Sterling 882.00290.00 manual

15, 30, and 60 CFM Dryers With AP-0 Controls Part Number: 882.00290.0 0 Bulletin Number: DH1-640-2 Effective: 05/15/06 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed [...]

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 ............................................................................................. 6 Safety Symbols Used in this Manual ..................................................................... 6 1-2 Safety Tag In[...]

Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup ................ 25 Redundant Safety Controller Display .................................................................. 26 Setting the Redundant Safety Controller ............................................................. 26 Restoring the WATLOW Redundant Safety Controller to F[...]

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 dryer while working on it. • DO NOT wear loose clothing or jewelry, which can be caught while working on a dryer. In addition, cover or tie back long hair. • Clean the dryer and surrounding area DAILY , and inspect the machine for loose, missing or broken parts. • Shut off power [...]

Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and m aintenance instructions for 15, 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[...]

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 250ºF (82 ºC to 121ºC). • 2.5” hose connections Electrical Features • Process thermocouple to be connected to drying hopper air inlet.[...]

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) or below 180ºF (82ºC), 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 [...]

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 maintaining 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 d[...]

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 lif t the box off carefully; avoiding staples in the 1’ x 4’ wood supports. Cut th[...]

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[...]

Chapter 4: Operation 4-1 Start-up 1. Turn on (energize) the disconnect switch in your power drop, and then turn on the one on the dryer. 2. Turn the system ON/OFF switch to ON to energize the display panel. 3. Close the slide gate at the bottom of the drying hoppe r. Make sure that the blowers turn in the right direction . 4. Fill the drying hopper[...]

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 except for the process air set point are factory set and adjusted; normally, no field adjustment to t[...]

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 8.8.8.8 Set Value Numeric LED During normal operation, the set value[...]

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[...]

Adjustment Level Indicator Name Description Auto-Tune Mode (At) See Page 19 of Chapter 3 for instructions on how to Auto-Tune your dryer. Note: Although the controller is calibrated at the factory, the manufacturer recommends that the unit be Auto-Tuned prior to dryer startup. Temperature Input Shift Mode (TnS) This setting is used to offset an err[...]

Entering Operating Parameters to Select Modes To enter the display: 1. Press the Mode Display key to view the Run/Stop & Alarm 1 Modes. 2. Press and to set the higher or lower the values of the param eter or turn that function On or Off. The SV readout displays the different values for the parameter within a mode. 3. To switch modes within a le[...]

Process Air Dew Point Display Optional The Process Air Dew Point meter indicates the cu rrent process air delivery moisture content. Standard dryers use a microprocessor-based controller for displaying dew point air temperature. The controller is a modular, self-contained unit removable from the m ounting housing. All parameters are factory set and[...]

Redundant Safety Controller Display Optional The Redundant Safety Controller limits the pr ocess air temperature from exceeding the upper temperature range set by the E5CN Temperature Controller. Standard dryers use a microprocessor-based controller for limiting the process air temperature. The controller is a modular, self-contained unit removable[...]

Entering Operating Parameters to Select Modes To enter the display: 1. Press both the Up and Down keys for three seconds from the home page. The word SEE will appear in the upper display and PAGE will appear in the lower display. 2. Press the Advance Key to move through the param eter prompts. 3. Press the Up or Down keys to change the parameter va[...]

4-3 System Operation Procedures Controller Operation (Without Optional Alarm Horn & Reset Button) 1. Turn the disconnect on the control panel to the ON position. Power is applied to the voltage line fuses, line side of the control power switch and the temperature controller. 2. Turn the control power switch to the ON position. Power is applied [...]

5. If the 1TCU (E5CN) controller faults, the opti onal redundant high temperature safety device opens, or the process heater safety switch opens, a heater fault is generated. “ HIGH TEMP ” is displayed on the relay screen. The alarm light is activated. The process heater, regen heater, and process/regen blower are turned off. Turn the OFF-ON-ST[...]

a. The valve motor rotates until the cam switch makes 2 transitions. b. If the cam switch does not make a transition within 10 seconds, a valve motor fault is generated. “VALVE MTR” is displayed on the relay screen, the alarm horn and light are activated. The valve motor, heaters, and blower shut off. Pressing the ALARM RESET pushbutton will de[...]

Reset the motor overload and turn the Off-On-Start switch to the START position to restart the dryer. 7. The valve position limit switch enables the right bed heater and provides an input signal to the programmable relay when actuated by the cam lobe. Each heater is ON-OFF controlled by the OMRON E5C2 controller. 8. Upon completion of the HEAT port[...]

Temperature Controller Alarm and/or Regen Heater Temp Switch and/or Process Heater Temp Switch and/or Redundant Temp Safety Blower Overload Valve Motor Time-Out No Alarms 4-4 Auto-Tuning the Dryer HIGH TEMP PROC BLWR VALVE MTR HEAT 35 COOL 30 SYSTEM NORMAL 1. For Auto-tuning, press the level key once. The AT screen will show with the setting OFF . [...]

4. Turn the system ON/OFF switch to OFF . 5. If needed, empty the drying hopper. 6. For maintenance or a long term shutdown, open (de-energize) the electrical disconnects at the dryer and at the power drop. Dehumidifying Dryers Chapter 4: Operation 33 of 53[...]

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 [...]

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 11: 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 Silic on Strip and Stick Gask et 16 Mes h 0.028 D iameter Wire Stainless Stee l Scr een (2) 4-4 0 screw s Hi Tem peratur e Snap Sw i tch Regener atio n Heat er 1" Wide x 1/8" T hick[...]

Figure 12: 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 11). 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 as[...]

Figure 13: Process Heater Location and Disassembly Procedures Undo (6) 10-32 Button Head Screws using 1/8 Allen Wrench 1" Wide x 1/8" Thick High Temperature Gasket (2) 4-40 screws Hi Temperature Snap Switch 1. Sketch the heater wiring configuration so you can properly re-wire the heater. 2. Remove the ceramic nuts and wires to the heater [...]

Replacing/Cleaning the Cooling Coils WARNING! Hazardous electrical current present. Disconnect and lock out power be fore you replace heater elements! Figure 14: Cooling Coil Location and Disassembly Note: To clean the cooling coil, use compressed air or a steam cleaner to blow the dust off or clean any oily residue on the coil. Replacement Procedu[...]

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 (or certified elect rician should trouble shoot the unit) , line fuses removed, and with the machine tagged as [...]

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. The limit switch on the valve may not have been wired correctly. The valve has made enough rotations and the correct positio[...]

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 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 Technical Specifications Annex B Information The following design information is pr[...]

24. The machine is not equipped with cable-less controls. 25. Color-coded (harmonized) power cord is sufficient for proper installation. 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 15: Standard Model (180°F to 250[...]

Figure 16: 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 17: 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 [...]

7-4 Spare Parts List Figure 18: Level 1 Spare Parts List (Electrical & Mechanical) DRYER S PA RE PART S LI ST AD15, AD30, A D60 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 om ponent s ) 208V 3PH 220V 50 HZ 3PH 230V 3PH 400V 50 HZ 3PH 460V 3PH 575V 60 HZ 3[...]

Figure 19: Level 2 & 3 Spare Parts List (Electrical & Mechanical) DRYER SPA RE PARTS LIST AD15 , A D30 , A D6 0 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 46[...]

7-5 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[...]

7-7 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[...]