Sterling SDA Series 25-100 manual

SDA Series 25-100 (15-60 cfm) Compact Dehumidifying Dryers Part Number: 882.00291.0 0 Bulletin Number: DH1-635 .2 Effective: 12/1/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We [...]

Shipping Information 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 and co[...]

Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in this Manual ........................................................................... 5 1-2 Safety [...]

Process Air Dew Point Display ............................................................................. 25 Setting the High Dew Point Alarm ........................................................................ 25 Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup ................. 25 4-2 Dryer Operation Procedures ............[...]

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[...]

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 its capabilities and limitations. Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or through a casual attitude toward machinery form ed over a perio[...]

• Shut off power to the dryer when it is not in use. T urn the switch to the OFF position, or unplug it from the power source. Maintenance Responsibility Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety a priority to effectively repair and maintain equipment. Before removing, adjusting, or replacing[...]

Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d maintenance instructions for 1 5, 30 and 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 ser[...]

Figure 1: Typical Dryer Air Flow Schematic 2-3 Standard Features Mechanical Features • Dual desiccant beds • Electrically-actuated air valve • 13X Molecular Sieve • Single regenerative process blower • Drying temperature range of 180ºF to 230ºF (82 ºC to 110ºC). • 2.5” hose connections Electrical Features • Process thermocouple [...]

• Mercury process heater contactor • Process high temperature alarm light • Process/regeneration heater box • High temperature safety system (Process/Regeneration) Controller Features • Mitsubishi programmable relay controller • Display of process temperature set point and actual settings 2-4 Options Options marked with “*” indicate[...]

Safety Circuit Standards Safety circuits used in industrial systems protect the o perator and maintenance personnel from dangerous energy. They also provide a means of locking out or isolating the energy for servicing equipment. Various agencies have contributed to the establis hment of safety standards that apply to the design and manufacture of a[...]

Chapter 3: Inst allation 3-1 Uncrating the Equipment Dehumidifying Dryers 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 supports. Cut the[...]

Figure 2: Suggested Lift Rigging for Cart Mount Dryers 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 cause damage to the equipment and/or injury to personnel! Figure 3: Suggested Lift Rigging for Floor Mounted Dryers PROCESS[...]

Figure 4: Suggested Lift Rigging for Machine Mounted Dryers PROCESS TEMPERATUR E DEW POINT CONT ROL POWE R ON OFF ALAR M POWER ON ON O F F 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 cu. ft. (8[...]

3-4 Setup Procedures This section provides the procedures necessary fo r configuring your Dehumidifying Dryer. Configuration of your dryer includes checking for pr oper blower rotation, making dryer/drying hopper process air connections and the optional aftercooler (on 15 a nd 30 cfm models). We recommend that you carry out these procedures in the [...]

Drying Hopper Air Trap Considerations Our exclusive air trap assembly on the top of the drying hopper prevents am bient air from contaminating the material being dried . To ensure that your unit will operate at peak efficiency, do the following: • Keep the material level at the mid point of the air trap This can be achieved by utilizing a hopper [...]

trapped air from the system. Make sure the aftercooler has the proper supply water temperature. 6. Set the process set point on the temperature controller. 7. After the proper pre-drying time for the in itial hopper fill has elapsed, fully open the drying hopper slide gate. Note: To allow proper residence time du ring continuous processing, maintai[...]

Chapter 4: Operation 4-1 Controller Description and Operation Identifying Control Panel Indicator Lights and Switches for the Standard Controller Switches Main Power. This switch allows the dryer to receive power from the main power supply (3 phase only). Dryer Control ON/OFF Switch. This switch energizes or de-energizes control power to the indica[...]

Optional Controller – Optional Three Phase Control Panel shown with Optional Dew Point Monitor Process Air Temperature Controller Our dryers use a microprocessor-based PID temp erature controller for maintaining process air temperature. The controller is a modular, self-contained unit you c an remove from the mounting housing. All parameters exce[...]

Identifying Process Air Temperatu re Controller LED Indicators Indicator Name Description PV 8.8.8.8 Process Value Numeric LED During normal operation, the process value ( PV ) numeric LED indicator displays the process temperature at the To Process thermocouple. It also lists parameters during setup and error messages if any errors occur. SV 8.8.8[...]

Setting the Process Air Temperature When setting the process air temperature, consult with the resin manufacture for the recommended drying temperature. To change the process air temperature set point with the dryer running: • Press to raise the set point to the temperature you want. • Press to lower the set point to the temperature you want. R[...]

Indicator Name Description preprogrammed by the operator. Proportional Band Mode (P) This setting controls the amount in which the manipulated variable ( MV) is proportionate to the deviated value or controller error. Integral Time Mode (I) Setting this feature, gives the control an action that is proportionate to the time integral of the control e[...]

Figure 7: Settings for Process Temperature Controller (E5CN), Part No. A0567917 Mode Parameter Setting range Default Manuf. setting Run/Stop Run/Stop Run - Operation Alarm value 1 -1999 to 9999 0 25 Mode Parameter Setting range Default Manuf. setting AT execute/cancel ON, OFF OFF Various Temperature input shift -199.9 to 999.9 0.0 - Proportional Ba[...]

Note: The dew point alarm monitors and indicates a deviation from the set point. 4-2 Dryer Operation Procedures Controller Operation 1. Turn the disconnect (if applicab le) on the control panel to the ON position. Power is applied to the voltage line fuses, line side of the control power switch. 2. Turn the control power switch to the ON position. [...]

4. If either the left or right bed safety temperature switch opens, a regen heater fault is generated. “HIGH TEMP” is displa yed on the relay screen. The alarm light is activated. 5. If the process temperature controller faults or the process heater safety switch opens, a heater fault is generated. “HIGH TEMP” is displayed on the relay scre[...]

The following is a list of Alarm Display Messages which can be found on the relay screen: HIGH TEMP Temperature Controller Alarm and/or Regen Heater Temp Switch and/or Process Heater Temp Switch and/or Redundant Temp Safety VALVE MTR Valve Motor Time-Out PROC BLWR Blower Overload HEAT 15 COOL 50 SYSTEM NORMAL No Alarms 15, 30, & 60 cfm Compact [...]

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 dehumidifying dryer. Perform them at the regular intervals listed on the dryer checklist on the previous page. Servicing Process Air Filters Caution! Operating the dryer without the proces s air filter installed voids [...]

Cleaning with Compressed Air Blow clean, dry compressed air up and down the pleats, blowing out the filter from the inside out. Remove loose dirt fr om the filter with compressed air or vacuum from the outside. Caution! DO NOT clean/wash filter with water! After each cleaning: • Inspect the filter element. Briefly hold a light bulb behind the ele[...]

WARNING! Handling desiccant material is HAZAR DOUS. Wear an N-100 type safety filter mask or equivalent to avoid prolonged breathing of desiccant dust. Wear safety goggles and gloves to avoid contact with eyes and skin. • Handle with adequate ventilation. • Wash hands thoroughly after handling. + FIRST AID + In case of eye contact, immediately [...]

Figure 10: Desiccant Bed Location and Disassembly Valve & Air Manifold Casting Desiccant Assembly Rod Regeneration Heater Wire Conduit Assembly Lower Air Manifold Casting Gasket Hollow Desiccant Tank Caution! You should properly dispose of any discarded desiccant. Consult local disposal regula tions for more information. 11. Inspect each desicc[...]

Replacing the Process/Regeneration Heater The dehumidifying dryers utilize a single-phase Ca lrod-type heater element. This heater element is mounted in the center compartment in the desiccant beds. Although the replacement procedure is the same for each heater, the wattage varies by model, voltage, temperature range, etc. WARNING! Hazardous electr[...]

5. Disconnect heater thermostat safety. 6. Pickup and place the top casting in a safe place. 7. Pickup the desiccant can to reveal the heater. 8. Using a 1/8” Allen wrench, remove the four (4) 10-32 screws on the heater plate. 9. Remove the wires to the heater plate assembly being removed or replaced. 10. Remove the two (2) 4-40 screws for the te[...]

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, steam clean it. 7. Place the coil back in its housing. Make su re the gasket is OK, replace if necessary. 8. Inset the four 10-32 bolts back in place. 9. Turn the water to the cooling coil back on. 15, 30, &[...]

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 Dryer Status The process temperature has exceeded the alarm set point. The process heater contactor has failed in the closed position. Check heater contactor, replace if necessary. Check the Process He ater box high temperature snap switch, replace if nece ssary The high temperature snap switch of the process h[...]

Alarm Message Cause Corrective Action Dryer Status Limit switch may be out of position. Re-adjust the switch to make sure it trips when it is at the high position, and it does not touch the cam when it is at the low position. VALVE MTR The limit switch on the valve may not have been wired correctly. The valve has made enough rotations and the corre[...]

Chapter 7: Appendix 7-1 Warranty Unless otherwise specified, this product includes a Standard ONE YEAR P ARTS WARRANTY. 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[...]

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 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 complianc[...]

Aftercooler Design Specifications Entering water temp. ºF ºC 85ºF 50°F (If used as Plasticizer trap) 29ºC 10°C (If used as Plasticizer trap) 7-3 Drawings and Diagrams Figure 14: Standard Model (180°F to 230°F) Air Flow Schematic Drying Hopper Filter High Pressure Peripheral Blower Moisture Exhaust Regeneration Make Up Air 15, 30, & 60 c[...]

Figure 15: High Heat Model (180°F to 400°F) Air Flow Schematic Drying Hopper Filter High Pressure Peripheral Blower Regeneration Make Up Air Moisture Exhaust After-Cooler Process Heater Figure 16: Low Heat Model (120°F to 250°F) Air Flow Drying Hopper Filter High Pressure Peripheral Blower Regeneration Make Up Air Moisture Exhaust Cooler 15, 30[...]

7-4 Spare Parts List Figure 18: Level 1 Spare Parts List (Electrical & Mechanical) DRYER SPA RE PARTS LIST 15, 30, 60 cfm Models 15CFM 15CFM 15CFM 15CFM 15CFM 15CFM 15CFM 30CFM 30CFM 30CFM 30CFM 30CFM 30CFM 30CFM 60CFM 60CFM 60CFM 60CFM 60CFM 60CFM Mech anical Compo nents 115V 3P H 208V 3P H 220V 50 HZ 3PH 230V 3P H 400V 50 HZ 3PH 460V 3P H 575[...]

HI-CORE DESICCANT D RYER 15/30/60 CFM UNITS 15 CFM Item Qty Part # Description 21 1 A0571669 SCHEMATIC, 1 5 CFM POWER 120 VAC 1 25 1 A0566840 GRAPHIC, ASD CONTROL, 1 ∅ 26 1 A0571672 COMM ON PARTS, 120VAC CONTROL 27 1 A0534258 FUSE BLOCK, 2 P 30A CC 28 1 A0538062 FUSE, PR OC BLOWER, LP-CC-5 220VAC 1 ∅ 25 1 A0566840 GRAPHIC, ASD CONTROL, 1 ∅ 26[...]

33 3 A0568935 FUSE, HEATER S, KTK-R-9 230VAC 3 ∅ HIGH HEAT 33 3 A0534048 FUSE, HEATER S, KTK-R-15 400VAC 3 ∅ LOW HEAT 33 3 A0534041 FUSE, HEATER S, KTK-R-5 400VAC 3 ∅ HIGH HEAT 33 3 A0568935 FUSE, HEATER S, KTK-R-9 460VAC 3 ∅ LOW HEAT 33 3 A0534041 FUSE, HEATER S, KTK-R-5 460VAC 3 ∅ HIGH HEAT 33 3 A0534044 FUSE, HEATER S, KTK-R-8 575VAC 3[...]

40 1 A0558000 CONTACTOR, IEC, 9A, 120VAC COIL 41 1 A0558078 RELAY, OVERLOAD, IEC, .32-1A 33 1 A0568936 FUSE, HEATERS, KTK-R-25 220VAC 1 ∅ LOW HEAT 33 1 A0534047 FUSE, HEATERS, KTK-R-12 220VAC 1 ∅ HIGH HEAT 33 1 A0534051 FUSE, HEATERS, KTK-R-30 208VAC 3 ∅ LOW HEAT 33 3 A0534048 FUSE, HEATERS, KTK-R-15 208VAC 3 ∅ HIGH HEAT 33 3 A0534051 FUSE,[...]

40 1 A0558000 CONTACTOR, IEC, 9A, 120VAC COIL 41 1 A0558079 RELAY, OVERLOAD, IEC, 1-2.9A 575VAC 3 ∅ 24 1 A0571675 COMM ON PARTS, 3 ∅ POWER 28 1 A0534802 FUSE, XFMR SECONDARY, LP-CC-3.5 31 1 A0558192 TRANSFORMER, 575X120 PSF 32 2 A0534800 FUSE, XFMR, PRIMARY, FNQ-R-0.5 40 1 A0558000 CONTACTOR, IEC, 9A, 120VAC COIL 41 1 A0558079 RELAY, OVERLOAD, [...]

A0571673 220V CONTROL COMMON P ARTS ITEM QTY PA RT # DESCRIPTION 1 1 A0571676 SUBPANEL, 16.75X9.75 2 1 A0570597 CONTR OL PANEL, 5.7X12 3 4 1 A0541669 SWITCH, ROCK ER, ILLUM, 220VAC, GRN 5 1 A0563801 LITE, 3MM, 220 VAC, RED 6 1 A0541660 LITE, 3MM, 120VAC, GRN 7 2 A0571685 CONTACT OR, MERCURY 2P 30A 8 1 A0541290 RELA Y , DPDT, 220 VAC, 10A 9 1 A05055[...]

Warranty Returns Prior to the return of any material, authorization must 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 returns are to be shipped prepaid . The invoice number and date or purchase or der number and date must be supplied. After inspecti[...]

Our products are sold by a w orld-wide net w ork of indep en dent sales representatives. Co ntact our Sales Department for the name of the sales representative neares t you. Contract Department Call [ 630 ] 595-1060 Mond ay–Friday, 8am–5pm CST Let us install your s y stem. The Contract De partment o ffers any or all of these servic es: project [...]