeesaeeseesaueeaueeaeeeseeeses 14 2 3 Mechanical Installation leeseeeeeeeecseeceeeseee nennen nnne nnne nennen nnne nnns 14 2 4 Safety eiusm 15 2 5 General Responsibility c ccsccccseececeseecceeeeccseeseeaeecseeeeseseecseueeeseeeesseneessaeeessags 16 2 6 Operator Responsibility esseeessesssessseeseeennenn nennen nnne 16 2 7 Maintenance ReSponsibllity ccccccccscccececececeeeceeeceeeceeeeceeecauesaeeseuecsueseueseaeesaes 18 2 8 viz S NE P E M 19 Shipping M OV IVICA OV CNET TEE 22 Unpacking and Inspection cccccccescecececseeceeeceeeceeceeeeceesaeecaeesauecsuessuecsueseaessaes 22 3 P In the Event of Shipping Damages sesssesssseeseeeeeennneen nennen 22 3 3 If the Shipment is Not Complete seessesssseessseseseeenneen nnne nnne 23 3 4 If the Shipment is Not Correct cccccceeccceeccce cece ceseeeeeeeceseuceceeeeseueeseeesseeeesaeessaees 23 3 5 BSS ie oretest a t nm iu Ui E ee ately ae see E nsd ease E E OE fate 23 PITS CAH OND 24 4 1 210 S10 c 24 4 2
21. ON switch to START to start the dryer Heaters turn on and solenoid opens 6 Setthe process set point on the temperature controller 7 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 em Page 45 SMD Series Dehumidifying Dryers RE 7 3 Shutting Down the Dryer 1 When processing is complete close the hopper slide gate and shut down any in line companion equipment Turn the Dryer ON OFF selector switch to OFF Turn the system ON OFF switch to OFF If needed empty the drying hopper For maintenance or a long term shutdown open de energize the electrical disconnects at the dryer and at the power drop Page 46 T SMD Series Dehumidifying Dryers Maintenance 6 8 1 Work Rules The installation operation and maintenance of this equipment 1s to be conducted in accordance with all applicable work and safety codes for the installation location This may include but is not limited to OSHA NEC CSA and any other local national and international regulations In addition you must observe the following specific work rules M Keep these operating instructions on hand and follow them when installing operating or maintaining your dryer M If the instructions become damaged or unreadable you
22. PSI for 10 seconds or more the alarm will sound The process heater and solenoid valve will shut off Sterli Page 41 CU SMD Series Dehumidifying Dryers Wm 6 When no fault conditions exist the display reads SYSTEM NORMAL 7 When a dew point fault is generated by the optional dew point controller the alarm horn and light will activate The alarm light will flash indicating a non critical fault Press Alarm Reset to deactivate the alarm until the next dew point fault occurs 8 The dryer is shut off by turning the control power switch to the OFF position 9 Refer to Schematic drawing A0566087 enclosed in the control enclosure 6 2 Controller Operation With Optional Alarm Horn amp Reset Button 1 Turn the disconnect on the control panel to the ON position Power is applied to the voltage line fuses line side of the control power switch and the temperature controller 2 Turn the control power switch to the ON position Power 1s applied to the programmable relay and dew point controller The solenoid will move to the start position as follows 2 1 The solenoid opens and air begins to flow The heaters are also activated Note The relay screen which contains the Alarm Display Messages is located inside the controller enclosure For a list of Alarm Display Messages see Section 6 3 on Page 44 WARNING Do not attempt to check the Alarms on the Controller located within the unit enclosure unless
23. Rigging and Placing the DIiyet cccccecccceeeeeeeeeceeeeseeeeneeeeneueeeeeeeseueesaeeesaeeeseeesaaees 24 4 3 Making Electrical Connections seeesseesssssssseeeenerenn nennen 25 4 4 Making Dryer Drying Hopper Process Air Connections eeeesseseeesssss 26 4 5 Drying Hopper Air Trap Considerations ccccccceceeceseeeceeeecaeeeeeeeeseueessueesseeesaeees 27 CONU OLS aeina rerne riri EA EEE EEEN 29 5 1 Identifying Control Panel Indicator Lights and Switches for Standard Controller 29 5 2 Process Air Temperature Controller ccccccccccccesceceececeeceseeeeceeceseueesaueeseeesneesaaes 31 5 3 Identifying Process Air Temperature Controller LED Indicators 32 5 4 Identifying Temperature Controller Keys ccccceeeeccseeeeeeeeeeeeeseeeseeeeesaeeeeseeeeeseaees 33 5 5 Setting the Process Air Temperature cccccsescccceececceseeecseecseueeceeeeesceneecsaneessens 33 5 6 Restoring the ESCN Temperature Controller to Factory Setup 34 5 7 Process Air Dew Point Display ccccccceeceeeeeeeeeseeeseeeseeeeeeeseeeeseesaeeeseeeseeeseesages 36 5 8 Setting the High Dew Point Alarm seeessesssssseseeeeennnee menn 37 5 9 Restoring the E5CK Dew Point Meter to Factory Setup eeeesesuss 37 5 10 Redundant Safety Controller Display
24. TERIAL SMD Series Dehumidifying Dryers RE 5 8 8 8 8 8 81 8 8 8 LL LL LL O O O O O O co 400V 50 HZ 3PH 30CF 208v 3PH p20v so Hz sPH socr psv aH hocr feo sPH focr prsv eo Hz 3PH aocF 208v 3PH fe p20v so Hz 3PH eocr IL 5 gt z m prc LLL LLL E LLL LA L LL ILLIS ji Lj LS pL LL LL L LE p gg ee eee ee ee ee ee LEE ee LL tf UL EL tf resl anne ae 8 13 3 3 3 3 pot LE OE OE L3 P oL P PL ft ft ft tt Saa EN es a a cs gy lI ee eee LEES ESE a 1L L2 LL LL L2 lj pt 2 2 LE2 2 1 L 2 1 LOL2 5 j Lj 1 1 1 1 1d 1d 1d oo 1 O 2 Page 57 Figure 14 Level 2 amp 3 Spare Parts List Electrical amp Mechanical 2 2 i wl wy O OF OF O MINI DRYER SPARE PARTS LISTSMD30 and SMD60 eo L 3 460V 3PH OCFM co brsv 60 Hz apH noc zoev oeH Bocrw 220v 50 HZ aPH G0CFM 230v oPH eocFm 40v 50 Hz 3PH 60CFM asov aH eocFm 578v co Hz 3PH 60cFM 208V 3PH 220V 50 HZ 3P 230V 3PH 400V 50 HZ 3PH LEVEL 2 Electrical Components PART SIZE 0530042 Mercury Heater Contactor 0567917 Process Air Temperature Controller A0544089 Regeneration Air Temperature Controller A0558065 0505417 Regeneration I Couple Relay LEVEL 2 Mechanical Components A0548621 Ceramic Cap for the End of Heater Elements A0566
25. al controls 1s necessary Figure 7 Typical Temperature Controller Temperature PV display SV display Operation indicators Levelkey Sr T SMD Series Dehumidifying Dryers Page 31 5 3 Identifying Process Air Temperature Controller LED Indicators Process Value Numeric LED During normal operation the process value PV numeric LED indicator displays the process temperature at the To Process thermocouple It also lists parameters during setup and error messages if any errors occur Vim Set Value Numeric LED During normal operation the set value SV numeric LED indicator displays the process set point temperature selected for the dryer The dryer then maintains this set point temperature This LED indicator also displays parameter and pre set function values during configuration setup OUT1 Lit when Control Output 1 is on The Out1 indicator lights when the controller signals the process heaters to be energized OUT2 Lit when Control Output 2 is on Not used in this application AT Flashes during auto tuning in process value PV screen Press and hold the beige Level Key for 1 second when the controller is in default mode and the set value will flash Press the A up and down O keys to set the values ALARM Lights in the Operation Indicator Section when the output function assigned to auxiliary output 1 turns on The ALARM indicator lights when the process temperature exceeds
26. arranty is the responsibility of the purchaser The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty Many types of Sterling equipment carry an additional one year service policy Consult your Sterling sales representative for specific details Stein i f Sterling a gt am MAXIMIZESYOUR PROCESSING POWER PO Box 245018 e 5200 W Clinton Avenue e Milwaukee WI 53224 9518 USA Phone 414 354 0970 e Fax 414 354 6421 http www sterlco com Service Department Call Toll Free 800 783 7835 Sterling Auxiliary Equipment for the Process Industries PO Box 245018 5200 West Clinton Avenue e Milwaukee WI 53224 9518 414 354 0970 e Fax 414 354 6421 e MA amp m ap Scrap Process Heating Automated Material Recovery Systems Cooling Parts Removal Processing
27. can obtain additional copies from Sterling M Only qualified personnel familiar with this equipment should work on or with this unit M Work only with approved tools and devices M Disconnect power before servicing your dryer If the disconnect switch you installed has a lockout lock it in the OFF position before you perform any maintenance or service 8 2 Servicing Process Air Filters Important D Operating the dryer without the process air filter installed voids your warranty Filter cleaning is an important part of your dryer maintenance program SMD dryers have two compressed air filters in the process air system The filters protect the membrane from being contaminated by oil particles Regular filter cleaning is essential to keep your dryer operating at peak efficiency ai SMD Series Dehumidifying Dryers Page 47 Wm Recommendations for Cleaning and Replacing Filters Turn off and or lock out electrical power to the dryer 2 Remove the back access cover 3 Locate the 2 compressed air hoses and filter bowls connected to the filters AM NING 4 Remove the filter bowls LX CZ SMD Series Dehumidifying Dryers Page 48 wes 5 Locate filters 6 Remove the filters 7 Replace particulate filter with new element 8 Replace coalescing filter with new element e Reassmble in the opposite order of disassembly Important i DO NOT clean wash filter with water
28. dryer enclosure panels guards and safety devices are in place and functioning properly 2 8 1 Description and Objectives This section includes information on safety devices and procedures that are inherent to the SMD 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 1s recommended to supplement these procedures in order to provide a safer working environment At the completion of this section the operator and maintenance personnel will be able to e Identify and locate specific safety devices e Understand the proper use of the safety devices provided e Describe the function of the safety devices 2 8 2 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 the 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 SMD Dryer however it 1s the responsibility of the personnel opera
29. e no frequent repetitive cycles that require manual control repetitive functions are automatic while the dryer is operating An inspection report detailing the functional test is included with the dryer The machine is not equipped with cableless controls Color coded harmonized power cord is sufficient for proper installation CU SMD Series Dehumidifying Dryers Page 7 Wm Charts and Figures 1 Typical SMD Dryer Components 11 2 Typical Dryer Air Flow Schematic 12 3 SMD Series Floor Mount Dimensions 13 4 Suggested Lift Rigging for SMD Dryers Floor Mount 25 D Dryer Hose Connections to Hopper 26 6 Typical Control Panel 30 M Typical Temperature Controller 31 8 Setting List for Process Temperature Controller 36 9 Typical Dew Point Display Monitor 37 12 process Heater Location amp Disassembly St Page 8 ED SMD Series Dehumidifying Dryers Wm General Information 1 1 1 Models Covered This manual provides instructions for installing and operating Sterling SMD30 and SMD60 membrane dryers The number designation represents air flow capacity SMD30 models have a 30 cfm air flow capacity and SMD60 models have a 60 cfm capacity 1 2 Equipment Function Sterling membrane mini dryers are designed to generate heated dehumidified air at carefully controlled temperatures for use in plastic drying systems Drying systems are sized to meet the specific requirements stated by the purchaser at the time of purchase Moisture remo
30. eeccceeccaecceeecsecegeeaueecseesueecaeecaeessensaees 50 Troubleshooting cessestuedinenkikt ie REREREEFERERENUEFRFETEEESERUKEK EPI NE o3 Dryer OG ONS sirin orrn EE E EE EEE EENES 56 Spare mt ghee eee 57 ju opare Pans ee EEE nee ee eee eee eee 57 Technical ASSISTANCE 1 csccsensecesccnecnncnnsnensescenensennsannees 59 12 1 Contact Information for Technical Assistance cccccccecceceecceeeeeeeeeeaeeeeeeeeeaeeeeaaees 59 12 7 Returned Material Policy oenttno ctu ite ta oo ac uxo auo vU nvanswensldensyancedenuxedcustbsavebencedteineds 60 MES oe ee een ea eee ees 61 Safety Tag Information 1 eee eere e eren nnns 63 13 1 SMD Dryer Safety Tags cece ccccccccsseeecesseeceeeesaseeeceseceeeeecaseeseeeesseueessasesssanees 63 13 2 Dryer Identification Serial Number Tag ccccsecccceeeceeeeeeeeseeeeeeeeeeesaeeeeseeeeeseeees 64 SMD Series Dehumidifying Dryers Wm Safety Considerations Sterling SMD Series membrane dryers are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personnel injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices Mi Mi Mi Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Disconnect and or lock out power befo
31. en which contains the Alarm Display Messages is located inside the controller enclosure WARNING Do not attempt to check the Alarms on the Controller located within the unit enclosure unless you are a qualified electrician The following is a list of Alarm Display Messages which can be found on the relay screen Temperature Controller Alarm and or Regen Heater Temp Switch and or HIGH TEMP Process Heater Temp Switch and or FAULT Redundant Temp Safety Insufficient Air Pressure to Run Unit Alarm AIR PRES SW Multiple Alarms HIGH TEMP FAULT No Alarms SYSTEM NORMAL Page 44 T SMD Series Dehumidifying Dryers Wm Startup Shutdown and Operation 7 7 1 Pre Startup Checks M Check the process hose for tight connections M Check hopper exhaust filter for tight connection M Check all companion equipment such as the drying hopper verify that the loading system is ready for operation M Verify that all dryer electrical connections are tight Important e Clean the rust preventing oil from inside the drying hopper ey Failure to clean the hopper fouls the desiccant and voids your warranty 7 2 Starting Up the Dryer 1 Turn on energize the disconnect switch in your power drop then turn on the one on the dryer 2 Turn the system ON OFF switch to ON to energize the display panel 3 Close the slidegate at the bottom of the drying hopper 4 Fill the drying hopper with material 5 Turn the dryer
32. ently taken from the area before you checked in the shipment Notify Sterling immediately of the shortage 3 4 If the Shipment is Not Correct 3 5 Returns Important P m If the shipment is not what you ordered contact Sterling immediately For shipments in the United States and Canada call 1 414 354 0970 for all other countries call 001 414 354 0970 Include the order number and item Hold the items until you receive shipping instructions Do not return any damaged or incorrect items until you receive shipping instructions from Sterling SMD Series Dehumidifying Dryers Page 23 Installation 4 1 Work Rules The installation operation and maintenance of this equipment must be conducted in accordance with all applicable work and safety codes for the installation location This may include but is not limited to OSHA NEC CSA and any other local national and international regulations Read and follow these operating instructions when installing operating and maintaining this equipment If the instructions become damaged or unreadable you can obtain additional copies from Sterling Only qualified personnel familiar with this equipment should work on or with this dryer Work with approved tools and devices Disconnect the electricity before maintenance or service If the dryer is installed with a power cord that can be unplugged unplug it If the dryer is permanently wired to a powe
33. hile the lower display indicates the High Point Setting alarm value The factory setting for the High Point Alarm Value Z A is 150 F 23 C 8 8 5 12 Restoring the WATLOW Redundant Safety Controller to Factory Setup Page 38 If the preset parameters on the controller have been tampered with and it no longer functions properly call the Service Department at Sterling This controller is not meant to be modified T SMD Series Dehumidifying Dryers wey WATLOW Operating Parameters The WATLOW controller has only one mode selection ALARM The factory at Sterling sets the security level to protect the critical parameters from being accidentally changed Below is an explanation of the modes you will have access to and the Sterling default settings Entering Operating Parameters to Select Modes Sim To enter the display 1 Press both the Up CJ and Down J keys for three seconds from the home page The word SEE will appear in the upper display and PAGE will appear in the lower display 2 Press the Advance Key 1 d prompts to move through the parameter 3 Press the Up CJ or Down J keys to change the parameter value 4 Press the RESET Key at any time to return to the Home Page display Ur SMD Series Dehumidifying Dryers Page 39 Wm Figure 11 Setting List for Redundant Safety Controller WATLOW Part No A0555757 None Process Value Limit 1 Low Set Limit 1 High Set Limit 2 Low Set
34. ier 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 a 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 2 Typical Dryer Air Flow Schematic Humid Air mz Purge Page 12 T SMD Series Dehumidifying Dryers Wm Figure 3 SMD Series Floor Mount Dimensions 1 7 Specifying a Drying System 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 Sterling can advise you on necessary equipment and process time and temperature modifications required for your system E gt SMD Series Dehumidifying Dryers Page 13 ey Safety
35. lace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment ZZ SMD Series Dehumidifying Dryers Wm ONLY YOU can make safety work for you by constantly thinking about what is safe and what 1s not It is often the just once that an operator reaches into a dryer to remove material and it results in serious injury Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person REMEMBER e NEVER place your hands or any part of your body in any dangerous location e NEVER operate service or adjust the dryer without appropriate training and first reading and understanding this manual e NEVER try to pull material out of the dryer with your hands while it is running e Before you start the dryer check the following e Remove all tools from the dryer e Besure no objects tools nuts bolts clamps bars are laying in the hopper area e f your dryer has been inoperative or unattended check all settings before starting the unit e Atthe beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly e Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration 1s not only unsafe but will void the warran
36. ll a fused disconnect with a lockout feature in the power main leading to the dryer M The power drop must include a ground wire SMD Series Dehumidifying Dryers Page 25 SMD30 and SMD60 Electrical Schematics Refer to your Customer Information Packet on actual drawings for your specific dryer 4 4 Making Dryer Drying Hopper Process Air Connections Floor Mount Models M Use high temperature flexible dryer hose or rigid tubing to connect the dryer to the drying hopper M Keep the delivery hose to the drying hopper as short as possible to minimize heat loss We strongly recommend insulated hose for maximum energy savings M Make sure that hoses are not kinked or collapsed M 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 M Clamp hose adaptor onto dryer with hose clamps provided M Clamp hopper hose adaptor to hopper with clamp provided Figure 5 Dryer Hose Connections to Hopper d cU Page 26 T SMD Series Dehumidifying Dryers Wm 4 5 Drying Hopper Air Trap Considerations Sterling s exclusive air trap assembly on the top of the drying hopper prevents ambient air from contaminating the material being dried M Keep the material level at the mid point of the air trap for the dryer to operate efficiency M Use a hopper loader or vacuum conveying
37. lwaukee Wisconsin USA 414 354 0970 Page 64 T SMD Series Dehumidifying Dryers Wm Service Notes T SMD Series Dehumidifying Dryers Page 65 PROCESSIN Service Notes Page 66 T SMD Series Dehumidifying Dryers Wm Sterling warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions The Company s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one 1 year of equipment shipment to the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty This warranty does not apply to any equipment which in the Company s opinion has been subjected to misuse negligence or operation in excess of recommended limits or which has been repaired or altered without the Company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned The Company is not liable for any incidental consequential or special damages or expenses The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts Any sales use excise or other tax incident to the replacement of parts under this w
38. mal and the sensor 1s probably broken short circuited or incorrectly wired Other service problems or questions can be answered by contacting the Sterling Service Department ai SMD Series Dehumidifying Dryers Page 55 Wm Dryer Options 10 The following is a list of options which your Dryer may have been equipped with Dew Point Monitor Audible Alarm with Silence Button High Temperature Option with Aftercooler Casters AP1 PLC Control System Page 56 T SMD Series Dehumidifying Dryers Wm 11 Spare Parts 11 1 Spare Parts List SMD Series Dehumidifying Dryers Figure 13 Level 1 Spare Parts List Electrical amp Mechanical MINI DRYER SPARE PARTS LISTSMD30 and SMD60 LEVEL 1 Electrical Components 0534042 6 Fuse forthe Heater Elements A0534044 8 Fuseforthe Heater Elements LEVEL 1 Mechanical Components W00015435 Dew Point Sensor Insert Cable A0548556 Dew Point Sensor A0568459 CoalescingFillerElement A0568458 Particulate Air FilterElement_ 0566859 Membrane Air Dryer 00 W00013983 High Temperature Gasket A0566676 High Temperature SnapSwitch A0568009 Pressure Switch A0556547 jSolinid Valve O A0566682 Dew Point Sample Hose 1 4 O D Teflon Tube A0568008 Compressed Air Hose MA
39. n Bed LED Power LED is off wiring to PLC Faulty PLC PLC Power light is on Run wl is off and or Error Replace PLC light is on Process air in high temperature e one condition PLC Regeneration Heater Insufficient power to PLC Check power supply and power Left Right output indicators both Power light is off wiring to PLC off Faulty PLC PLC Power light is on Run dy is off and or Error Replace PLC light is on Loss or reduction of process air temperature Material being dried differs from Loss or reduction in drying material specified at the time of capacity purchase indicators both off MATERIAL CU SMD Series Dehumidifying Dryers Page 53 Wm Problem Possible cause Corrective action Check resin manufacturer s data sheet for proper drying Process temperature set too temperature Make sure plant high due to operator error personnel are aware of the correct process temperature set point High temperature alarm not set mE l Reset high temperature alarm Material in drying hopper cakes properly or meltdown occurs Process set point is out of Restore temperature controller acceptable range to factory pre sets Function set for degrees Celsius C set point at degrees Fahrenheit F Verify correct Celsius or Fahrenheit settings Verify that the thermocouple is Process thermocouple not in l l l properly installed in the inlet airflow tube Leaking process ai
40. name of the sales representative nearest you MATERIAL PRESS Contract Department Call 414 354 0970 Monday Friday 8am 5pm CST Let Sterling install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations dy Tex Sterling Sterling 5200 W Clinton Ave A em Milwaukee WI 53223 mm O 414 354 0970 e Fax 414 354 6421 MAXIMIZEVOURIPROCESSING POWER LX Ge SMD Series Dehumidifying Dryers Page 59 Wm 12 2 Returned Material Policy Page 60 12 2 1 Credit Returns Prior to the return of any material authorization must be given by Sterling ARMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from Sterling returned 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 12 2 2 Warranty Returns Prior to the return of any material authorization must be given by Sterling ARMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be
41. o the factory setup Call the Service Department at Sterling for detailed instructions E5CN Operating Parameters The E5CN controller has several mode selections Within each mode are numerous parameters that can be set The factory at Sterling sets the security level to protect the critical parameters from being accidentally changed Below 1s an explanation of the operating modes you will have access to and the Sterling default settings Available E5CN Modes Operation Level Run Stop Mode r S When RUN is selected the control is running When STOP is selected the control 1s stopped When the control 1s stopped the STOP display lights The default is set to RUN Alarm Value 1 Mode AL 1 This setting 1s used to indicate how many degrees the process temperature will be allowed to exceed the set point temperature An alarm output will de energize the heaters Adjustment Level Auto Tune Mode At This feature 1s used to automatically set the optimum PID parameters proportional band integral time and derivative time for the set point value by changing the variables which had been modified previously Note Although the controller is calibrated at the factory Sterling recommends that the unit be Auto Tuned prior to dryer startup Temperature Input Shift Mode TnS This setting is used to offset an error between the set point and the actual temperature The entire input range is
42. o this equipment that could alter the CE compliance Ambient temperature 40 degrees Celsius Maximum 104 degrees Fahrenheit Humidity range 50 relative humidity Altitude Sea level Environment Clean dust free and non explosive Radiation None Vibration Minimal i e machine mounting Allowable voltage fluctuation 10 Allowable frequency fluctuation Continuous 1 Intermittent 2 Nominal supply voltage 460 3 60 Verify on serial number tag 11 Earth ground type TN system has one point directly earthed through a protective conductor Power supply should include a ground connection Over current protection is supplied in the dryer but additional protection should be supplied by the user The door mounted disconnect serves as the electrical disconnect device Dryer is not equipped with local lighting Functional identification Dryer is equipped with a CE mark Dryer is supplied with an operating manual in the language of the destination country Cable support may be required for power cord depending on final installation No one is required to be in the interior of the electrical enclosure during the normal operation of the unit Only skilled electricians should be inside the enclosure for maintenance Doors can be opened with a screwdriver but no keys are required Two hand control is not required or provided All dryers should be moved around and set in a place with a lift truck or equivalent There ar
43. ote The only functional buttons on this contoller are the up and down keys 5 8 Setting the High Dew Point Alarm The high dew point alarm setting 1s changed by pressing the up and down keys to input the alarm value The factory setting for Alarm Value 1 AL is 10 F 23 C 5 9 Restoring the E5CK Dew Point Meter to Factory Setup If the preset parameters on the controller have been tampered with and it no longer functions properly call the Service Department at sterling This controller is not meant to be modified Note The dew point alarm monitors and indicates a deviation from the set point SMD Series Dehumidifying Dryers Page 37 9 10 Redundant Safety Controller Display Optional The Redundant Safety Controller limits the process air temperature from exceeding the upper temperature range set by the ESCN Temperature Controller Standard Sterling dryers use a microprocessor based controller for limiting the process air temperature The controller is a modular self contained unit removable from the mounting housing All parameters are factory set and adjusted normally no field adjustment to the internal controls are necessary Figure 10 Typical Redundant Safety Controller Display 5 11 Setting the Redundant Safety Controller The Redundant Safety Controller alarm setting is changed by pressing the up and down keys to input the alarm value The upper display reading indicates the Process Value w
44. pensating lead wires and terminals Use a dedicated thermocouple Thermocouple and controller are connector If a connector is a connected by wires other than metal different from the proper lead wires thermocouple and controller a temperature error may result Sensor is broken or short circuited Replace with a good sensor Process value is abnormal or Process thermocouple not in Verify that the thermocouple is not obtained AON uud installed in the inlet l tube Separate input wires as far as possible from the origin of the noise Check Mode selector switch 6 The controller is influenced by noise or other induction Celsius temperatures used instead of Fahrenheit or vice e ON F ersa e OFF C Process value shifted because Set input shift value to 0 or set the input shift function is used mode selector switch 4 to OFF Determining Temperature Controller Errors or Sensor Errors Using a Thermocouple If the controller displays a temperature that is close to room temperature 70 F 21 C when you short circuit controller input terminals the controller is normal and the sensor is probably broken short circuited or incorrectly wired Using a Platinum Resistance Thermometer If the controller displays a temperature of about 0 0 C 32 F when you insert a 100 ohm resistor between terminals A and B of the controller and you short circuit controller terminals B and B the controller is nor
45. pneumatic i e compressed air sources prior to servicing or cleaning any Dryer including all SMD units Failure to do so may result in serious injury At no time must anyone remove the lockout or reconnect the twist plug other than the person who installed the lockout or who unplugged the twist plug 2 8 5 Lock Outs Plugs and Other Safety Devices WARNING 100 97 LM Page 20 The SMD Dryer utilizes several types of safety devices The Line Cord Plug This 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 Disconnect both of these items to ensure optimum maintenance personnel safety when cleaning or servicing this equipment p ZZ SMD Series Dehumidifying Dryers Wm Notes LX Ge SMD Series Dehumidifying Dryers Page 21 Wm Shipping Information 3 3 1 Unpacking and Inspection You should inspect your Sterling dehumidifying dryer for possible shipping damage If the container and packing materials are in re usable condition save them for reshipment if necessary 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 case of breakage damage shortage or incorrect shipment refer to
46. r hoses Repair or replace Dryer operates beyond its Check dryer and drying hopper capacity sizing manifold flow freely through sensor Coalescing filter saturated Replace with new element Large particle filter dirty Replace with new element Membrane contaminated Replace The internal mechanism is not inserted properly into the housing The power supply is not Properly connect the power connected to its terminals supply to the power supply properly terminals No power is supplied or the Supply a voltage of 85 to 125 supplied power is not within the VAC to the power supply specified range terminals of the controller Check control power fuse for continuity Turn disconnect switch and control power switch ON No setting change possible on The key protection switch is set Set the key protection switch to temperature controller to ON OFF Properly insert the internal mechanism into the housing Nothing displays when the controller is turned on Disconnect switch or Control Power switch not set to ON Control Power fuse blown ENI Page 54 P SMD Series Dehumidifying Dryers Wm Problem Possible cause Corrective action Inout polarity on thermo couple l UPATE y sii p Properly wire the terminals is wrong or connection is wrong Input type setting is incorrect A a A e M QE l input type selector rotary switch No compensating lead wires used for extension of the thermocouple Use proper com
47. r main you must install a fused power disconnect to allow the disconnect to be locked in the OFF position Open and lock out the disconnect installed in the control enclosure 4 2 Rigging and Placing the Dryer Page 24 Take care when rigging and placing the dryer Figures 4A and 4B on the following pages show a suggested safe rigging diagram It lets you lift the dryer hopper unit vertically Adjust chain lengths at the center sling bracket before you lift the unit Your dryer has built in lifting lugs L SMD Series Dehumidifying Dryers Wm CAUTION e Use caution and observe safety rules when lifting and placing your dryer Figure 4 Suggested Lift Rigging for SMD Dryers Floor Mount USE Overhead Crane USE FORK LIFT TRUCK Note Floor Mounted Dryers can be lifted by hoist or fork lift 4 3 Making Electrical Connections M The serial tag lists voltage phase and amp draw information M Line voltage must be within plus or minus ten percent 10 of the voltage listed on the serial tag or damage may occur Phase imbalance must be less than two percent 2 M Fulfill all national state and local safety and electrical code requirements M A qualified electrician should make all electrical connections IS Make sure all electrical connections are tight M Connect main power to the dryer at the disconnect or terminals in the upper right corner of the control enclosure M Insta
48. re servicing or maintaining the dryer Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on this equipment It is a good idea to remove the fuses and carry them with you Make sure the dryer and components are properly GROUNDED before switching on power Do not jump or bypass any electrical safety control Do not restore power until all tools test equipment etc have been removed and the dryer and allied equipment are fully reassembled Only PROPERLY TRAINED personnel familiar with the information within this manual should work on this equipment CU SMD Series Dehumidifying Dryers Page 5 we STERLING SMD Series Membrane Dryers This dryer is manufactured by ACS Inc at the ACS Wood Dale facility ACS Inc 800 N Wood Dale Rd Wood Dale IL 60191 Phone 630 595 1060 Fax 630 595 6641 The equipment is distributed in Europe by our European facility ACS EUROPE Daniels Industrial Estate BATH ROAD Stroud Gloucestershire England GL5 3TJ Phone 44 1453 768980 Fax 44 1453 768990 p Page 6 SMD Series Dehumidifying Dryers Wm Annex B Information The following design information is provided for your reference O eee OD UL a c 9 m 12 13 14 15 16 17 18 19 20 2k 22 23 24 25 26 2 No modifications are allowed t
49. sed to indicate a statement of company policy directly or indirectly related to the safety of personnel or protection of property A CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury We A WARNING indicates a potentially hazardous situation which if 3 not avoided could result in death or serious injury A DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury This word will be limited to the most serious situation s The term IMPORTANT emphasizes areas where equipment damage could result or provides additional information to make a step or procedure easier to understand Disregarding information marked IMPORTANT would not be likely to cause personal injury REPORTING A SAFETY DEFECT NOTE If you believe that your equipment has a defect which could cause injury you should immediately discontinue its use and inform sterling at our address listed in this manual The principle factors which can result in injury are l Failure to follow proper operating and clean out procedures 1 e lockout tagout 2 Failure to maintain a clean and safe working environment P Stering SMD Series Dehumidifying Dryers Page 15 Wm 2 5 General Responsibility NO MATTER WHO YOU ARE Safety is important Owners operators and maintenance personnel must realize that every day safety is a vital aspect of their jobs
50. system to maintain the proper material level Notes SMD Series Dehumidifying Dryers Page 27 Notes Page 28 T SMD Series Dehumidifying Dryers Wm Controls 5 5 1 Identifying Control Panel Indicator Lights and Switches for Standard Controller Switches System OFF ON START Switch The OFF ON START switch energizes or de energizes control power to the indicator panel and starts the dryer The controller can be energized without the dryer running Optional Alarm Silence Switch Press the ALARM SILENCE switch to silence the horn when a high temperature process regeneration or blower failure alarm activates Indicator Lights Alarm Light This feature works in conjunction with the alarm horn to warn the operator of a high bed safety temperature a regeneration heater fault or a blower failure This warning 1s reset by pressing the alarm silence button SMD Series Dehumidifying Dryers Page 29 Figure 6 Typical Control Panel DRYER CONTROL ALARM HORN ON Page 30 T SMD Series Dehumidifying Dryers wey 5 2 Process Air Temperature Controller Sterling dryers use a microprocessor based PID temperature controller for maintaining process air temperature The controller is a modular self contained unit 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 intern
51. ting and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices ai SMD Series Dehumidifying Dryers Page 19 Wm 2 8 3 Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue For example if a safety switch is guarding a motor and the safety switch fails the motor should not be able to run 2 8 4 Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are utilized on SMD models are primarily concerned with the pneumatics and electrical power disconnection and the disabling of moving parts that may need to be accessed during the normal operation of the machine Some of the safety devices utilize a manual activator This 1s the method of initiating the safety lock out This may be in the form of a plug disconnect plug lever or a handle Within this lockable handle there may be a location for a padlock Personnel servicing the equipment should place a padlock in the lockout handle WARNING Always disconnect and lockout all electrical power and
52. ty on your equipment e When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting e Report the following occurrences IMMEDIATELY e unsafe operation or condition e unusual dryer action e leakage e improper maintenance e NEVER stand or sit where you could slip or stumble into the dryer while working on it e DO NOT wear loose clothing or jewelry which can be caught while working on a dryer In addition cover or tie back long hair P Stering SMD Series Dehumidifying Dryers Page 17 Wm e Clean the dryer and surrounding area DAILY and inspect the machine for loose missing or broken parts e 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 2 Maintenance Responsibility Page 18 Safety 1s essential to the good health of both operator and machine If you are a maintenance worker you must make safety a priority in order to effectively repair and maintain equipment BEFORE REMOVING ADJUSTING OR REPLACING PARTS ON A MACHINE REMEMBER TO DO THE FOLLOWING e TURN OFF all air and electric supplies and all accessory equipment at the machine e DISCONNECT AND LOCK OUT electrical and pneumatic power and attach warning tags to the disconnect switch and air shutoff valve
53. val from hygroscopic moisture attracting plastic pellets is an essential step in the manufacture of high quality plastic products Sterling dehumidifying dryers are used to generate very low dew point air heated to a controlled temperature for drying plastic pellets and regrind 1 3 Necessary Documents The documents listed below are necessary for the operation in stallation and maintenance of Sterling SMD30 through SMD60 dryers Additional copies are available from Sterling Familiarize the appropriate personnel with these documents M This manual M The schematic and assembly drawings included in the customer information packet M The Customer Parts List included in the information packet M Operation and installation manuals for any optional controls or auxiliary equipment in the drying system ai SMD Series Dehumidifying Dryers Page 9 Wm 1 4 Standard Features M Electrical solenoid valve Drying temperature range of 160 F to 400 F Mitsubishi programmable relay controller M M M Display of process temperature set point and actual settings M Process thermocouple to be connected to drying hopper air inlet M Nema 12 control enclosure 1 5 Options NFPA79 machinery electrical standards Non fused electrical disconnect Branch fusing Mercury process heater contactor Regeneration temperature control Process high temperature alarm light Process regeneration heater box High temperature safety s
54. ystem Process Regeneration Options can tailor your Sterling dehumidifying dryer to meet the exact requirements of the drying task being performed M Process temperature up to 400 F or below 160 F including pyrex sight glass and silicone insulated delivery hose M Drawer magnet stainless steel construction M Casters two 2 fixed and two 2 swivel Page 10 ZZ SMD Series Dehumidifying Dryers Wm Figure 1 Typical SMD Dryer Components Standard Air Filter X Heater Box Pressure Membrane Switch Dryer Pressure Gage Solenoid Valve 4 Compressed Air Inlet Large Particle Filter Coalescing Filter 0 01 Micron Optional Dust Collector SMD Series Dehumidifying Dryers PROCESSING Page 11 1 6 The Drying System Sterling Membrane Compressed air 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 force to remove the moisture with the minimum purge required The Moisture Vent Compressed Air 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 performs the actual water vapor from air separation This second coating allows air to pass through it over 20 000 times eas
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