Sterling STT40 manuale d’uso

Sterling Material Processing Operation Instructions Dehumidified air dryer STT40 STT70[...]

STT40 / STT70 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 operation instructions are for*: (* please fill in personally) Serial number: Year of manufacture: Date of Delivery[...]

STT40 / STT70 3 Sterling Material Processing retains all rights to cha nge the information in these operation instructions at any time without notice. We assume no liability for any errors from direct or indirect damage resulting in context with these operation instructions. Copying, translation or publication in any form ex cept for personal u se [...]

STT40 / STT70 4 Table of contents 1. General Information ................................................................................................. 1-1 1.1. Warnings and symbols .......................................................................................... 1-1 1.2. Explanations and information ....................................[...]

STT40 / STT70 5 8.2. Grounding the equipment against electrostatic charging ...................................... 8-2 8.3. Electrical Connection ............................................................................................ 8-3 8.4. Connection of Return Air Cooler (Optional) ........................................................ 8-[...]

STT40 / STT70 General Information 1-1 1. General Information  These operation instructions are addressed to all users of this device. These operation instructions must be followed by every person working on or with the unit. 1.1. Warnings and symbols The following warnings and symbol s are used in these operating instru ctions:  This symbol i[...]

STT40 / STT70 General Information 1-2 When disposing of drying agents / batteries / oil, observe all official rules. Caution: High noise pollution ! For anyone working on the e quipment, hearing protection should be worn. Avoid impairment of hearing! Caution: Danger of being crushed ! Disconnect the equipment from the main power supply before start[...]

STT40 / STT70 General Information 1-3 1.2. Explanations and information Various terms and designations a re used in these operating instruction s to ensure clarity. Therefore please note that the terms used in the text stand for the corresponding explanation s listed below. • Equipment: ”Equipment” can mean an individual unit, a machine or an[...]

STT40 / STT70 Safety instructions 2-1 2. Safety instructions  These safety instructions apply to all persons around the operating equipment. Please inform all persons around the operating equipment of the direct and indirect haza rds connected with it. These operation instructions are to be used by all persons assigned activities connected with [...]

STT40 / STT70 Safety instructions 2-2 2.1 General The operating personnel of this equipm ent must be at least 16 years old. Please read these operation instru ctions carefully before operating the equipment for the first time. Contact us should questions arise. This avoid s injury and damage to equipment! These operation instructions must be kept a[...]

STT40 / STT70 Safety instructions 2-3 2.1.1. Assembly Compare the connected loads with those of the main power supply. Danger, ele ctrical shock hazard! When using lifting gear, please ob serve the pertai ning regulation s. Caution: Danger of accidents! Do not modify, add other equipment or change t he design of the equipm ent without the approval [...]

STT40 / STT70 Safety instructions 2-4 2.1.3. Maintenance Before starting maintenance wo rk, appoint a supervisor. Inform personnel respo nsible for the system before beginni ng maintenance work. Caution: Danger of accident s! Disconnect the equipment from m ain power su pply before starting maintenance procedure s to ensure that it cannot be switch[...]

STT40 / STT70 Safety instructions 2-5 2.2. For the safety of the device Never change settings witho ut carefully assessing the co nsequences. Use only original Sterling spare part s. Observe the maintenance instructions. Keep a record of all maintenance work and rep airs. Please note that electronic component s can be damaged by static discha rge. [...]

STT40 / STT70 Start up 3-1 3. S t art up  This chapter is addressed to the operators of the machine. It assumes the operator has genera l skills with drying equipment and that the functional description has been read and understood. Ensure that the operators have the required experience. ) Make sure that the main switch is set to the “0" [...]

STT40 / STT70 Start up 3-2 3.1. Initial Operation Check whether the inlet of the drying hopp er is closed by a lid or whether a conveyor unit (optional) is installed. If not, manufacture a suitable lid and install it on the inlet of the drying hoppe r or install the optional conveyor unit. ) Attachments which are not supplied by Sterling must be ma[...]

STT40 / STT70 Start up 3-3 Turn the “Hopper” release switches (ST1, ST2) to the “I” position. To set the drying temperature, turn the temperature controller to 176° F (+80 °C). Press the “PGM” key one time. Set the drying temperature to 176° F using the arrow keys. After 2 seconds, the display will flash and the value will be stored.[...]

STT40 / STT70 Start up 3-4 3.2. Continuous Operation Note: To see a quick start guide for operation of this dryer see chapter 14. ) Fill at least half of the drying hopper with material. 3.2.1. Switching the Dry er on Turn on the dryers’ main power switch to the on position.  The “run” signal lamp turns on. For operation with the optional [...]

STT40 / STT70 Start up 3-5 3.2.2. Setting the Dry ing Temperature Turn the “Hopper” (ST1, ST2) relea se switches to the “I” position. For each drying hopper, set the re quired process drying temperatu re by using the corresponding temperature controller. Check whether the set proce ss drying temperatur e is appropriate for the material s wh[...]

STT40 / STT70 Start up 3-6 Autotuning the temperature controller Press the “EXIT” key for at least 2 seconds. “tunE” flashes. Autotuning can take several minute s. If “tunE” stops flashing, Autotuning is finished. Press the “EXIT” key.[...]

STT40 / STT70 Start up 3-7 3.3. Switching the Dryer off Turn the “Timer” switch to the position: / Wait until the blower has stopped. The blower w ill continue runni ng for 10 minutes once the dryer is turned off. If there is a return air cooler insta lled, switch off its coolant circuit. Turn off the dryer’s main power switch.  The “pow[...]

STT40 / STT70 Error and error correction 4-1 4. Error and error correction  This chapter is directed at the operators of the equipment. It assumes the operator has genera l skills in dealing with drying systems and that the “start-up” description has been read and understood. Ensure in each and every case that the operators have the relevant[...]

STT40 / STT70 Error and error correction 4-2 The following errors can cause an alarm: Blower The blower pressure is too lo w. Check the blower. Vacuum sens or is defective. Regeneration heater 1 The safety temperature limiter on regene ration heater 1 has been activated. Check the safety temperature limiter. Call the Sterling Service Department. Re[...]

STT40 / STT70 Maintenance 5-1 5. Maintenance  This chapter is intended for persons having skills in electrical and mechanical areas due to their tr aining, experience and supporting documentation. Personnel using the instructions in this chapter mu st be familiar with accident prevention regulati ons, operating conditions, safety regulations and[...]

STT40 / STT70 Maintenance 5-2 ) Please observe the maintenance schedule. Before starting maintena nce work, clean the equipment of oil, fuel or lubricant. Ensure that materials and inci dentals as well as spare parts required for operation are disposed of properly and in an environmentally sound manner. Use only original Sterling spare parts. Keep [...]

STT40 / STT70 Maintenance 5-3 5.1. Maintenance schedule The checklist below contains a list of items wh ich should be insp ected and/or replaced to keep your Dehumidifying Dryer operatin g at peak effici ency. Perform each inspection at the regul ar intervals listed below. System model # Serial # Every week Date/ By Date/ By Date/ By Date/ By Date/[...]

STT40 / STT70 Maintenance 5-4 5.2. Preventative Maintenance This section describes maint enance procedu res wh ich will increase the longevity and efficiency of your dehumidifying dryer. Perform them at the regular intervals listed on the dryer che cklist on the previous page. 5.2.1. Servi cing Process Air Filters Caution! Operating the dryer witho[...]

STT40 / STT70 Maintenance 5-5 5.2.2. Cleaning or Replac ing the Return Air Filter STT40 / STT70 • Detach the screw on the housing of the return air filter and remove the housing cover. • Remove the nut of the filter cartridge. • Remove the filter cartridge. • Clean the inside of the return air filter housi ng. Use non-fibrous cleaning cloth[...]

STT40 / STT70 Maintenance 5-6 5.2.3. Servicing the De w Point Monitor The accuracy of the dew point monitor on mini dryer syst ems depends on proper op eration of the dew point sensor and the co ntrol board. The dew poi nt sensor is in the process air stream and is therefore susceptible to contamination. Dew point sensor life depends o n: • Air t[...]

STT40 / STT70 Maintenance 5-7 5.3. Corrective Maintenance This section provides you with the information necessary to correct or r epair any issues which might appear during the normal operation of your dehumidifying dryer. Although we have li sted how to perform these procedures, it is reco mmen ded that you call the Service Department to have any[...]

STT40 / STT70 Maintenance 5-8 5.3.2. Replacing Worn Desiccant • DESICCANT BEDS ARE HOT DURING OPERATION. To avoid burn hazard, make sure desiccant beds are sufficiently cool before replacing worn desiccant. To access the Desiccant Bed: 1. Disconnect electrical power to the dryer. 2. Remove dryer side panels. 3. Remove any internal hoses that may [...]

STT40 / STT70 Maintenance 5-9 12. Replace any intern al hoses that were removed to ch ange desiccant. Figure 3: Required Desiccant Amounts Dryer 8 x 12 bead Total model Part no. lbs. Kg STT 40 13.23 6 STT 70 W00018051 28.76 13 5.4. Disposing of Drying Agents Please note that drying cells are repla ced or refilled by Sterling only if they are empty.[...]

STT40 / STT70 Maintenance 5-10 5.5. Replacing the Process Heater The dehumidifying dryers utilize a thru-phase Calr od -type heater element. This heater element is mounted to the inlet of the drying hopper. Althou gh the replacement pro cedure is the same for each heater, the wattage varies by m odel, voltage, temperature range, etc. • Hazardous [...]

STT40 / STT70 Maintenance 5-11 7. Re-clamp process heater assembly onto the drying hopper. 8. Reattach wiring acco rding to the sketch that was made previously. 9. Replace the air hose to the proce ss heater. 10. Replace access cover on junction box of process heater assembly. 5.5.1. Repla cing/Cleaning the Cooling C oils • Hazardous electrical c[...]

STT40 / STT70 Maintenance 5-12 5.5.2. Replacing t he re generation heating coil • Hazardous electrical current present. Disconnect and lock out power before you replace heating element! Figure 6: Heating Coil Location and Disassembly 1. In order to gain access to the heating element, the cover plate on the si de of the dryer must be removed. 2. R[...]

STT40 / STT70 Maintenance 5-13 5.6. Cleaning the Drying Hopper Set the “Timer” release switch to the position. / Wait until the blower has stopped. The blower w ill continue runni ng for 10 minutes once the dryer is turned off. If there is a return air cooler insta lled, switch off the coolant circuit. / Switch off the dryer’s main power swit[...]

STT40 / STT70 Maintenance 5-14 STT 25 Open the toggle-type fastene rs (A) at the hoppe r lid and fold the hopper lid upwards (if in use: re move before the single conveyor). Clean the drying hopper. Close the hopper lid and clo se the toggle-type fasteners (A) (if in use: re-mou nt the single conveyor). ) When cleaning, remove any granules remainin[...]

STT40 / STT70 Functional description 6-15 6. Functional description  This functional description is addr essed to the operators of the equipment. This functional description assumes the operator has a general familiarity with drying equipment. Verify that the operators have the appropriate skills.[...]

STT40 / STT70 Functional description 6-16 6.1. General Information The dehumidified air dryers were devel oped for drying plastic granules. Due to their comp act construction, they can be utilized for drying next to the processing machine (d rying hopper on the processing machine) or with one or more drying hoppers as a mova ble facility (compact f[...]

STT40 / STT70 Functional description 6-17 ➀ ➁ ➀ ➈ ➇ ➂ ➃ ➃ ➄ ➅ ➆ Figure 9: Functional diagram of STT40 / STT70 All functions are fully automatic. The dryer is equipped with two drying cells. One dr ying cell is part of the drying cycle; the other drying cell is regenerated simultaneou sly. Part of the dehumidified air is used f[...]

STT40 / STT70 Functional description 6-18 1 = “hopper” release switch STT1, STT2 (STT2 onl y STT70) 2 = dew point display (op tional) 3 = “power” signal lamp 4 = “trouble” signal lamp 5 = main power switch 6 = “Timer” release switch 7 = timer clock (op tional) 8 = temperature controller “drying hopper” STT1, STT 2 (STT2 only STT[...]

STT40 / STT70 Functional description 6-19 6.2. Drying Hopper (Optional) The material is dried in the drying hopper. The dehumidified air is heated and then co nducted through the material in the drying hopper a nd removes moisture. Drying hoppers mu st have the appropriate dimensions for their specific use so that the desired final moisture content[...]

STT40 / STT70 Functional description 6-20 6.2.1. Hopper Heater Each drying hopper has its own heate r. The temper ature of the dehumidified air is adjusted by means of the temperature controller. The setti ng range i s from +140°- +356°F (+60 - +180 ° C). The current temperature can be read off the digital di splay (= actual value ). If you are [...]

STT40 / STT70 Functional description 6-21 DEFA ULT SETTINGS FOR JU MO TEMP. CONTROLLER Model number: dT RON 16.1 B 70.3011 Contact information: Germany USA MoltkestraBe 13-31 885 Fox Chase, Suite 103 36035 Fulda, Germany Coatesville, PA 19320, USA Ph: +49 661 60 03-7 27 Ph: 610- 380-8002 or 1-800-554-JUMO Fax: +49 661 60 03-5 08 Fax: 610-380-8009 E[...]

STT40 / STT70 Functional description 6-22 6.3. Connection to a Pneum atic Conveying System (Optional) Your dryer works best in combination with a pneumatic conveying system. When assembled this way, your drying hopper will always be supplied with sufficient material. The dryer will only take as much material as is required by the processi ng machin[...]

STT40 / STT70 Transporting, Assembly and Storage 7-1 7. T ransporting, Assembly and S torage  This chapter is intended for all operating personnel of the equipment. Personnel using these instructions must be knowledgable in the regulations for the prevention of accidents, the operating conditions, safety regulations and their implementation. Ens[...]

STT40 / STT70 Transporting, Assembly and Storage 7-2 7.1. Transporting and Packing  Please ensure that the lifting equipment has an adequate carrying capacity. Note that the dryer system is top-heavy . Risk of toppling! ) The machine must not be ti lted or laid on its side. The equipment has undergo ne a rigorous operating test in the factory an[...]

STT40 / STT70 Transporting, Assembly and Storage 7-3 7.2. Assembly  Please ensure the lifting equipment has an adequate carrying capacity. Check the load capacity where the dryer is to be installed, particularly if it is to be installed on a platform. The place selected for installation should be as vibration-free as possible. The main power swi[...]

STT40 / STT70 Assembly instructions 8-1 8. Assembly instructions  These installation instructions are intended for persons with skills in electrical and mechani cal areas due to their training, experience and supporting documentation. Personnel using these installation instructions must be knowledgeable in the regulations for the prevention of a[...]

STT40 / STT70 Assembly instructions 8-2 8.1. Installation of the exhaust fan for regeneration of exhaust air When plastics are being dried that relea se harmful gases during the drying p rocess, care must be taken that the regeneration exhaust air is disp osed of in an environmentally sound way. At the same time the throughput of the regeneratio n [...]

STT40 / STT70 Assembly instructions 8-3 8.3. Electrical Connection  The electrical connection of the dryer and the hopper heaters may only be done by Sterling service staff or by qualified staff authorized by Sterling. Other persons are not permi tted to perform any electrical connection. Observe the rules of the state and local electricity boar[...]

STT40 / STT70 Assembly instructions 8-4 8.4. Connection of Return Air Cooler (Optional) ) A return air cooler must be used if the return air temperature is higher than 149°F (+65 °C). You can connect the return air cool er to a coolant circuit or to the water main network. The water flow rate in the water main network * is for: STT40 approx. 7.16[...]

STT40 / STT70 Troubleshooting 9-1 9. T roubleshooting 9.1. 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 removed, and with the machine tagged as out of service. The use[...]

STT40 / STT70 Troubleshooting 9-2 Problem Possible cause Corrective action Process heaters are faulty. Check for open heaters. Replace if required. Solid-state temperature controller faulty. Replace. Loss or reduction of process air temperature. Process temperature was adjusted in error by plant personnel. Make sure that plant personnel are aware o[...]

STT40 / STT70 Troubleshooting 9-3 Problem Possible cause Corrective action Process temperature set too high due to operator error. Check resin manufacturer’s data sheet for proper drying temperature. Make sure plant personnel are aware of the correct process temperature set point. High temperature alarm not set properly. Reset high temperature al[...]

STT40 / STT70 Troubleshooting 9-4 Problem Possible cause Corrective action No setting change possible on temperature controller. The key protection switch is set to ON . Set the key protection switch to OFF . Input polarity on thermo-couple is wrong or connection is wrong. Properly wire the terminals. Input-type setting is incorrect. Properly set t[...]

STT40 / STT70 Technical data 10-5 10. T echnical dat a 10.1. STT40 amount of dehumidified air: max. 1,412.69 ft 3 /h, (40 m 3 /h) operating voltage: 230 V/AC/50 Hz special voltages can be supp lied upon request connecte d load: 2.6 kW calorific output (drying) * : max. 1.5 kW *depending on the equipment with hop per heaters calorific output (regene[...]

STT40 / STT70 Technical data 10-6 10.3. Dimension Sheet STT 40 STT 70 A 27.5” (700 mm) 35.5” (900 mm) B 3.2” (80 mm) 3.2” (80 mm) C 35.5” (900 mm) 35.5” (900 mm) D 11.8” (300 mm) 15.7” (400 mm) Dimensions in inches (mm) . Specifications may be subject to change without notice.[...]

STT40 / STT70 Spare parts list 11-1 11. Sp are p art s list  This spare parts list must be used only by trained personnel. Other persons are not permitte d to modify or repair the equipment.[...]

STT40 / STT70 Spare parts list 11-2 STT40 Pos. ID-number Description 1 valve stem 31940 shaft 31938 housing 36212 disc with bush 84130 disc flywheel DU 2 83957 filter cartridge, when operating without return air cooler 83956 filter cartridge, when ope rating with return air cooler 3 84129 blower STT40 4 85819 guide roll with fixing device 5 85820 g[...]

STT40 / STT70 Spare parts list 11-3 STT70 Pos. ID-number Description 1 valve stem 31940 shaft 31938 housing 36212 disc with bush 84130 disc flywheel DU 2 83957 filter cartridge, when operating without return air cooler 83956 filter cartridge, when ope rating with return air cooler 3 85677 blower STT70 4 85819 guide roll with fixing device 5 85820 g[...]

STT40 / STT70 Spare parts list 11-4 Operating unit Pos. ID-number Description 1 82368 main switch 2 82394 LED element, green 82393 cap 82495 fixing adapter 3 82494 LED element, white 82392 cap 82495 fixing adapter 4 26207 dew point display (optional) 5 82395 selector switch actuator 82490 contact element 6 87454 temperature controller TT1, TT2 7 85[...]

STT40 / STT70 Spare parts list 11-5 Control unit STT40 85280 motor 84131 radiator 0.7 kW 83339 pull-button 87440 contact element 83411 controller 82516 temperature limiter 88440 contactor 85941 terminal 85940 fuse 99102 fuse 88806 relay holder 88816 relay 84510 thermal breaker Hopper heater 85688 radiator 1,5 kW 85652 safety temperature limiter Con[...]

STT40 / STT70 Electrical manual 12-1 12. Electrical manual  This electrical manual is intended to be used by Sterling service personnel and trained personnel authorized by Sterling only. Other persons are not permitte d to modify or repair the equipment.  Connection diagram no.: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _  Currently not [...]

STT40 / STT70 Accessories 13-1 13. Accessories  Basic setting on temperature controller  Digital timer  Spare parts list Drying Hoppers ST 25 - ST 64 00  _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _  _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _[...]

STT40 / STT70 Accessories 13-2 Basic temperature controller setting s STT40  This information is intended to be used by Sterling service personnel and trained personnel authorized by Sterling only. Other persons are not permitte d to modify or repair the equipment. Settings, if temperature is displayed in F° Code C111 0 0 0 0 C112 2 0 3 0 C113 [...]

STT40 / STT70 Accessories 13-3 Basic temperature controller setting s STT70  This information is intended to be used by Sterling service personnel and trained personnel authorized by Sterling only. Other persons are not permitte d to modify or repair the equipment. Settings, if temperature is displayed in F° Code C111 0 0 0 0 C112 2 0 3 0 C113 [...]

14. Quick St art Guides 14.1. for STT 40 Dryer 1. Check all wiring connectio ns to ensure that they are in the correct place and have a good tight connection. 2. Hook up main single-pha se power and ground. The following pictu re shows the correct location. Main power High Temp Safety Main Power Connection Heater Connection Thermocouple 3. Turn the[...]

4. Turn the dryer operation switch to the desir ed position. If you have a seven day timer installed, set it to “On with timer” position, otherwise set it to “On without timer” position. The blower will start. An explanation is given in the following diagram. 5. Turn the hopper heater switch to po sition “I” Position “O” Position ?[...]

6. Once in position “I”, temperature controller will display as shown below. Blower must be running for temperature cont roller to be on. Te mperature setting will vary as the processed desired temperature is changed. Also, a description of the buttons are listed belo w. Note: For initial start-up or if the dryer has not run for an e xtended pe[...]

It is recommended that the dryer be Self-Opt imized. The following steps should be taken to self optimize the dryer: a.) Press and hold the “EXIT” button for at least 2 seconds. b.) “tunE” will flash while self-optimization is in progress (can take several minutes) c.) When “tunE” stops flash ing; self-optimization is completed. d.) Whe[...]

14.2. Proper Shut-down Guide for STT 40 Dryer 1. Turn the hopper heater switch to position “0” Position “O” Position “I” 2. With the main disconnect power in the “ON” position, turn the dryer operation switch to the “OFF” position, this will automatically enable the system to go into cool down mode. That means the blower will ru[...]

14.3. Quick Start Guide for STT 70 Dryer 1. Check all wiring connection s to ensure that they are in the correct place and have a good tight connectio n. 2. Hook up main three-phase power and gr ound. The following picture sho ws the correct location. Main power High Temp Safety Main Pow er Connection Heater Connection Thermocouple 3. Turn the disc[...]

5. Turn the hopper heater switch to position “I” Position “O” Position “I” 6. Once in position “I”, the temperature contro ller will display as shown below. Blower must be running for temperature cont roller to be on. Te mperature setting will vary as the processed desired temperature is changed. Also, a de scription of the buttons [...]

Note: Due to the following circumstance s: - initial dryer start-up - dryer not running for long period of time - dryer has been unplugge d and moved to a different location It is recommended that the dryer be Self-Opt imized. The following steps should be taken to self optimize the dryer: a.) Press and hold the “EXIT” button for at least 2 sec[...]

14.4. Proper Shut-down Guide for STT 40 Dryer 1. Turn the hopper heater switch to position “0” Position “O” Position “I” 2. With the main disconnect power in the “ON” position, turn the dryer operation swit ch to the “OFF” position, this will automatically enable the system to g o into cool down mode. That means the blower will [...]

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 manufacture d to Sterling engineering des ign specifications, whic h will maximize your equipment’s performance and efficiency. To assist in expediti ng y[...]