Sterling SDF 400 manual

Sterling Material Processing Operating Instructions Dehumidified air dryer SDF 250 SDF 400 SDF 500 With Touch control unit[...]

SDF 250/400/500 2 Sterling Material Processing 5200 West Clinton Ave. Milwaukee, WI 53223 Telephone: (414) 354-0970 Fax: (414) 354-6421 www.sterlco.com Technical service: Service department Telephone: (800) 423-3183 Edition: 12/03 These operating instructions are for*: (* please fill in personally) Serial number: Year of manufature: Date of Deliver[...]

SDF 250/400/500 3 Sterling Material Processing retains all rights to change the information in these operating instructions at any time without notice. We assume no liability for any errors or direct or indirect damage resulting in context with these operating instructions. Copying, translation or publication in any form except for personal use of [...]

SDF 250/400/500 4 Table of contents 1. Gen era l I nfo rma tio n ............................................................................................. 1-1 1.1 . W arn ing s a nd sym bol s....................................................................................... 1-2 1.2 . E xpl ana tio ns and in for mat ion .....................[...]

SDF 250/400/500 5 6.3. Connection to a Pneumatic Conveying System (Optional) ... ... ... ... ... ... ... ... ... ... . 6-18 6.4 . R etu rn Air Co ole r ( Opt ion al) ........................................................................... 6- 18 7. Tra nsp ort , A sse mbl y a nd Sto rag e ..........................................................[...]

SDF 250/400/500 General Information 1-1 1. General Information  These operating instructions are addressed to all users of the device. These operating instructions must be used by every person charged with work on the unit.[...]

SDF 250/400/500 General Information 1-2 1.1. Warnings and symbols The following warnings and symbols are used in these operating instructions:  This symbol indicates danger to life! Fatal or serious injury is possible if the corresponding instructions, regulations or warnings are not observed. L This symbol indicates that serious injury is possi[...]

SDF 250/400/500 General Information 1-3 When disposing of drying agents / batteries / oil, observe all official rules. Caution: High noise pollution ! For all work on the equipment, hearing protection should be worn. Avoids impairment of hearing! Caution: Danger of crushing ! Disconnect the equipment from mains supply before starting mainenance pro[...]

SDF 250/400/500 General Information 1-4 1.2. Explanations and information Various terms and designations are used in these operating instructions to ensure clarity. Therefore please note that the terms used in the text stand for the corresponding explanations listed below. • Equipment: ”Equipment” can mean an individual unit, a machine or an [...]

SDF 250/400/500 Safety instructions 2-1 2. Safety instructions  These safety instructions apply to all persons within the range of action of the equipment. Please inform all persons within the range of action of the equipment of the direct and indirect hazards connected with the equipment. These operating instructions are to be used by all perso[...]

SDF 250/400/500 Safety instructions 2-2 2.1. General The operating personnel of this equipment must be at least 16 years old. Please read these operating instructions carefully before taking into operation for the first time. Contact us should questions arise. This avoids injury and damage to equipment! These operating instructions must be kept ava[...]

SDF 250/400/500 Safety instructions 2-3 2.1.1. Assembly Compare the connected loads with those of the mains supply. Danger of injury through electrical shock! When using lifting gear, please observe the pertaining regulations. Caution: Danger of accidents! Do not modify, add other equipment or change the design of the equipment without the approval[...]

SDF 250/400/500 Safety instructions 2-4 to people and material! 2.1.3. Maintenance Before starting maintenance work, appoint a supervisor. Inform the responsible personnel before maintenance work on the system is started. Caution: Danger of accidents! Disconnect the equipment from mains supply before starting maintenance procedures to ensure that i[...]

SDF 250/400/500 Safety instructions 2-5 2.2. For the safety of the devices Never change settings without carefully assessing the consequences. Use only original Sterling spare parts. Observe the maintenance instructions. Keep a record of all maintenance works and repairs. Please note that electronic components can be damaged by static discharge. Be[...]

SDF 250/400/500 Start up 3-1 3. Start up  This chapter is addressed to the operators of the machine. This chapter assumes general skills with drying systems and SPS (PLC) control units. This chapter assumes that the functional description has been read and understood. It must be ensured that the operators have the relevant skills. F Note down al[...]

SDF 250/400/500 Start up 3-2 3.1. Control Unit The control system is switched on at the main switch. The control system is operated via the ”Touch Screen and the keyboard of the operator panel. The facility’s control system is factory-programmed. Nevertheless, you have to set specific values (basic parameters) which are dependent on the process[...]

SDF 250/400/500 Start up 3-3 3.2. Switching on the Dryer Switch on the system by means of the main switch. & The control system carries through a self-test; after that the “Start-Screen” with date and time is displayed 3.3.[...]

SDF 250/400/500 Start up 3-4 Basic parameters 3.3.1. Entering Dryer Values Return air cooler on/orr “I”: enabling the return air cooler “O” disabling the return air cooler Target value Actual value Status Dryer Back to “Start-Screen”[...]

SDF 250/400/500 Start up 3-5 Heater Reg. Act. The regenerated heat temperature will be displayed. Exit air Act. The current temperature of the used air will be displayed. & If the unit is operates with “dew point controlled changeover point with dew point display” (optional): Dew point max. Enter the maximum permissible (worst allowed) dew [...]

SDF 250/400/500 Start up 3-6 3.3.2. Entering hopper values Return air cooler on/orr “I”: enabling the return air cooler “O” disabling the return air cooler Enter hopper name Status Hopper Back to “Start-Screen” STT 1[...]

SDF 250/400/500 Start up 3-7 Hopper temp Target Enter the drying temperature for the drying hopper. Hopper temp Act. The current temperature at the feed opening of hopper flap will be displayed. & If the unit operates with motor flaps (optional): Granule Temp Enter the material temperature at which the flap on the drying hopper should close. &a[...]

SDF 250/400/500 Start up 3-8 3.3.3. Setting the timer[...]

SDF 250/400/500 Start up 3-9 Enter for each day the switching on time and the switching off time in hours and minutes. Off / Internal / External Select operation mode: ”internal” = operation with internal timer, “external” = operation with external timer (if present), ”off” = operation without timer. & The timer is only operating, w[...]

SDF 250/400/500 Start up 3-10 3.3.4. Observing processing status Actual operation status: The following operation statuses can be displayed: • system is off • system is on • blower runs on • valve block • regeneration will be finished in x min. Actual hopper temperature displayed in °C Status dryer LED grey - dryer off LED green - dryer [...]

SDF 250/400/500 Start up 3-11 3.3.5. Setting date and time Date/Time Enter the desired day and time.[...]

SDF 250/400/500 Start up 3-12 3.3.6. Changing language & This function is password protected. Enter the password (password: 792154) ****** ******[...]

SDF 250/400/500 Start up 3-13 & If the password has been entered correctly, the language can be changed.[...]

SDF 250/400/500 Start up 3-14 3.4. Continuous operation When you have carried through all basic settings, you can start with continuous operation. F Make sure that hoppers which are not in use are separated from the dehumidified air supply. Make sure that the set drying temperatures are suited for the materials in the hoppers. After first filling, [...]

SDF 250/400/500 Start up 3-15 Or[...]

SDF 250/400/500 Start up 3-16 3.5. Switching the dryer/hopper heater off Switch off the hopper heater: Switch off the dryer: L Wait until the regeneration phase is finished and the blower has come to a standstill. Switch off the dryer at the main switch. Disconnect the power supply. F Never switch off the dryer directly at the main switch[...]

SDF 250/400/500 Error and error correction 4-1 4. Error and error correction  This chapter is directed at the operators of the equipment. This chapter assumes general skills in dealing with drying systems and SPS (PLC) control units. This chapter assumes that the “start-up” description has been read and understood. It should be ensured in ea[...]

SDF 250/400/500 Error and error correction 4-2 F Failures must be repaired immediately. & Alarm messages are displayed in plain language on the screen of the operator device. An alarm is given by flashing of the LED “alarm”. The display of alarm messages in the operator device can only be erased by pressing the “ACK” key. The failure is[...]

SDF 250/400/500 Error and error correction 4-3 4.1. Actual messages Following alarm messages can be displayed: PLC (= SPS) Battery is Empty Replace the SPS battery. The Safety Switch Regeneration Blower Has Been Actuated Check the blower. Check the fuses. Short circuit check of the blower. Vacuum Regeneration Blower The regeneration blower does not[...]

SDF 250/400/500 Error and error correction 4-4 Error Bypass Flap The bypass flap does not close or closes too slowly. Check the bypass flap. Error Valve Block The valve block has not reached the proper position. The main switch is placed in the off position. Check the position of the valve block. Press the “ACK” key and put the main switch in t[...]

SDF 250/400/500 Error and error correction 4-5 Excess Temperature Heater Hopper X (X = number of the drying hopper) The temperature of the hopper heater is too high. Check the safety temperature limiter. Sterling Service. Insufficient Temperature Heater Hopper X (X = number of the drying hopper) The temperature of the hopper heater is too low. Chec[...]

SDF 250/400/500 Error and error correction 4-6 Overload Regeneration Heater - STB has been activated Check the safety temperature limiter (= STB). Check regeneration heater. Short circuit check. Overload Drying Heater - STB has been activated Check the safety temperature limiter (= STB). Check drying heater. Short circuit check. Main switch hopper [...]

SDF 250/400/500 Error and error correction 4-7 4.2. Alarm protocol & Alarm messages are displayed in plain language with date and time in the alarm protocol.[...]

SDF 250/400/500 Maintenance 5-1 5. Maintenance  This chapter is intended for persons with skills in electrical and mechanical areas due to their training, experience and received instructions. Personnel using the instructions in this chapter must be instructed of the regulations for the prevention of accidents, the operating conditions and safet[...]

SDF 250/400/500 Maintenance 5-2 F Please observe the maintenance schedule. Before starting maintenance work, clean the equipment of oil, fuel or lubricant. Ensure that materials and incidentals required for operation as well as spare parts are disposed of properly and in an environmentally sound manner. Use only original Sterling spare parts. Keep [...]

SDF 250/400/500 Maintenance 5-3 5.1. Maintenance schedule Daily: Check warning signs on equipment for good legibility and completeness Clean return air filters and casing (depending on dust build-up) Weekly: Check main switch for proper function Check the signal lamps for proper functioning Every three months: Clean filter of the regeneration blowe[...]

SDF 250/400/500 Maintenance 5-4 5.2. Cleaning or Replacing the Air Filter Switch off the hopper heater: And the dryer: L Wait until the regeneration phase is finished and the blower has come to a standstill. Switch off the main switch of the dryer. Interrupt the mains supply so that the device cannot be switched on unintentionally. If there is a re[...]

SDF 250/400/500 Maintenance 5-5 5.2.1. Cleaning or Replacing the Return Air Filter Open the panel (A) by means of the provided switch cabinet key. Open the tension ring on the housing of the return air filter (B) and remove the housing cover. Remove the nut of the filter cartridge. Remove the filter cartridge. Clean the inside of the return air fil[...]

SDF 250/400/500 Maintenance 5-6 5.2.2. Cleaning or Replacing the Regeneration air filter Open the back panel. Slide the air filter (A) off the nozzle. Blow compressed air through the clogged air filter from the inside out or replace the air filter. Install the cleaned/new air filter (A). Mount the back panel. F Never operate the dryer without regen[...]

SDF 250/400/500 Maintenance 5-7 5.2.3. Filter of the electrical cabinet Remove the lid of the filter. Remove the filter mat. Blow through the filter mat with compressed air from inside to outside or renew the filter mat. Clean the filter housing. Use lint-free cleaning rags. Re-install the cleaned/new filter mat. Replace the lid of the filter. F Ne[...]

SDF 250/400/500 Maintenance 5-8 5.3. Disposing of Drying Agents Please note that drying cells are replaced or refilled by Sterling only if they are empty. When disposing of drying agents, observe all official rules. Since used drying agents may contain impurities from the dried materials, treat them as special waste. & It is not possible for St[...]

SDF 250/400/500 Maintenance 5-9 5.4. Cleaning the Drying Hopper Switch off the hopper heater and the dryer: L Wait until the regeneration phase is finished and the blower has come to a standstill. Switch off the main switch of the dryer. Interrupt the mains supply so that the device cannot be switched on unintentionally. If there is a return air co[...]

SDF 250/400/500 Maintenance 5-10 STT 25 Open the toggle-type fasteners (A) at the hopper lid and fold the hopper lid upwards (if in use: remove before the single conveyor). Clean the drying hopper. Close the hopper lid and close the toggle-type fasteners (A) (if in use: re-mount the single conveyor). F Remove any granules remaining in the cleaning [...]

SDF 250/400/500 Maintenance 5-11 STT 60 - 1600 Open the cleaning opening of the drying hopper: Lift and turn the handle (A) to open the lock, if in use: remove before the single conveyor (STT 400 - STT 1600: 2 handles). Clean the drying hopper. Close the cleaning opening of the drying hopper: Turn the handle (A) until the cleaning opening is locked[...]

SDF 250/400/500 Maintenance 5-12 5.5. Changing the battery of the control system  This work may be carried through only by qualified personnel trained in the field of electrical engineering. F The battery may be changed only with the control system switched on. Open the control box by means of the control box key which is part of the supply. Ope[...]

SDF 250/400/500 Maintenance 5-13 Close the control box. L Store backup batteries in a dry and cool place. Backup batteries can be stored for approx. 5 years. If backup batteries are not treated properly, they can ignite, explode and cause severe burning. & Order number battery: ID 83809 Batteries must be disposed of in keeping with the relevant[...]

SDF 250/400/500 Maintenance 5-14 5.5.1. Resetting the control values  This electrical work is intended to be carried out only by trained personnel. After changing the battery or the PLC the control values should be resetted. All control values are set back to the standard settings. Open the control box with the switch box key which is part of th[...]

SDF 250/400/500 Functional description 6-15 6. Functional description  This functional description is addressed to the operators of the equipment. This functional description assumes general familiarity with drying equipment. It should be verified that the operators do indeed have the appropriate skills.[...]

SDF 250/400/500 Functional description 6-16 6.1. General Information The dryers work according to the dehumidified air principle, i.e., the air is not only heated but also dehumidified before it flows through the drying hopper. In this manner, plastic granules can be dried down to a very small residual moisture content. The drying takes place conti[...]

SDF 250/400/500 Functional description 6-17 6.2. Drying Hopper (Optional) The material is dried in the drying hopper. The dehumidified air is conducted through the material in the drying hopper and takes up moisture. Drying hoppers must have the appropriate dimensions for their specific use so that the desired final moisture content is reached. Whe[...]

SDF 250/400/500 Functional description 6-18 6.3. Connection to a Pneumatic Conveying System (Optional) Your drying facility works best in combination with a pneumatic conveying system. In this way, your drying hopper will always be supplied with sufficient material. The facility will only take as much material as is required by the processing machi[...]

SDF 250/400/500 Transport, Assembly and Storage 7-1 7. T ransport, Assembly and Storage  This chapter is intended for all operating personnel of the equipment. Personnel using these instructions must be instructed in the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation. Ensure [...]

SDF 250/400/500 Transport, Assembly and Storage 7-2 7.1. Tansport and Packing  Please ensure adequate carrying capacity of the lifting equipment. Note that the dryer system is top-heavy. Risc of toppling! F The machine must not be tilted or laid on its side. The equipment pass a rigorous operating test in the factory and are packed carefully to [...]

SDF 250/400/500 Transport, Assembly and Storage 7-3 with a workshop crane Check if the eyelets are installed on the dryer housing. If this condition is met, fasten the transport cables to the eyelets. If this condition is not met, mount the eyelets and then fasten the transport cables to the eyelets. Disassemble the eyelets after set-up. Figure 6: [...]

SDF 250/400/500 Transport, Assembly and Storage 7-4 7.2. Assembly  Please ensure adequate carrying capacity of the lifting equipment. Check the carrying capacity of the point of installation, particularly if installed on a platform. The place selected for installation should be as free of vibrations as possible. The main switch must be freely ac[...]

SDF 250/400/500 Assembly instructions 8-1 8. Assembly instructions  These installation instructions are intended for persons with skills in electrical and mechanical areas due to their training, experience and received instructions. Personnel using these installation instructions must be instructed in the regulations for the prevention of accide[...]

SDF 250/400/500 Assembly instructions 8-2 8.1. Installation of the exhauster fan for regeneration of exhaust air When plastics are being dried that release harmful gases during the drying process, care must be taken that the regeneration exhaust air is disposed of in an environmentally sound way. At the same time the throughput of the regeneration [...]

SDF 250/400/500 Assembly instructions 8-3 8.3. Electrical Connection  Observe the rules of the local electricity board. Check that the supply voltage and the power frequency are in accordance with the data on the nameplate of the device. The electrical connection may only be carried through or assigned by Sterling service staff or by qualified s[...]

SDF 250/400/500 Assembly instructions 8-4 8.4. Compressed Air Supply A compressed air supply is needed to operate the valve stem. Check whether the compressed air piping has been installed and connected properly. Check whether fittings, length and quality of the hose assemblies are in accordance with the requirements. The operating pressure is 5-6 [...]

SDF 250/400/500 Technical data 9-1 9. T echnical data Basic Version Central control unit for operating the dryer and the drying hoppers. Drying temperature adjustment for all connected hoppers • SPS-S7 PLC • Touch-screen • Timer clock • Regeneration heater with safety temperature limiter • Isolated alarm output • Optical alarm Optional [...]

SDF 250/400/500 Technical data 9-2 Dimension Sheet Dimensions and data without obligation. Dimensions in mm. Specifications may be subject to alterations.[...]

STT 25 – STT 6400 Accessories 10-1 10. Accessories o Spare parts list Drying Hoppers STT 25 – STT 6400 o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _[...]

Sterling Material Processing Accessories Spare parts list Drying Hoppers STT 25 – STT 6400[...]

STT 25 – STT 6400 2 Sterling Material Processing 5200 West Clinton Ave. Milwaukee, WI 53223 Telephone: (414) 354-0970 Fax: (414) 354-6421 www.sterlco.com Technical service: Service department Telephone: (800) 423-3183 Edition: 07/03 These operating instructions are for*: (* please fill in personally) Serial number: Year of manufature: Date of Del[...]

STT 25 – STT 6400 3 Sterling Material Processing retains all rights to change the information in these operating instructions at any time without notice. We assume no liability for any errors or direct or indirect damage resulting in context with these operating instructions. Copying, translation or publication in any form except for personal use[...]

STT 25 – STT 6400 4[...]

STT 25 – STT 6400 5 Pos. ID Description 1 Radiator hopper heater 85343 1.5 kW 85338 3.0 kW 85363 6.0 kW 85651 9.0 kW 95828 18.0 kW, 27.0 kW, 36.0 kW, 63.0 kW 87094 27.0 kW, 48.0 kW, 63.0 kW 2 18232 Hand flap Ø 80 92241 Tension ring 2 16523 Hand flap Ø 150 (> TT 1200) 96099 Tension ring 94231 Dichtring 3 06925 Flow indicator Ø 80 92241 Tensi[...]

STT 25 – STT 6400 6 Pos. ID Description 13 18232 Hand flap 92241 Tension ring 94233 Sealing ring 14 30306 Lid 16 92241 Tension ring 17 94233 Sealing ring (optional, if flap in use) 18 30350 Grounding set Multiplier PT 100: ID Description 86371 Pt 100 (3 m) 89846 Pt 100 (6 m) 93303 PT 100 (9 m) 86387 PT 100 (12 m) 83015 PT 100 (15 m) Drying Hopper[...]