Sterling SDA Series 25-100 15 cfm manual

SDA Series 25-100 (15, 30, & 60 cfm) Compact Dehumidifying Dryers Part Number: 882.00291.0 0 Bulletin Number: DH1-635.3 Effective: 05-15-07 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ __________________[...]

15, 30, & 60 cfm Compact Dryers 2 Shipping Information Unpacking and Inspection You should inspect your dryer for possible shipping damage. Thoroughly check the equipment for any dam age th at might have occurred in transit, such as broken or loose wiring and components, l oose hardware and mounting screws, etc. In the Event of Shipping Damage [...]

15, 30, & 60 cfm Compact Dryers 3 Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in this Manual ...................................................[...]

15, 30, & 60 cfm Compact Dryers 4 Identifying Control Panel Indicator Lights and Switches for the Standard Controller .......... 20 Process Air Temperature Controller .................................................................................... 21 Setting the Process Air Temperature........................................................[...]

15, 30, & 60 cfm Compact Dryers 5 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your drying system. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective main tenance. N[...]

15, 30, & 60 cfm Compact Dryers 6 1-2 Safety Tag Information Dryer Safety Tags Hot! Read Operation a n d I n s t a l l a t i o n M a n u a l High Voltage Earth Ground Inside Enclosure PE Protected Earth Lifting Point Ground 1-3 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated [...]

15, 30, & 60 cfm Compact Dryers 7 ; When welding or brazing in or around this equipment, make sure VENTILATION is ADEQUATE . PROTECT adjacent materials fro m flame or sparks by shielding with sheet metal. An approved FIRE EXTINGUISHER should be clo se at hand and ready for use if needed. ; Do not restore power until you remove all tools, test e[...]

15, 30, & 60 cfm Compact Dryers 8 The operator’s responsibility does not end with e fficient production. The operator usually has the most daily contact with the equipment 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[...]

15, 30, & 60 cfm Compact Dryers 9 • Shut off power to the dryer when it is not in use. T urn the switch to the OFF position, or unplug it from the power source. Maintenance Responsibility Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety a priority to effectively repair and maintain equipment. Be[...]

15, 30, & 60 cfm Compact Dryers 10 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d maintenance instructions for 1 5, 30 and 60 cfm dehumidifying dryers. Model num bers are listed on the serial tag. Make sure you know the model and serial number of your equipment before conta[...]

15, 30, & 60 cfm Compact Dryers 11 Figure 1: Typical Dryer Air Flow Schematic 2-3 Standard Features Mechanical Features • Dual desiccant beds • Electrically-actuated air valve • 13X Molecular Sieve • Single regenerative process blower • Drying temperature range of 180ºF to 230ºF (82 ºC to 110ºC). • 2.5” hose connections Electr[...]

15, 30, & 60 cfm Compact Dryers 12 • Mercury process heater contactor • Process high temperature alarm light • Process/regeneration heater box • High temperature safety system (Process/Regeneration) Controller Features • Mitsubishi programmable relay controller • Display of process temperature set point and actual settings 2-4 Optio[...]

15, 30, & 60 cfm Compact Dryers 13 Safety Circuit Standards Safety circuits used in industrial systems protect the o perator 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 establis hment of safety standards that a[...]

15, 30, & 60 cfm Compact Dryers 14 Chapter 3: Inst allation 3-1 Uncrating the Equipment Dehumidifying Dryers are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 1. Pry the crating away from the skid. Note: Remove the nails holding the box to the skid and lif t the box off carefully; avoiding staples i[...]

15, 30, & 60 cfm Compact Dryers 15 Figure 2: Suggested Lift Rigging for Cart Mount Dryers Caution! Do not use a hoist to move or rig your Drying/Conveying System when it is mounted on a cart! Moving the unit with a hoist will cause it to become unstable and may cause damage to the equipment and/or injury to personnel! Figure 3: Suggested Lift R[...]

15, 30, & 60 cfm Compact Dryers 16 Figure 4: Suggested Lift Rigging for Machine Mounted Dryers Caution! When using a hoist to move a machine mounted dryer, ALWAYS attach chains to the three (3) locations/lifting points on the unit! Moving the Dryer without the chains attached to all of the lifting points will cause the unit to become unstable a[...]

15, 30, & 60 cfm Compact Dryers 17 3-4 Setup Procedures This section provides the procedures necessary fo r configuring your Dehumidifying Dryer. Configuration of your dryer includes checking for pr oper blower rotation, making dryer/drying hopper process air connections and the optional aftercooler (on 15 a nd 30 cfm models). We recommend that[...]

15, 30, & 60 cfm Compact Dryers 18 Drying Hopper Air Trap Considerations Our exclusive air trap assembly on the top of the drying hopper prevents am bient air from contaminating the material being dried . To ensure that your unit will operate at peak efficiency, do the following: • Keep the material level at the mid point of the air trap This[...]

15, 30, & 60 cfm Compact Dryers 19 trapped air from the system. Make sure the aftercooler has the proper supply water temperature. 6. Set the process set point on the temperature controller. 7. After the proper pre-drying time for the in itial hopper fill has elapsed, fully open the drying hopper slide gate. Note: To allow proper residence time[...]

15, 30, & 60 cfm Compact Dryers 20 Chapter 4: Operation 4-1 Controller Description and Operation Identifying Control Panel Indicator Lights and Switches for the Standard Controller Switches Main Power. This switch allows the dryer to receive power from the main power supply (3 phase only). Dryer Control ON/OFF Switch. This switch energizes or d[...]

15, 30, & 60 cfm Compact Dryers 21 Optional Controller – Optional Three Phase Control Panel shown with Optional Dew Point Monitor Process Air Temperature Controller Our dryers use a microprocessor-based PID temp erature controller for maintaining process air temperature. The controller is a modular, self-contained unit you c an remove from th[...]

15, 30, & 60 cfm Compact Dryers 22 Identifying Process Air Temperatu re Controller LED Indicators Indicator Name Description PV 8.8.8.8 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[...]

15, 30, & 60 cfm Compact Dryers 23 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: • Press to raise the set point to the temperature you want. • Press to lower the s[...]

15, 30, & 60 cfm Compact Dryers 24 Indicator Name Description preprogrammed by the operator. Proportional Band Mode (P) This setting controls the amount in which the manipulated variable ( MV) is proportionate to the deviated value or controller error. Integral Time Mode (I) Setting this feature, gives the control an action that is proportionat[...]

15, 30, & 60 cfm Compact Dryers 25 Figure 7: Settings for Process Temperature Controller (E5CN), Part No. A0567917 Mode Parameter Setting range Default Manuf. setting Run/Stop Run/Stop Run - Operation Alarm value 1 -1999 to 9999 0 25 Mode Parameter Setting range Default Manuf. setting AT execute/cancel ON, OFF OFF Various Temperature input shif[...]

15, 30, & 60 cfm Compact Dryers 26 Note: The dew point alarm monitors and indicates a deviation from the set point. 4-2 Dryer Operation Procedures Controller Operation 1. Turn the disconnect (if applicab le) on the control panel to the ON position. Power is applied to the voltage line fuses, line side of the control power switch. 2. Turn the co[...]

15, 30, & 60 cfm Compact Dryers 27 4. If either the left or right bed safety temperature switch opens, a regen heater fault is generated. “HIGH TEMP” is displayed on the relay screen. The alarm light is activated. 5. If the process temperature controller faults or the process heater safety switch opens, a heater fault is generated. “HIGH [...]

15, 30, & 60 cfm Compact Dryers 28 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 Process Heater Temp Switch and/or Redundant Temp Safety and/or the blower pressure switch is not detecting pressure. Valve Motor Time-Out Blower Overload[...]

15, 30, & 60 cfm Compact Dryers 29 Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule The checklist below contains a list of items wh ich should be inspected and/or replaced to keep your Portable Drying/Conveying System operating at peak efficiency. Perform each inspection at the regular intervals listed below. System model # Serial #[...]

15, 30, & 60 cfm Compact Dryers 30 5-2 Preventative Maintenance This section describes maintenance procedures which will increase the longevity and efficiency of your dehumidifying dryer. Perform them at the regular intervals listed on the dryer checklist on the previous page. Servicing Process Air Filters Caution! Operating the dryer without t[...]

15, 30, & 60 cfm Compact Dryers 31 Cleaning with Compressed Air Blow clean, dry compressed air up and down the pleats, blowing out the filter from the inside out. Remove loose dirt fr om the filter with compressed air or vacuum from the outside. Caution! DO NOT clean/wash filter with water! After each cleaning: • Inspect the filter element. B[...]

15, 30, & 60 cfm Compact Dryers 32 WARNING! Handling desiccant material is HAZAR DOUS. Wear an N-100 type safety filter mask or equivalent to avoid prolonged breathing of desiccant dust. Wear safety goggles and gloves to avoid contact with eyes and skin. • Handle with adequate ventilation. • Wash hands thoroughly after handling. + FIRST AID[...]

15, 30, & 60 cfm Compact Dryers 33 Figure 10: Desiccant Bed Location and Disassembly Caution! You should properly dispose of any discarded desiccant. Consult local disposal regula tions for more information. 11. Inspect each desiccant screen for tears or holes where desiccant burned-through. Replace desiccant can if needed. 12. After cleaning e[...]

15, 30, & 60 cfm Compact Dryers 34 Replacing the Process/Regeneration Heater The dehumidifying dryers utilize a single-phase Ca lrod-type heater element. This heater element is mounted in the center compartment in the desiccant beds. Although the replacement procedure is the same for each heater, the wattage varies by model, voltage, temperatur[...]

15, 30, & 60 cfm Compact Dryers 35 5. Disconnect heater thermostat safety. 6. Pickup and place the top casting in a safe place. 7. Pickup the desiccant can to reveal the heater. 8. Using a 1/8” Allen wrench, remove the four (4) 10-32 screws on the heater plate. 9. Remove the wires to the heater plate assembly being removed or replaced. 10. Re[...]

15, 30, & 60 cfm Compact Dryers 36 5. Visually inspect the coil for leaks, dirt, and ant sign of volatiles. 6. Blow the dust out, or if the coil is covered with plasticizer, steam clean it. 7. Place the coil back in its housing. Make su re the gasket is OK, replace if necessary. 8. Inset the four 10-32 bolts back in place. 9. Turn the water to [...]

15, 30, & 60 cfm Compact Dryers 37 Chapter 6: T roubleshooting 6-1 Introduction 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 m ust be accomplished with the power off, line fuses rem oved, and with the machine tagged as out of ser[...]

15, 30, & 60 cfm Compact Dryers 38 Alarm Message Cause Corrective Action Dryer Status The process temperature has exceeded the alarm set point. The process heater contactor has failed in the closed position. C heck heater contactor, replace if necessary. Check the Process Heater box high temperature snap switch, replace if nece ssary The high t[...]

15, 30, & 60 cfm Compact Dryers 39 Alarm Message Cause Corrective Action Dryer Status Limit switch may be out of position. Re-adjust the switch to make sure it trips when it is at the high position, and it does not touch the cam when it is at the low position. VALVE MTR The limit switch on the valve may not have been wired correctly. The valve [...]

15, 30, & 60 cfm Compact Dryers 40 Chapter 7: Appendix 7-1 Technical Specifications Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equi pment that could alter the CE compliance 2. Ambient temperature: 0 degrees Celsius – Maximum (104 degrees Fahrenheit) 3. Humidity [...]

15, 30, & 60 cfm Compact Dryers 41 Aftercooler Design Specifications Entering water temp. ºF ºC 85ºF 50°F (If used as Plasticizer trap) 29ºC 10°C (If used as Plasticizer trap) 7-2 Drawings and Diagrams Figure 14: Standard Model (180°F to 230°F) Air Flow Schematic Drying Hopper Filter High Pressure Peripheral Blower Moisture Exhaust Rege[...]

15, 30, & 60 cfm Compact Dryers 42 Figure 15: High Heat Model (180°F to 400°F) Air Flow Schematic Figure 16: Low Heat Model (120°F to 250°F) Air Flow Drying Hopper Filter High Pressure Peripheral Blower Regeneration Make Up Air Moisture Exhaust Cooler Drying Hopper Filter High Pressure Peripheral Blower Regeneration Make Up Air Moisture Exh[...]

15, 30, & 60 cfm Compact Dryers 43 7-3 Spare Parts List Figure 18: Level 1 Spare Parts List (Electrical & Mechanical) DRYER SPA RE PARTS LIST 15, 30, 60 cfm Model s 15CFM 15CFM 15CFM 15CFM 15CFM 15CFM 15CFM 30CFM 30CFM 30CFM 30CFM 30CFM 30CFM 30CFM 60CFM 60CFM 60CFM 60CFM 60CFM 60CFM Mech ani cal Co mp one nts 115V 3P H 208V 3P H 220V 50 HZ[...]

15, 30, & 60 cfm Compact Dryers 44 HI-CORE DESICCANT D RYER 15/30/60 CFM UNITS 15 CFM Item Qty Part # Description 21 1 A0571669 SCHEMATIC, 1 5 CFM POWER 120 VAC 1 25 1 A0566840 GRAPHIC, ASD CONTROL, 1 ∅ 26 1 A0571672 COMM ON PARTS, 120VAC CONTROL 27 1 A0534258 FUSE BLOCK, 2 P 30A CC 28 1 725.00761.00 FUSE, PROC BL OWER, LP-CC-6 220VAC 1 ∅ 2[...]

15, 30, & 60 cfm Compact Dryers 45 33 3 A0534047 FUSE, HEATER S, KTK-R-12 230VAC 3 ∅ HIGH HEAT 33 3 A0534048 FUSE, HEATER S, KTK-R-15 400VAC 3 ∅ LOW HEAT 33 3 A0534043 FUSE, HEATER S, KTK-R-7 400VAC 3 ∅ HIGH HEAT 33 3 A0534044 FUSE, HEATER S, KTK-R-8 460VAC 3 ∅ LOW HEAT 33 3 A0534042 FUSE, HEATER S, KTK-R-6 460VAC 3 ∅ HIGH HEAT 33 3 A[...]

15, 30, & 60 cfm Compact Dryers 46 40 1 A0558000 CONTACTOR, IEC, 9A, 120VAC COIL 41 1 A0558078 RELAY, OVERLOAD, IEC, .32-1A 33 1 A0534051 FUSE, HEATERS, KTK-R-30 220VAC 1 ∅ LOW HEAT 33 1 725.00860.00 FUSE, HEATERS, KTK-R-20 220VAC 1 ∅ HIGH HEAT 33 1 A0568936 FUSE, HEATERS, KTK-R-25 208VAC 3 ∅ LOW HEAT 33 3 725.00860.00 FUSE, HEATERS, KTK-[...]

15, 30, & 60 cfm Compact Dryers 47 40 1 A0558000 CON TACTOR, IEC, 9A, 120VAC COIL 41 1 A0558079 RELAY, OVERLOAD, IEC, 1-2.9A 575VAC 3 ∅ 24 1 A0571675 COMMON PARTS, 3 ∅ POWE R 28 1 A0568940 FUSE, XFMR SE CONDARY, FNM-1.25 31 1 A0558192 TRANSF ORMER, 575X120 PSF 32 2 A0536886 FUSE, XFMR, PRIMARY, FNQ-R-0.25 40 1 A0558000 CON TACTOR, IEC, 9A, [...]

15, 30, & 60 cfm Compact Dryers 48 A0571673 220V CONTROL COMMON P ARTS ITEM QTY PAR T # DESCRIPTION 1 1 A0571676 SUBPANEL, 16.75X9.75 2 1 A0570597 CONTROL PANEL, 5.7X12 3 4 1 A0541669 SWITCH, ROCKER, ILLUM, 220VAC, GRN 5 1 A0563801 LITE, 3MM, 220 VAC, RED 6 1 A0541660 LITE, 3MM, 120VAC, GRN 7 2 A0571685 CONTACTOR, MERCURY 2P 30A 8 1 A0541290 RE[...]

15, 30, & 60 cfm Compact Dryers 49 7-5 Returned Material Policy Credit Returns Prior to the return of any material authorization m ust be given by the manufacturer. A RMA 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 returned is sub[...]

15, 30, & 60 cfm Compact Dryers 50 7-7 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 783-7835 o r call [ 262 ] 641-860 0, Fax [262 ] 641-8653 The ACS Customer Service Group will provide your compan y with genuine OEM qualit y parts manufactured t o engineering design specific ations, wh ic h will maximiz e your equi[...]