Sterling DH1-610-2 manual

SDAA 25-100 Small Dryer With AP-1 Controls Part Number: 882.00294.0 0 Bulletin Number: DH1-610-2 Effective: 05/15/06 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to[...]

Shipping Information Unpacking and Inspection You should inspect your portable drying/conveying s ystem 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 [...]

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

Disconnect Switch ...................................................................................... 21 Control Power Switch ................................................................................. 21 Touch Screen ............................................................................................. 21 Alarm Horn & Light ...[...]

Replacing the Process Heater ............................................................................. 45 Replacing/Cleaning the Cooling Coils ................................................................. 46 CHAPTER 6: TROUBLESHOOTING ........................................ 48 6-1 Introduction...............................................[...]

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. No other maintenance should be undertak[...]

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 within design specifications, followin[...]

; 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 equipm ent, etc., and the equipment and[...]

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. Operator Responsibility 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 it[...]

• NEVER stand or sit where you could slip or stumble into the equipment while working on it. • DO NOT wear loose clothing or jewelry, which can be caught while working on the equipment. In addition, cover or tie back long hair. • Clean the equipment and surrounding area DAILY , and inspect the machine for loose, missing or broken parts. • S[...]

Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d maintenance instructions for 1 5, 30 or 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 contacting the manufacturer for parts or serv[...]

2-3 Standard Features Mechanical Features • Rugged compact cart with handles and sturdy 4” (10 cm) casters. • Dual desiccant beds • Electrically-motorized air valve • 13X Molecular Sieve • Single regenerative process blower • Drying temperature range of 180ºF to 250ºF (82 ºC to 121ºC) • 2.5” hose connections Electrical Feature[...]

2-4 Options Options marked with “*” indicate options that can be factory installed or retrofitted in the field. • * Process temperature up to 400ºF (204º C), including aftercooler with dryer and silicone insulated delivery hose. Note: For below 180°F (82ºC), cooler needs to cool the air coming out of the desiccant tank prior to entering t[...]

Every effort has been made to incorporate these standards into the design of the drying system; however, it is the responsibility of the personnel operating and m aintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices. Fail Safe Operation If a safety device or circuit should fail, the [...]

Chapter 3: Inst allation 3-1 Uncrating the Equipment Portable Drying/Conveying Systems 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 lift the box off carefully; avoiding staples in the 1’ x 4’ wood sup[...]

Figure 1: Suggested Lift Rigging for Cart Mount Dryers ON O F F PROCESS TEMPERATURE DEW POINT CONTROL POWER ON OFF ALARM ALARM Silencer ALARM HORN DO NOT USE USE FORK LIFT TRUCK 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 [...]

Figure 3: Suggested Lift Rigging for Cart Mounted Dryers ON O F F PROCESS TEMPERATURE DEW POINT CONTROL POWER ON OFF ALARM ALARM Silencer ALARM HORN Mounting flange Hopper mounting flanges on 0.75 and can drill to match existing machine throat. Diameter hole: Notes: and 1.5 cu. ft. (20 & 40 liter) hoppers are supplied blank so the customer 3.0 [...]

3-4 Setup Procedures This section provides the procedures necessary for configuring your portable drying/conveying system. Configuration of your unit includes checking for proper blower rotation and installing the optional aftercooler (on 60 cfm models). We recommend that you carry out these procedures in the order given here. Note: Before carrying[...]

NOTE: If the Aftercooler is used as a plasticizer trap, the water temperature of 50°F or lower is recommended. 3-5 Initial Start-up Pre-Startup Checks ; Check the process and return hoses for tight connections. ; Check all companion equipment, such as the drying hopper; verif y that the loading system is ready for operation. ; Verify that all drye[...]

Figure 2: Process Autotune Screen 1. The autotune feature can be enabled by pressing the START/STOP button located in the center of the screen. 2. AUTOTUNE IN PROGRESS or PROCESS NOT ACTIVE will inform the operator of the current status of this feature. 3. At this point the operator can return back to the DRYER MENU or MAIN MENU by touching the app[...]

Chapter 4: Operation 4-1 Controller Description and Operation Identifying Control Panel Components for the AP-1 Controller Disconnect Switch The Disconnect Switch is located in the front upper right hand corner of the control enclosure. It allows the user to disconnect power to the dryer for emergency shutdown, service or long periods of inactivity[...]

Process Air Temperature Controller Control package use a PLC with a touch screen interface to control the operation of the dryer and the optional conveying system. This secti on of the manual will address those parameters that allow the user to optimize the drying/c onveying s ystem for specific applications. Figure 4: Dryer Status Screen on Touch [...]

Main Menu Screen The MAIN MENU provides information on the following drying/conveying s ystem parameters: • DRYER MENU (some submenus are password protected) • ALARM HISTORY • HELP MENU • SYSTEM MENU • NO USERS LOGGED ON This section of the manual will focus on the dryer features portion of the controller at this time. Press the DRYER MEN[...]

Machine Status The area in the lower left portion of the touch screen conveys two lines of information relating to the overall operation of the dryer. Th e following is a list of typical machine/dryer summary status line text messages: 1. Left Bed In Process 2. Right Bed In Process 3. Process Offline 4. Valve Changing Position 5. Auto start Timer E[...]

Dryer Menu Screen The screen shown above will allow the operator to set/review operating parameters for the following: • DRYER STATUS • DRYER SETUP (requires supervisory password) • OVERDRY PROTECT (requires supervisory password) • ALARMS • AUTO TUNE (requires supervisory password) • DEW PT SETUP (Dew Point Setup) • AUTO START (requir[...]

Buy pressing the MORE screen, you can choose for the temperatures to display in degrees F or degree C . ( Note; Changing the temperature scale, requires adjusting the alarm values.) When these settings have been made, the opera tor now has a choice of returning to the DRYER MENU, BACK (takes you back to the DRYER SETUP 1 of 3 ) or pressing MORE to [...]

The PROCESS RETURN AIR TEM PERATURE displays the air temperature as it leaves the drying hopper. If this temperature is above 150°F, an aftercooler is required. By pressing the DISABLE or ENABLE the operator disable or enable this feature of the dryer. This feature is used to prevent the over dryi ng of the plastic resin in the drying hopper. At t[...]

Enter the values you would like to set in the screen by pressing the number keys. Press ENT (Enter) when you are finished to set the new values or CLR (Clear) to erase the current values and reenter new ones. The next feature in the DRYER MENU is the ALARMS button/screen. Alarms (Retains 100 of the most recent alarms) This screen allows the operato[...]

Dew Pt Setup This screen allows the operator to set the dew point alarm value. The HIGH LIMIT ALARM VALUE is an audible/visual alarm which will sound when the process air dew point rises to this value. Values can be set for degrees F a hrenheit between – 40 through +15 degrees and degrees Celsius between -40 through -10 degrees. Setting Values By[...]

By touching the ON TIME and OFF TIME sections on the screen, the operator can enter the values for the time they wish the dryer to turn on and off. See the next page for instructions on setting values for this feature. Pressing the AUTOSTART TIMER DISABLED button will activate this dryer feature. Pressing AUTOSTART TIMER ENABLED will deactivate thi[...]

System Menu The screen shown above will allow the operator to set/review operating parameters for the following: The above screen will allow the operato r to set/review operating parameters; • SYSTEM SETUP • SET CLOCK • HOUR METERS • ALARM HISTORY • I / O STATUTUS (Input and output status) • SYSTEM BACKUP • SERVICE • MAIN MENU SYSTE[...]

Note: If password(s) feature is enabled, please write down y passwords and file them in a secure location. our At this point the operato touching the appropriate button r can return back to the MAIN MENU or SYSTEM MENU by on the screen. Set Clock This menu allows the operator to set the AUTOSTART CLOCK and the ALARM CLOCK . Press the SET AUTOSTART [...]

Set Alarm Clock In this screen the user can set the variables wh ich are used to time and date stamp alarms. This feature works in conjunction with the ALARM screen (See page 31) to notify the user of n shown above, the operator (Month, Day, Year, Hours and Minutes) he wishes to change. d reenter issues which the Dryer had encountered during its op[...]

Input Status (UPDATE) This screen allows the operator to view the status of the variables contributing to the input of material into the drying system. It also is useful in troubleshoot ing system issues (i.e. a dirty filter or low material level in a hopper). At this point the operator may choose the SYSTEM MENU button to go back to the system men[...]

At this point the operator may choose to return to the SYSTEM MENU or MAIN MENU by pressing the appropriate buttons. Service Menu This service menu screen is PASSWORD PROTECTED and meant for manufacturer personnel use only. Press the RETURN key to go back to the SYSTEM MENU . Touching the MAIN MENU button in the SYSTEM MENU screen, will return the [...]

Because of the size of the screen, only three (3) comments/alar ms can be viewed at a time. To view alarms not visible on the screen, press the DOWN button. To return to a particular alarm, press the UP button to scroll upward in the alarm history. Pressing CNV (Convey) in this screen will take the operator to the CONVEY STATUS of the system. You w[...]

lower display indicates the High Point Setting al arm value. The factory setting for the High Point Alarm Value ( L1-hi ) is 150 ° F (-23 ° C). Restoring the WATLOW Redundant Safety Controller to Factory Setup If the preset parameters on the controller have b een tampered with and it no longer functions properly, call the Service Department. Note[...]

UdSP Upper Display Look None, Process Value, Limit 1 Lo w Set, Limit 1 High Set, Limit 2 Low Set, Limit 2 High Set, Alarm 2 Low Set, Alarm 2 High Set, Limit 3 Low Set, Limit 3 High Set, Alarm 3 Low Set, Alarm 3 High Set Process - LdSP Lower Display Look None, Process Value, Limit 1 Lo w Set, Limit 1 High Set, Limit 2 Low Set, Limit 2 High Set, Alar[...]

4. If either the left or right bed safety temperature switch opens, a REGEN TEM SAFETY is generated. The alarm horn and light are activated. The process heater, regen heater, and process/regen blower are turned off. Pressing the ALARM SILENCE button on the touch screen will deactivate the alarm horn and light. 5. Turn the Off-On switch to the ON po[...]

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 # Every Day Date/ By Date/ By Date/ By D[...]

5-2 Preventative Maintenance This section describes maintenance procedures which will increase the longevity and efficiency of your Portable Drying/Conveying System. Perform them at the regular intervals listed on the checklist on the previous page. Servicing Process Air Filters Caution! Operating the dryer without the proces s air filter installed[...]

Vacuuming Try vacuum-cleaning a soiled filter first. Vacuuming removes most large particles and surface contaminants, and may suffice for the firs t time you clean a filter. Use a commercial- duty (recommended) or household vacuum cleane r. Vacuum the filter from the air intake (dirty) side only. Cleaning with Compressed Air Blow clean, dry compres[...]

5-3 Corrective Maintenance This section provides you with the informati on necessary to correct or repair any issues which might appear during the norma l operation of your dehumidifying dryer. Although we have listed how to perform these procedures, it is recommended that you call the Service Department to have any in-d epth maintenance performed.[...]

Figure 8: Desiccant Bed Location and Disassembly Undo (4) 10-32 Butto n Head Scr ew s using 1/8 Allen Wrenc h Des iccant C ap 1" Wide x 1/8" T hick Silicon Strip and Stick Gask et 16 Mes h 0.028 D iameter W ire Stainless Stee l Scr een (2) 4-4 0 screw s Hi Tem perature Snap Sw i tch Regener atio n Heat er 1" Wide x 1/8" T hick H[...]

Figure 9: Required Desiccant Amounts Dryer 8 x 12 bead Total model Part no. lbs. Kg 15 cfm 7.0 3.25 30 cfm 15.75 7.25 60 cfm W00018051 37.5 17.0 Replacing the regeneration heaters Procedures (see figure 8). 1. Sketch the heater wiring configuration so you can properly re-wire the heater. 5 Remove the ceramic nuts and wires to the heater plate assem[...]

Procedures 1. Sketch the heater wiring configuration so you can properly re-wire the heater. 2. Remove the ceramic nuts and wires to the heater plate assembly being removed or replaced. 3. Remove the six (6) 10-32 button head screw s securing the process heater plate using a 1/8” Allen wrench and slide out the assembly. 4. Remove the heater(s) fr[...]

Replacement Procedures 1. Shut down the dryer, tag out and lock out the controls if necessary. 2. Shut the water off to the cooling coil. 3. Remove the four 10-32 bolts. 4. Gently slide the cooling coil out. 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, ste[...]

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 service. The use of good quality test equi[...]

Alarm Message Cause Corrective Action Dry er Status The process temperature thermocouple is not conne cted to the temperature controller. Make sure the connections are correct and tight. PROCESS SENSOR FAIL The process temperature thermocouple is open. The process temperature thermocouple is damaged. Replace the thermocouple. - Dryer Shuts Down: - [...]

Alarm Message Cause Corrective Action Dry er Status The process temperature thermocouple is not conne cted to the temperature controller. Make sure the connections are correct and tight. PROCESS SENSOR FAIL The process temperature thermocouple is open. The process temperature thermocouple is damaged. Replace the thermocouple. - Dryer Shuts Down: - [...]

Alarm Message Cause Corrective Action Dryer Status Make sure all the hose connections inside the dry er are tight. Check the regeneratio n heater fuses. Replace if necessary. Check the heater contactors. Replace if necessary. Check the heaters. Replace if necessary. REGEN LOW TEMP The regeneration temperature did not get within the alarm set point.[...]

Alarm Message Cause Corrective Action Dryer Status Make sure the process air filter is clean. Clean or replace if necessary. Check the rotation of the blower. The process blower pressure switch did not detect enough pressure. Process blower overload has tripped. Check the pressure switch hose connection. Repl ace hoses or the pressure switch. Proce[...]

Alarm Message Cause Corrective Action Dryer Status Check the pressure setting of the filter pressure differential switch against the print. Adjust accordingly. DIRTY FILTER The filter pressure differential switch has tripped. Check the filter pressure differential switch to make sure it is functioning. Replace is necessary. - Dryer Normal : - Proce[...]

6-2 Determining Temperature Contro ller Errors or Sensor Errors Using a Thermocouple If the controller displays a temperature that is close to room temperature (70ºF/21ºC) when you short-circuit controller input terminals, the control ler is normal and the sensor is probably broken, short-circuited, or incorrectly wired. Other service problems or[...]

Chapter 7: Appendix 7-1 Warranty Unless otherwise specified, this product includes a Standard ONE YEAR P ARTS. Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free fro m defects in workmanship and material when used under recommended conditions, as set forth in the operating manuals for such[...]

applicable federal and state law, but not by the United Nations Convention on Contracts for the Sale of Goods. Customer Responsibilities Any sales, use, or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser. 7-2 Optional Components The following is a list of options which your Portable Drying/C[...]

22. Two-hand control is not required or pro vided. 23. All dryers and conveying equipm ent shoul d be moved around and set in a place with a lift truck or equivalent. 24. There are no frequent repetitive cycles that require manual control ⎯ repetitive functions are automatic while the drying and conveying system is operating. 25. An inspection re[...]

Figure 13: High Heat Model (180°F to 400°F) Air Flow Schematic Optional Return Air Cooler Utilizing -40F dew point air to regenerate and cool the desiccant. Double wall constructed heater housing and desiccant container. Low watt density heaters, can operate safely with minimum air flow. Regeneration thermocouple, monitors and controls the regene[...]

Figure 14: Low Heat Model (120°F to 250°F) Air Flow Schematic Utilizing -40F dew point air to regenerate and cool the desiccant. Double wall constructed heater housing and desiccant container. Low watt density heaters, can operate safely with minimum air flow. Regeneration thermocouple, monitors and controls the regeneration temperature Pressure [...]

7-5 Spare Parts List Figure 15: Level 1 Spare Parts List (Electrical & Mechanical) DRYER S PA RE PART S LI ST AD15, AD30, A D 60 15CFM 15CFM 15CFM 15CFM 15CFM 15CFM 30CFM 30CFM 30CFM 30CFM 30CFM 30CFM 60CFM 60CFM 60CFM 60CFM 60CFM 60CFM LEVE L 1 ( Ele ct ric al C omponents ) 208V 3PH 220V 50 HZ 3PH 230V 3PH 400V 50 HZ 3PH 460V 3PH 575V 60 HZ 3P[...]

Figure 16: Level 2 & 3 Spare Parts List (Electrical & Mechanical) DRYER SPA RE PARTS LIST AD1 5, A D30, A D60 15CFM 15CFM 15CFM 15CFM 15CFM 15CFM 30CFM 30CFM 30CFM 30CFM 30CFM 30CFM 60CFM 60CFM 60CFM 60CFM 60CFM 60CFM 208V 3PH 220V 50 HZ 3PH 230V 3PH 400V 50 HZ 3PH 460V 3PH 575V 60 HZ 3PH 208V 3PH 220V 50 HZ 3PH 230V 3PH 400V 50 HZ 3PH 460V[...]

7-6 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 subject to 15% ($75.00 minimum) restocking[...]

7-8 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423-3183 or call [ 630 ] 595-1060, Fax [630] 475-700 5 The ACS Customer Service Group w ill provide your company with genuine OEM quality parts manufactured to engi neering design specific ations, which will maximize your e quipment’s performance and efficiency. T o as[...]