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Sterling 350-2100 CFM manual

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Table of contents for the manual

  • Page 1

    OPERATION AND INSTALLATION MANUAL SDA SERIES 350 - 2100 CFM LARGE DEHUMIDIFYING DRYERS IMPORTANT: PLEASE READ CAREFULLY BEFORE A TTEMPTING TO INSTALL OR OP ERATE EQUIPMENT Bulletin No: DH1-655-1 Part No: 882.00225.00 Effec tive: 4-28-08[...]

  • Page 2

    DH1-655.1 ii Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvem ent. Specifications, appearance, and dimensions described in t[...]

  • Page 3

    DH1-655.1 iii Shipping Info 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 According to the contract terms[...]

  • Page 4

    DH1-655.1 iv Table of Contents CHAPTER 1: SAFETY ................................................................ 6 1-1 How to Use This Manual ............................................................................................. 6 Safety Symbols Used in this Manual ..................................................................... 6 1-2 [...]

  • Page 5

    DH1-655.1 v 5-5 Setting the High and Low Temperature Alarms ........................................................ 28 5-6 Temperature Controller Autotune Procedure ............................................................ 29 5-7 Temperature Controller Internal Switches ................................................................. 29 5-8 Te[...]

  • Page 6

    350-2100 cfm Dryers Chapter 1: Safety 6 of 58 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your dehumidifying dryer. The purpose is to assist you in applying effici ent, proven techniques that enhance equipment productivity. This manual covers only light corrective [...]

  • Page 7

    350-2100 cfm Dryers Chapter 1: Safety 7 of 58 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[...]

  • Page 8

    350-2100 cfm Dryers Chapter 1: Safety 8 of 58 1-3 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national a nd local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international[...]

  • Page 9

    350-2100 cfm Dryers Chapter 1: Safety 9 of 58 1-4 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended inst ructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machin e should become familiar with its op[...]

  • Page 10

    350-2100 cfm Dryers Chapter 1: Safety 10 of 58 Learn and always use safe operation. Cooperate with co-workers to promote safe practices. Immediately report any potentially dangerous s ituation to your supervisor or app ropriate person. REMEMBER: • NEVER place your hands or any part of your body in any dangerous location. • NEVER operate, servic[...]

  • Page 11

    350-2100 cfm Dryers Chapter 1: Safety 11 of 58 Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric supplies and all accessory equipment at the m achine, and disconnect and lockout electrical power. Attach warning tags to the disconnect switch. When you need to perform maintenance or repa ir work on a dryer[...]

  • Page 12

    350-2100 cfm Dryers Chapter 2: Functional Description 12 of 58 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installati on, and m aintenance instructions for WD/SDA/CDA 350, 425, 500, 600, 7 00, 850, 1000, 1250 , 1500, 1800, and 210 0 cfm large dehumidifying dryers in both standard 300 ˚ F and [...]

  • Page 13

    350-2100 cfm Dryers Chapter 2: Functional Description 13 of 58 2-5 The Closed Loop Drying System ACS dryers force hot, dry air through the resin in the dr ying hopper, where the air picks up moisture from the material and is drawn back to the dryer. In the dryer, moisture is stripped from the air by a desiccant bed. The dried process air is then re[...]

  • Page 14

    350-2100 cfm Dryers Chapter 2: Functional Description 14 of 58 When a desiccant bed is on- line, it absorbs moisture from the process air. In time, the bed becomes saturated with moisture and needs to be regenerated. The dryer automatically redirects the process airflow to the second bed, and starts the regeneration cycle on the first bed. During r[...]

  • Page 15

    350-2100 cfm Dryers Chapter 2: Functional Description 15 of 58 Figure 3: Dryer Dimensions ? E A B C REAR VIEW TOP VIEW D 34" RADIUS DESICCANT TOWER (LEFT SIDE) OPTIONAL AFTERCOOLER REGEN BLOWER AND FILTER PROCESS BLOWER PROCESS HEATER PROCESS AIR OUTLET PROCESS RETURN FILTER 1.5" MPT INLET 1.5" MPT OUTLET ELECTRICAL ENCLOSURE PROCESS[...]

  • Page 16

    350-2100 cfm Dryers Chapter 2: Functional Description 16 of 58 G F I H LEFT 18" MINIMUM MAINTENANCE CLEARANCE 24" SUGGESTED MINIMUM VERTICAL CLEARANCE WD-2100 WD-1800 WD-1250 WD-1500 WD-850 WD-1000 100 90½ 82½ 44½ 90.5 88 70½ 91½ 83 100 90½ 82½ 44½ 90.5 88 70½ 91½ 83 100 90½ 82½ 44½ 90.5 88 70½ 91½ 83 84 88 56 34½ 90 87½ [...]

  • Page 17

    350-2100 cfm Dryers Chapter 3: Installation 17 of 58 Chapter 3: Inst allation 3-1 Work Rules The installation, operation, and maintenance of this equipm ent must be conducted in accordance with all applicable work and safety codes for the installation location. This may include, but not limited to, OSHA, NEC, CSA, a nd any other local, national and[...]

  • Page 18

    350-2100 cfm Dryers Chapter 3: Installation 18 of 58 ; Keep the delivery (to the drying hopper) hose as short as possible to minimize heat loss. Insulated hose is recommended and available for maximum energy savings. ; Do not use insulated hose on the return (from the drying hopper) ; Do not shorten the return hose. The return air to the blower mus[...]

  • Page 19

    350-2100 cfm Dryers Chapter 3: Installation 19 of 58 Figure 5: Typical Control Panel Process Heater Amps Regen Heater Amps Redundant High Temp Safety Redundant High Temp Alarm -40 -35 -30 -25 -20 -15 -10 -5 0 DEW POINT(F.) Redundant High Temp Reset A0542534 A0542757 A0542533 Adjustment Air Temp Low Regen Process Dew Point High Regen Air Temp Regen [...]

  • Page 20

    350-2100 cfm Dryers Chapter 4: Control Panel 20 of 58 Chapter 4: Control Panel 4-1 Control Panel Indicator Lights PROCESS BLOWER ON This indicator lights when the process blower is energized. PROCESS HEATER ON This indicator lights when the process air heaters are energized. HIGH PROCESS AIR TEMPERATURE ALARM ; This indicator lights when the temper[...]

  • Page 21

    350-2100 cfm Dryers Chapter 4: Control Panel 21 of 58 ; The alarm mode and value are factory-set to track 25°F below the process setpoint. The alarm value is a deviation above the process setpoint. ; This alarm is informational. If the alarm light stays lit for an extended period of time, check for blown fuses or possible burnt-out heaters. ; When[...]

  • Page 22

    350-2100 cfm Dryers Chapter 4: Control Panel 22 of 58 VALVE POSITION ERROR A pair of position switches confirm proper shifting of the valves. If full travel is not confirmed by the switches, the cycle will not begin on the new bed. 4-2 Switches and Meters ON/OFF SELECTOR SWITCH This energizes or de-energizes the dryer's control power. START/ST[...]

  • Page 23

    350-2100 cfm Dryers Chapter 4: Control Panel 23 of 58 ; If one or two of a heater's three meters indicates a low reading, a burned-out heater is likely, and should be serviced. 4-3 PLC Control These dryers are equipped with an Omron C28K programmable logic controller (PLC). The "brick" type PLC has 28 I/O points - 16 inputs an d 12 o[...]

  • Page 24

    350-2100 cfm Dryers Chapter 4: Control Panel 24 of 58 Figure 6: Process Air Temperature Controller[...]

  • Page 25

    350-2100 cfm Dryers Chapter 4: Control Panel 25 of 58 4-5 Temperature Controller LED Indicators Process Value Numeric LED During normal operation, this red LED on the control displays the process temperature at the "To Process" thermocouple. It also lists parameters during setup and error messages if an error occurs. Set Value Numeric LED[...]

  • Page 26

    350-2100 cfm Dryers Chapter 4: Control Panel 26 of 58 4-6 Temperature Controller Keys – (See Figure 5 in Section 3-6) LEVEL KEY When pressed for two seconds or more, this key sel ects the next of the three indication levels (0, 1 and 2) where specific control parameters may be set. The control defaults to level 0 on power up. REMOTE KEY This key [...]

  • Page 27

    350-2100 cfm Dryers Chapter 5: Startup, Shutdown & Operation 27 of 58 Chapter 5: S t artup, Shut down & Operation 5-1 Pre-Startup Checks ; Check the process and return hoses for tight connections. ; Check that all companion equipment, such as the drying hopper, l oading system and aftercooler are ready for operation. ; Check the dryer elect[...]

  • Page 28

    350-2100 cfm Dryers Chapter 5: Startup, Shutdown & Operation 28 of 58 6. If the dryer has an aftercooler, make sure there is proper flow of cooling water flow through the coil, and any trapped air has been bled from the system. 7. Make sure the damper on the hopper ai r inlet tube is about 50% ope n. 8. Remove the lower end of the 2½" fle[...]

  • Page 29

    350-2100 cfm Dryers Chapter 5: Startup, Shutdown & Operation 29 of 58 The low temperature alarm value is a deviation of the process air temperature set point. The alarm value will track the set temperature. If the low temperature alarm is set to "-25", a low tem perature alarm occurs if the process air temperature falls more th an 25?[...]

  • Page 30

    350-2100 cfm Dryers Chapter 5: Startup, Shutdown & Operation 30 of 58 5-9 Changing the Display from Fahrenheit to Centigrade To change the display from the factory °F setting to °C: 1. Disconnect main electrical power to the dryer. 1 23456 ON 2. Press up the latch at the bottom of the control m odule's front panel and slide out the contr[...]

  • Page 31

    350-2100 cfm Dryers Chapter 5: Startup, Shutdown & Operation 31 of 58 5-11 Regeneration Monitoring System Signal Processor Dryer models 350 through 2100 have a 1/8 DIN signal processor that m onitors the bleed air discharged from the desiccant tower being regenerated. The si gnal processor has four programmable temperature setpoints that, when [...]

  • Page 32

    350-2100 cfm Dryers Chapter 5: Startup, Shutdown & Operation 32 of 58 • Press again to move one digit to the right. Then press to display the desired value. • Follow this procedure to set all four digits. • When satisfied with the value displayed, press to save the new value to the regeneration monitor's memory, and move on to the ne[...]

  • Page 33

    350-2100 cfm Dryers Chapter 5: Startup, Shutdown & Operation 33 of 58 Setting the Current Day of the Week, Hour and Minute: 1. Apply main power to the dryer. 2. Turn on the timer by sliding the left manual override switch to the "ON" position. The timer's memory is cleared on power up. 3. Press and hold MODE until TIM ADJ becomes[...]

  • Page 34

    350-2100 cfm Dryers Chapter 5: Startup, Shutdown & Operation 34 of 58 7. Press once. The hour and minute display returns to ze roes and the hour indicator should be blinking. Setting the stop time: 1. Press or until the desired dryer shut down hour is displayed. The shut down time is set in a 24-hour format. 2. Press to store the shut down hour[...]

  • Page 35

    350-2100 cfm Dryers Chapter 6: Maintenance 35 of 58 Chapter 6: Maintenance 6-1 Servicing the Process Air Filters (Models 350-700) WARNING: Operating the dryer without the process air filters installed will void the warranty. Filter Cleaning i s an importan t part of dryer maintenance. Dryer models 350 through 700 have single high temperature [up to[...]

  • Page 36

    350-2100 cfm Dryers Chapter 6: Maintenance 36 of 58 to remove all dirt and suds (less than 40 psi, no nozzl e). If the clean or downstream side of the filter has been contaminated with dirty water duri ng the soak c ycle, rinse from both sides. • Dry the filter before re-using. Circulate warm air at less than 160ºF. Do not use a light bulb to dr[...]

  • Page 37

    350-2100 cfm Dryers Chapter 6: Maintenance 37 of 58 service. Satisfactory filtration should be obtained through the second or third washing , however the dirt holding capacity of the filter decreases after each washing. After Each Cleaning: • Inspect the filter element – hold a light bulb behi nd t he element to find fatigued paper or residual [...]

  • Page 38

    350-2100 cfm Dryers Chapter 6: Maintenance 38 of 58 9. Remove the restriction from the filter element and re-install the clean filter. The alarm light should remain off. 6-6 Dewpoint Control System Service The Dewpoint Shift feature on dryer models 350 thro ugh 2100 depends on the pr oper operation of the dewpoint sensor and its control board. The [...]

  • Page 39

    350-2100 cfm Dryers Chapter 6: Maintenance 39 of 58 • Noticeable amounts of desiccant in the beds is a medium-brown color, or darker. If any of these signs are noticed, the desiccant in the desiccant beds should be replaced. Desiccant replacement kits are available from the Parts De partment. If you wish, the desiccant beds can be repacked at you[...]

  • Page 40

    350-2100 cfm Dryers Chapter 6: Maintenance 40 of 58 Figure 6: Desiccant Amounts Required Dryer Desiccant Required per Tower Model Large Bead Small Bead Total 350 30 76 106 350-RT 30 76 106 425 30 90 120 425-RT 30 90 120 500 40 100 140 500-RT 40 100 140 600 40 120 160 600-RT 40 120 160 700 40 35 175 700-RT 40 35 175 850 120 120 240 850-RT 120 120 24[...]

  • Page 41

    350-2100 cfm Dryers Chapter 6: Maintenance 41 of 58 6-10 Regeneration Heater Replacement Procedure Dryer models 350 through 2100 Dryers have four or eight three-phase regeneration heaters wired in the wye formation mounted in the insulated box directly above the lowe r valve. WARNING! WARNING! Disconnect and lock ou t power before heater replacemen[...]

  • Page 42

    350-2100 cfm Dryers Chapter 6: Maintenance 42 of 58 6-11 Restoring a Temperature Cont roller to the Factory Setup If the control's pre-set parameters have been tamper ed with and it will no longer c ontrol, try restoring the factory set up: 1. Turn off the p ower switch on the graphic displa y and remove all electrical power to the dryer. 2. P[...]

  • Page 43

    350-2100 cfm Dryers Chapter 6: Maintenance 43 of 58 Display Characters Sensor Type Switch Position Temp Range °C °F Thermocouple Type R 0 0 - 1,700 0 - 3,000 Thermocouple Type S 1 0 - 1,700 0 - 3,000 Thermocouple Type K 2 -200 to 1,300 -300 to 2,300 Thermocouple Type J 3 -100 to 900 -100 to 1,600 Thermocouple Type T 4 -200 to 400 -300 to 700 Ther[...]

  • Page 44

    350-2100 cfm Dryers Chapter 6: Maintenance 44 of 58 11. Slide the control chassis back into the control housing. The remaining parameters are set with the keypad. 12. Ready the dryer for startup with a real or simulated load. Restore the electrical power. 13. Turn the control power on. The PV LED will disp lay four zeros [ 0000] and then display th[...]

  • Page 45

    350-2100 cfm Dryers Chapter 6: Maintenance 45 of 58 Figure 7: Factory Pre-Set Control Parameters P arameter Setting Levels Parameter Description PV LED Display Dryer SV LED Setting Display at Power Up 10 ° F Alarm Range 10 ° F 0 Proportional Bandwidth 90.0 Seconds Reset Time 20 Seconds Rate Time 0 ° F Lower Limit Value of Control Range 250 ° F [...]

  • Page 46

    350-2100 cfm Dryers Chapter 6: Maintenance 46 of 58 Figure 8: Process Temperat ure Control Error Messages Message Cause Control Output Alarm Output With output unit other than current output unit With current output unit Input temperature has risen beyond the upper limit of the temperature range by more than 20 ° C [68 ° F] c OFF during reverse ([...]

  • Page 47

    350-2100 cfm Dryers Chapter 6: Maintenance 47 of 58 Figure 9: Regeneration Monito r Signal Processor Error Messages Item Condition Error Output Status Corrective M e s s a g e Compara- tive Outputs BCD Output Linear Output Commun- ications Action Device Failure CPU RAM error, external memory error, memory data error. OFF OFF OFF OFF Turn the power [...]

  • Page 48

    350-2100 cfm Dryers Chapter 6: Maintenance 48 of 58 6-12 Regeneration Monitor Advanced Programming The regeneration monitor has three menu levels, num bered 0 through 2. Each m enu level allows specific parameters to be viewed and/or set. Moving Between Levels Level 0, the RUN mode, is the default and automatic ally appears when the dryer is powere[...]

  • Page 49

    350-2100 cfm Dryers Chapter 6: Maintenance 49 of 58 LEVEL 1 In this level, the four setpoints can be changed, plus Hysteresis, Input Shift and Security Protection can be set. Use to move from one param eter to the next. When the desired parameter appears on the LED display, press to select that parameter for program- ming. The parameter’s current[...]

  • Page 50

    350-2100 cfm Dryers Chapter 6: Maintenance 50 of 58 Press after a ppears on the LED display. Use and to set the value. Then press to save the new setting to memory. Security Protection - When Security Protection is enabled, the setpoints can’t be changed when the Regeneration Monitor is in “RUN” mode. The setpoints can only be changed in Leve[...]

  • Page 51

    350-2100 cfm Dryers Chapter 6: Maintenance 51 of 58 LEVEL 2 In this level, parameters such as the type of temperature sensor connected to the regeneration monitor, Fahrenheit/centigrade display, and display refresh cycle can be set. moves from one parameter to the next. When the desired parameter appears on the LED display, press to select that par[...]

  • Page 52

    350-2100 cfm Dryers Chapter 7: Troubleshooting 52 of 58 Chapter 7: T roubleshooting PROBLEM POSSIBLE CAUSE CORRECT IVE ACTION Little or no air coming from process delivery tube. A. Dirty Filters A. Clean or replace filters. B. Desiccant beds contaminated by material or plasticizer leaking into the system. See Sec. 6-6. B. Replace desiccant C. Blowe[...]

  • Page 53

    350-2100 cfm Dryers Chapter 7: Troubleshooting 53 of 58 PROBLEM POSSIBLE CAUSE CORRECT IVE ACTION Loss or reduction of process air temperature. A. Process heaters are faulty. A. Check for open or shorted heaters. Replace if required. Check the fuses. B. Solid-state temperature controller faulty. B. Replace. C. Process temperature was adjusted in er[...]

  • Page 54

    350-2100 cfm Dryers Chapter 7: Troubleshooting 54 of 58 PROBLEM POSSIBLE CAUSE CORRECT IVE ACTION Material in drying hopper cakes, or meltdown occurs. A. Process temperature set too high due to operator error. A. Check resin manufacturer's data sheet for proper drying temperature. Make sure plant personnel are aware of the correct process temp[...]

  • Page 55

    350-2100 cfm Dryers Chapter 8: Appendix 55 of 58 Chapter 8: Appendix 8-1 Returned Material Policy Credit Returns Prior to the return of any material, authoriz ation must be given by the manufacturer . A RMS num ber will be assigned for the equipment to be returned. Reason for requesting the return must be given. All returned material purchased from[...]

  • Page 56

    350-2100 cfm Dryers Chapter 8: Appendix 56 of 58 -Notes-[...]

  • Page 57

    350-2100 cfm Dryers Chapter 8: Appendix 57 of 58 Preventive Maintenance Checklist Dehumidifying Dryers Dryer Model # Serial # EVERY WEEK Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Inspect all filters for wear, replace/clean if dirty or worn Check air regulator to make sure pr[...]

  • Page 58

    350-2100 cfm Dryers Chapter 8: Appendix 58 of 58 8-2 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 262 ] 641-8610 F ax: [26 2] 641-8653 The ACS Customer Serv ice Group will provide yo ur com pany with genuine OEM qualit y parts manufactured to engineering design specificati ons, which will maximize y[...]