Sterling SDA AP-1 manual

SDA Large AP-1 Control Dehumidifying Dryer Part Number: 882.00295.0 0 Bulletin Number: DH1-615-1 Effective: 04/28/2008 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed [...]

Large Dehumidifying Dryers ii Shipping Info Unpacking and Inspection You should inspect the large dehumidifying 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 Dam[...]

Large Dehumidifying Dryers iii Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping departme nt.[...]

Large Dehumidifying Dryers iv Table of Contents CHAPTER 1: SAFETY ................................................................ 7 1-1 How to Use This Manual ............................................................................................. 7 Safety Symbols Used in this Manual ...........................................................[...]

Large Dehumidifying Dryers v 3-7 Connecting Aftercooler/Precooler Cooling Water (Optional) ..................................... 32 3-8 Using the Drying Hopper Air Trap ............................................................................. 33 CHAPTER 4: CONTROLS ........................................................ 34 4-1 Controller Descr[...]

Large Dehumidifying Dryers vi Replacing the Regeneration Heater (Electric Dryers) ......................................... 62 CHAPTER 7: TROUBLESHOOTING ....................................... 64 7-1 Introduction................................................................................................................ 64 7-2 Basic Troubleshoo[...]

Large Dehumidifying Dryers Safety 7 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for in stalling, operating, and maintaining the large dehumidifying dryer. The purpose is to assist you in applying effici ent, proven techniques that enhance equipment productivity. This manual covers only light corrective main[...]

Large Dehumidifying Dryers Safety 8 Dryer Safety Tags Tag Description Tag Description Read Operation & Installation Manual High Voltage Inside Enclosure Hot! Lifting Point PE Protected Earth Ground Earth Ground 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design[...]

Large Dehumidifying Dryers Safety 9 ; Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment. We have long recognized the importance of saf ety and have designed and m anufactured our equipment with operator safety as a prime consid eration. We expect you, as a user, to abide by the foregoing reco[...]

Large Dehumidifying Dryers Safety 10 employer probably has established a set of safet y rules in your workplace. Those rules, this manual, or any other safety information will not keep you from being injured while operating your equipment. Learn and always use safe operation. Cooperate with co-workers to promote safe practices. Immediately report a[...]

Large Dehumidifying Dryers Safety 11 When you need to perform maintenance or repa ir work on a dehumidifying dr yer above floor level, use a solid platform or a hydraulic elevat or. If there is a permanently installed catwalk on your dryer, use it. The work platfor m should have secure footing and a place for tools and parts. DO NOT climb on the de[...]

Large Dehumidifying Dry ers Functional Description 12 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d maintenance instructions for 6 00-3000 cfm Large Dehumidifying Dry ers with AP1 contro l. These dryers are available with electric heaters or gas burners. Gas dryers are indicat[...]

Large Dehumidifying Dry ers Functional Description 13 moisture is stripped from the air by a desiccant bed. The dried process air is then re-heated and delivered back into the drying hopper to dr y material again. This system is a "closed loop", because ambien t (outside) air is never introduced into the process air. The closed loop syste[...]

Large Dehumidifying Dry ers Functional Description 14 Once the main air valve and closed loop regeneration valve are in place, the process air blower starts. The system monitors the process ai r blower’s overload, starter auxiliary contact feedback and air pressure. Loss of any of these items when the process air blower is running will cause the [...]

Large Dehumidifying Dry ers Functional Description 15 • Sequence shutdown switch ; NFPA86, UL, AGA & CGA machinery electrical stan dards (Gas Dryers) ; Available supply voltages of 208, 230, 460, 575/ 3/60 and 400/3/60 2-4 Options Dewpoint Extend The Dewpoint Extend option measures the temperature of the moist air as it is bled to the atmosph[...]

Large Dehumidifying Dry ers Functional Description 16 2-5 Drawings and Diagrams Regen. Filter Regeneration Blower Process Blower Optional After-cooler Process Air Filter Insulated Drying Hopper Left Desiccants Right Desiccants Process Heater Optional Regeneration Closed Loop Cooler Optional Regeneration Closed Loop Valve Regen. Exhaust Dryer Valve [...]

Large Dehumidifying Dry ers Functional Description 17 PS Differential Pressure Switch Filter Check Gage E F Dust Level Indicator Slide Gate Clamp Dust Pan Filter Retainer Dust Shroud Cartridge Filter Thumb Screws Optional dryer dust collector[...]

Large Dehumidifying Dry ers Functional Description 18 Process Aftercooler The optional aftercooler cools the moist air returning to the dryer from the drying hopper. The aftercooler can cool the return air from 250º F to about 150ºF. This maintains the dr yer’s efficiency and condenses the unwanted plasticizer from the air stream. The aftercool[...]

Large Dehumidifying Dry ers Functional Description 19 Figure 4: Process Air Dust Collector PS Differential Pressure Switch Filter Check Gage E F Dust Level Indicator Slide Gate Clamp Dust Pan Filter Retainer Dust Shroud Cartridge Filter Thumb Screws[...]

Large Dehumidifying Dry ers Functional Description 20 Material Overdrying Protection Material Overdrying Protection is an automatic system used to reduce the chance of over- drying, and possibly melting, the resin i n the drying hopper. Material Overdrying Protection activates when the return temperature is above a set value, indicating that all th[...]

Large Dehumidifying Dry ers Functional Description 21 Mechanical Options ; Low temperature operation (120°F to 250°F) ; High temperature operation (250°F to 400°F) ; Precooler (Required for temperatures be low 180°F, used with low temperature operation) ; Aftercooler (Required for temperatures above 250°F, used with hi gh temperature operatio[...]

Large Dehumidifying Dry ers Functional Description 22 2-6 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the large dehumidifying dryer. This manual is not in tended to supersede or alter safety standards established by the user of this equipment. Instead, the material contained [...]

Large Dehumidifying Dry ers Functional Description 23 In addition to the safety devices listed above, th ese dehumidifying dryers are equipped with a line cord plug. This allows the operator or maintenance personnel to unplug the system from its power source and tag it out. The plug can then be tagged with any num ber of approved electrical lockout[...]

Large Dehumidifying Dry ers Functional Description 24 Dimensions and Specifications 9 Denotes availability CFM 600 850 1000 1250 1500 2000 2500 3000 (Electric Dryer w/ Basic Control) 9 9 9 9 9 9 9 9 (Electric Dryer High Performance) 9 9 9 9 9 9 9 9 (Gas Dryer option in lieu of Electric- 180°F to 250°F) 9 9 9 9 9 9 9 9 Gas dryer 250°F -400°F tem[...]

Large Dehumidifying Dry ers Functional Description 25 Electrical Features CFM Drye r AMP Draw 600 850 1000 1250 1500 2000 2500 3000 Standard voltage Low Heat (Electric Dryers) Full load Amps 208v/3/60Hz. 152 217 249 314 378 230v/3/60Hz. 137 196 225 284 342 N/A 400v/3/50Hz. 79 113 129 163 197 270 339 424 460v/3/60Hz. 69 98 112 142 171 234 294 370 57[...]

Large Dehumidifying Dry ers Mechanical Installation 26 Chapter 3: Mechanical Inst allation 3-1 Uncrating the Equipment The large dehumidifying dryers are shipped mounted on a skid, encl osed 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 [...]

Large Dehumidifying Dry ers Mechanical I nstallation 27 ; Make sure all electrical connections are tight. 3-4 Making Gas Line Connections (Gas-Fired Models Only) Connect a gas line to the dryer’ s gas inlet. See Figure 6 for a detailed sche matic of the gas system. Figure 6: Gas Flow Schematic PS Fume Exhaust PS PS C B 1 2 3 4 4 6 7 8 9 10 11 12 [...]

Large Dehumidifying Dry ers Mechanical Installation 28 3-5 Checking for Proper Blower Rotation After the electrical connections have been made, check the process and regeneration blowers for proper blower rotation. Check blower rotation before making process air connections between the dryer and hoppers, and before connecting cooling water (for the[...]

Large Dehumidifying Dry ers Mechanical I nstallation 29 3-6 Making Dryer/Drying Hopper Process Air C onnections When making process air connections to your drye r, ensure that you take into consideration and make arrangements for the following: ; Use high-temperature flexible dryer hose or rigid tubing to co nnect the dryer to the drying hopper. ; [...]

Large Dehumidifying Dry ers Mechanical Installation 30 Process Air Heater on Dry ing Hopper Return air thermocouple location[...]

Large Dehumidifying Dry ers Mechanical I nstallation 31 Drying System with Dust Collector and Proc ess Air Heate r on Dryer Return air thermocouple location[...]

Large Dehumidifying Dry ers Mechanical Installation 32 After cooler Model Water Flow ( GPM ) AD600 10 AD850 10 AD1000 15 AD1250 15 AD1500 20 AD2000 25 AD2500 30 AD3000 35 High Temperature Gasket Stainless Steel Cooler Housing Cooling Coil Cooling Coil Pipe Gasket Cooling Coil Cover Plate Mounting Brackets High Temperature Gasket Cooling Coil Coolin[...]

Large Dehumidifying Dry ers Mechanical I nstallation 33 3-8 Using the Drying Hopper Air Trap Our exclusive air trap assembly in the top of the drying hopper prevents am bient air from contaminating the material being dried . To en sure that air does not enter the drying system, do the following (See Figure): ; Keep the material level above the bott[...]

Large Dehumidifying Dryers Controls 34 Chapter 4: Controls 4-1 Controller Description The AP1 control package uses a PLC with a touc h screen interface to control the operation of the dryer. See for descriptions of each screen. Figure 11: Controller Screen Descriptions Main Menu. The m ain navigational screen. Used to access status and set-up scree[...]

Large Dehumidifying Dryers Controls 35 4-2 Identifying Control Panel Comp onents for the AP-1 Optional 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. Control[...]

Large Dehumidifying Dryers Controls 36 • Copyright Information • PLC Version • Display Version After approximately 10-12 seconds the controller will flash to the Dryer Status Screen shown on the previous page. 4-4 Identifying Controller Screens Main Menu Screen (Main Menu Screen) The MAIN MENU provides information on the following system para[...]

Large Dehumidifying Dryers Controls 37 The DEW POINT value will give you a reading of what the actu al process air dew point is . The area in the lower lef t portion of the touch screen conveys two lines of information relat ing to th e over all operation of the dryer. The following is a list o f typical m achine/dryer sum mary status line text mes[...]

Large Dehumidifying Dryers Controls 38 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. To set the values in the next field, press ENT (Enter) to close the screen shown above. Then select th[...]

Large Dehumidifying Dryers Controls 39 By pressing the LOW TEMP or HIGH TEMP alarm buttons, the operator can enter the desired values to enable the alarm to go off at a specific deviation from setpoint (on the high or low side). When these settings have been made, the opera tor now has a choice of returning to the DRYER MENU or entering the MAIN ME[...]

Large Dehumidifying Dryers Controls 40 OVERDRY PROTECTION (Overdry Protection Screen - 1 of 2) This feature is used to prevent the overdryi ng of the plastic resin in the drying hopper. RETURN TEMP provides the actual temperature of the process air leaving the drying hopper. Press the MORE button located in the top r ight corner of the Ov er-Dry Pr[...]

Large Dehumidifying Dryers Controls 41 ALARMS (Alarm History Screen) This screen allows the operator to review the number and type of issues that the dryer has encountered during its operation. Problems can be viewed by Date, Hour, and Comment. Because of the size of the screen, only th ree (3) comments/alar ms can be viewed at a time. Alarm histor[...]

Large Dehumidifying Dryers Controls 42 DEW POINT SETUP (Dew Point Setup Screen) This screen allows the operator to set the dew point. The HIGH DEW PT ALARM is an audible/visual alarm that will sound when the process air dewpoint rises to this value. Values can be set between –40 through +30 degrees. The dewpoint sensor only reads to a maximum of [...]

Large Dehumidifying Dryers Controls 43 This button enab les and disables t he AutoStart Ti mer. HELP MENU (Help Menu Screen) The DRYER ALARMS button shows Help menus for Dryer Alarms. MAIN MENU (Main Menu Screen) This screen allows you to jump to the different areas of the controller to set, monitor, and operate different features of the dryer. Sys[...]

Large Dehumidifying Dryers Controls 44 • SYSTEM BACKUP • SERVICE MENU • MAIN MENU SYSTEM SETUP (System Setup Screen) This screen allows the operator to set alarm and password features. ALARM OFF DUR is the amo unt of time (0-99 m inutes) that the a larm and horn will stay off after the alarm silence button is pushed. (Whe n this function is s[...]

Large Dehumidifying Dryers Controls 45 The AP1 control system can detect and alarm a lo w material level condition in up to three (3) material hoppers. The material hopper assignments on the display are “Machine Hopper 1,” “Machine Hopper 2,” and “Drying Hopper.” Although your naming conventio ns may vary, the low material level detecti[...]

Large Dehumidifying Dryers Controls 46 Press the SYSTEM MENU button to return back to the sy stem menu screen and the next set of programmable features. HOUR METERS (Hour Meter Sc reen) This screen monitors the number of hours that the dryer has operated. In addition to monitoring the total number of hours of equipment operation, it al so has a res[...]

Large Dehumidifying Dryers Controls 47 (System Backup Screen) ACS Dryer control version 2.000 introduces a system backup feature. Pressing SAVE SETTINGS will save the s ystem variables for la ter recall. Pressing RESTORE SETTINGS will restore previously saved values. Pressing RESTORE FACTORY DEFAULTS will return the dr yer to its factory default st[...]

Large Dehumidifying Dryers Controls 48 This service menu screen is PASSWORD PROTECTED and meant for ACS 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 operator back to the overall menu screen. In this scree n, the operator will be able to select the b[...]

Large Dehumidifying Dryers Controls 49 Alarm Screen Example This is an example of what a typical Alarm screen looks like. The user will see the message causing the alarm in the top half of the display with an ALARM SILENCE button in the lower half. To turn off the alarm, the user must press the ALARM SILE NCE button. This will cancel the alarm. See[...]

Large Dehumidifying Dryers Controls 50 4-6 Setting the Redunda nt Safety Controller The Redundant Safety Controller alarm setting is changed by pressing the up and down keys to input the alarm value. The upper display reading indicates the Pr ocess Value, while the lower display indicates the High Point Setting al arm value. The factory setting for[...]

Large Dehumidifying Dryers Controls 51[...]

Large Dehumidifying Dryers Operation 52 Chapter 5: Operation 5-1 Start-up There are two possible methods of starting the dryer system: manually, by pressing the Start button on the Dryer Status screens, and automatic ally through use of the Auto Start Timer built into the dryer control system. Before operating the dryer, make sure all electrical co[...]

Large Dehumidifying Dryers Operation 53 5-2 Using the Dryer Status Screen From the Main Menu screen, press the DRYER button to access the Dryer Status screen. The Dryer Status screen displays the set point and actual process temperature as well as the actual dewpoint. (Dryer Status Screen) The area in the lower left portion of the screen displays t[...]

Large Dehumidifying Dryers Operation 54 5-3 Alarms Use the Alarm History screen to monitor syst em alarms. Fro m the Main Menu screen, press the Alarms button to access the Alarm History screen . The three m ost recent alarms appear at the top of the Alarm History screen. Use the DOWN and UP buttons to scroll through the alarms. ( Alarm History Scr[...]

Large Dehumidifying Dryers Operation 55 Alarm Comment Alarm Description Alarm Effect REGEN LOW TEMP Regeneration air temperature deviation is below low limit value. Possible heater failure. Alert Only DEWPOINT SENSOR The dew point sensor is out of range. Possible transducer or electronics failure. Disables Switch on Dew Point HIGH DEWPOINT The dew [...]

Large Dehumidifying Dryers Maintenance 56 Chapter 6: Maintenance 6-1 Maintenance Schedule The checklist below contains a list of items that should be inspected and/or replaced to keep your Large Dehumidifying Dryer operating at peak efficiency. Perform each inspection at the regular intervals listed below. Dryer Model # Serial # EVERY WEEK Date/ By[...]

Large Dehumidifying Dryers Maintenance 57 6-2 Preventative Maintenance Cleaning or Replacing the Process Air Filters Regular filter cleaning will keep your dryer op erating at peak efficiency. The process air filters protect the centrifugal blowers from pl astic fines being drawn in from the dr ying hopper. Filters should be cleaned when airflow re[...]

Large Dehumidifying Dryers Maintenance 58 Use the following procedure to clean or replace the filter cartridges: 1. Turn off and/or lock out el ectrical power to the dryer. 2. Remove the hand knobs or clamps securi ng the filter a ccess cover and remove the cover. 3. Remove the nut on the center retaining rod to remove a filter cartridge. 4. Vacuum[...]

Large Dehumidifying Dryers Maintenance 59 5. Remove the restricted filter cartridge from the housing again. The alarm light should stay off when the process blower operate s if the switch is adjusted correctly. 6. Re-install the obstructed cartridge filter. The alarm light should go on again if the switch is adjusted correctly. 7. Fine tune the swi[...]

Large Dehumidifying Dryers Maintenance 60 6-3 Corrective Maintenance Symptoms of Worn Out Desiccant The moisture adsorption capacity of the desi ccant used in Large Dehumidifying Dryers degrades after an indefinite period of time. Us eful life depends on variables such as material moisture content, plasticizer vapors in the re turn air and number o[...]

Large Dehumidifying Dryers Maintenance 61 6. Inspect the gaskets on each of the covers. Replace if necessary. 7. Re-install the covers. Figure 14: Desiccant Tower Assembly Regeneration Heater Cover. High Temperature Gaskets. Heater Element Mounting Plate. Access cover can be removed in order to replace desiccant. Viewing Glass, for checking the sta[...]

Large Dehumidifying Dryers Maintenance 62 High Temperature Gasket Double Wall Stainless Steel Heater Housing Heater Elements Heater Element Mounting Plate Stainless Steel Heater Housing Cover High Temperature Gasket Heater Assembly Gude Bars 1. Remove the bolts securing the process heater access cover. 2. Sketch the heater wiring configuration so t[...]

Large Dehumidifying Dryers Maintenance 63 1. Access the desiccant canisters by removing the panels on the dryer. 2. Remove the Regeneration Heater Cover. 3. Unscrew the six (6) screws on the Heater Element Mounting Plate. 4. Slide out the heater assembly, taki ng care to not damage the gaskets. 5. Unscrew the heater loops that need to be replaced. [...]

Large Dehumidifying Dryers Troubleshooting 64 Chapter 7: T roubleshooting 7-1 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[...]

Large Dehumidifying Dryers Troubleshooting 65 Problem Possible Cause Corrective Action Process heaters are faulty. Replace. Desiccant beds are contam i nated. Replace desic cant. Material being dried differs from material specified at the time of purchase. Drying systems are designed for the material that was originally specified. Different materia[...]

Large Dehumidifying Dryers Troubleshooting 66 7-3 Determining Temperature Cont roller 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, o[...]

Large Dehumidifying Dryers Appendix 67 Chapter 8: Appendix 8-1 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 manufact[...]

Large Dehumidifying Dryers Appendix 68 8-2 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 range: 50% relative [...]

Large Dehumidifying Dryers Appendix 69 8-3 Spare Parts List 600CFM 600CFM 600CFM 600CFM 600CFM 850CFM 850CFM 850CFM 850CFM 850CFM 1000CFM 1000CFM 1000CFM 1000CFM 1000CFM 1250CFM 1250CFM 1250CFM 1250CFM 1250CFM 1500CFM 1500CFM 1500CFM 1500CFM 1500CFM 2000CFM 2000CFM 2000CFM 2500CFM 2500CFM 2500CFM 3000CFM 3000CFM 3000CFM LEVEL 1 ( Electrical Compone[...]

Large Dehumidifying Dryers Appendix 70 8-4 LEVEL 3 ( Electrical Components ) 600CFM 600CFM 600CFM 600CFM 600CFM 850CFM 850CFM 850CFM 850CFM 850CFM 1000CFM 1000CFM 1000CFM 1000CFM 1000CFM 1250CFM 1250CFM 1250CFM 1250CFM 1250CFM 1500CFM 1500CFM 1500CFM 1500CFM 1500CFM 2000CFM 2000CFM 2000CFM 2500CFM 2500CFM 2500CFM 3000CFM 3000CFM 3000CFM PART # SIZE[...]

Large Dehumidifying Dryers Appendix 71 8-5 Dryer Identification (Serial Number) Tag (Located on back of Dryer) XXX Series Dryer Model Number XXX-15 Max Drying Capacity HR 460V Serial Number 060701R 1 Date of Manufacture 06/2003 4.5A Over-current Protec tion Device (s) 4.5A Total Frequency 50/60Hz Compressed air supply None Dryer Mass 400 lbs/(180 K[...]

Large Dehumidifying Dryers Appendix 72 8-5 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 262 ] 641-8610; Fax: [262] 641-86 53 The ACS Customer Service Group w ill provide your compa ny with genuine OEM quality parts manufactured to engi neering design specific ations, which will maximize your e quipm[...]