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Sterling SDF 500 Operating Instructions Manual

Dehumidified air dryer with touch control unit
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Operating Instructions

Dehumidified air dryer
SDF 250
SDF 400
SDF 500
With Touch control unit
Sterling Material Processing

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Summary of Contents for Sterling SDF 500

  • Page 1: Operating Instructions

    Operating Instructions Dehumidified air dryer SDF 250 SDF 400 SDF 500 With Touch control unit Sterling Material Processing...
  • Page 2 SDF 250/400/500 Sterling Material Processing 5200 West Clinton Ave. Milwaukee, WI 53223 Telephone: (414) 354-0970 Fax: (414) 354-6421 www.sterlco.com Technical service: Service department Telephone: (800) 423-3183 Edition: 12/03 These operating instructions are for*: (* please fill in personally) Serial number:...
  • Page 3 SDF 250/400/500 Sterling Material Processing retains all rights to change the information in these operating instructions at any time without notice. We assume no liability for any errors or direct or indirect damage resulting in context with these operating instructions.

  • Page 4: Table Of Contents

    Table of contents General Information ...1-1 1.1. Warnings and symbols...1-2 1.2. Explanations and information ...1-4 1.3. Legal basis ...1-4 1.4. Fields of applications...1-4 1.5. Notes on Usage...1-4 Safety instructions ...2-1 2.1. General...2-2 2.1.1. Assembly ...2-3 2.1.2. Operation ...2-3 2.1.3. Maintenance...2-4 2.2.
  • Page 5 6.3. Connection to a Pneumatic Conveying System (Optional) ...6-18 6.4. Return Air Cooler (Optional)...6-18 Transport, Assembly and Storage ...7-1 7.1. Tansport and Packing ...7-2 7.2. Assembly ...7-4 7.3. Storage ...7-4 Assembly instructions ...8-1 8.1. Installation of the exhauster fan for regeneration of exhaust air...8-2 8.2.

  • Page 6: General Information

    SDF 250/400/500 1. General Information These operating instructions are addressed to all users of the device. These operating instructions must be used by every person charged with work on the unit. General Information 1-1...

  • Page 7: Warnings And Symbols

    1.1. Warnings and symbols The following warnings and symbols are used in these operating instructions: This symbol indicates danger to life! Fatal or serious injury is possible if the corresponding instructions, regulations or warnings are not observed. This symbol indicates that serious injury is possible if the corresponding instructions, regulations or warnings are not observed.
  • Page 8 When disposing of drying agents / batteries / oil, observe all official rules. Caution: High noise pollution ! For all work on the equipment, hearing protection should be worn. Avoids impairment of hearing! Caution: Danger of crushing ! Disconnect the equipment from mains supply before starting mainenance procedures.

  • Page 9: Explanations And Information

    1.2. Explanations and information Various terms and designations are used in these operating instructions to ensure clarity. Therefore please note that the terms used in the text stand for the corresponding explanations listed below. Equipment: ”Equipment” can mean an individual unit, a machine or an installation. •...

  • Page 10: Safety Instructions

    SDF 250/400/500 2. Safety instructions These safety instructions apply to all persons within the range of action of the equipment. Please inform all persons within the range of action of the equipment of the direct and indirect hazards connected with the equipment.

  • Page 11: General

    SDF 250/400/500 2.1. General The operating personnel of this equipment must be at least 16 years old. Please read these operating instructions carefully before taking into operation for the first time. Contact us should questions arise. This avoids injury and damage to equipment! These operating instructions must be kept available at all times at the place of operation of the equipment.

  • Page 12: Assembly

    Do not modify, add other equipment or change the design of the equipment without the approval of the manufacturer. Caution: Danger of accidents! Attachments not supplied by Sterling must be manufactured in accordance with safety regulation EN 294. Danger of accidents! The equipment may only be operated when all the associated components are properly connected up and in accordance with the relevant regulations.

  • Page 13: Maintenance

    SDF 250/400/500 to people and material! 2.1.3. Maintenance Before starting maintenance work, appoint a supervisor. Inform the responsible personnel before maintenance work on the system is started. Caution: Danger of accidents! Disconnect the equipment from mains supply before starting maintenance procedures to ensure that it cannot be switched on unintentionally.

  • Page 14: For The Safety Of The Devices

    When you dispose of drying agents, observe all official rules. Note that drying cells are replaced or refilled by Sterling only if they are empty. The material level may not fall below 40 % in the drying hopper, when material is continuously removed from the drying hopper, but no material is continuously fed into the drying hopper (batch drying).

  • Page 15: Start Up

    3. Start up This chapter is addressed to the operators of the machine. This chapter assumes general skills with drying systems and SPS (PLC) control units. This chapter assumes that the functional description has been read and understood. It must be ensured that the operators have the relevant skills. Note down all set values of the control system.

  • Page 16: Control Unit

    SDF 250/400/500 3.1. Control Unit The control system is switched on at the main switch. The control system is operated via the ”Touch Screen and the keyboard of the operator panel. The facility’s control system is factory-programmed. Nevertheless, you have to set specific values (basic parameters) which are dependent on the processed material, for instance.

  • Page 17: Switching On The Dryer

    3.2. Switching on the Dryer Switch on the system by means of the main switch. & The control system carries through a self-test; after that the “Start-Screen” with date and time is displayed 3.3. SDF 250/400/500 Start up 3-3...

  • Page 18: Basic Parameters

    SDF 250/400/500 Basic parameters 3.3.1. Entering Dryer Values Return air cooler on/orr “I”: enabling the return air cooler “O” disabling the return air cooler Target value Actual value Status Dryer Back to “Start-Screen” Start up 3-4...
  • Page 19 Heater Reg. Act. The regenerated heat temperature will be displayed. Exit air Act. The current temperature of the used air will be displayed. & If the unit is operates with “dew point controlled changeover point with dew point display” (optional): Dew point max.

  • Page 20: Entering Hopper Values

    SDF 250/400/500 3.3.2. Entering hopper values Enter hopper name Return air cooler on/orr STT 1 “I”: enabling the return air cooler “O” disabling the return air cooler Status Hopper Back to “Start-Screen” Start up 3-6...
  • Page 21 Hopper temp Target Enter the drying temperature for the drying hopper. Hopper temp Act. The current temperature at the feed opening of hopper flap will be displayed. & If the unit operates with motor flaps (optional): Granule Temp Enter the material temperature at which the flap on the drying hopper should close.

  • Page 22: Setting The Timer

    SDF 250/400/500 3.3.3. Setting the timer Start up 3-8...
  • Page 23 Enter for each day the switching on time and the switching off time in hours and minutes. Off / Internal / External Select operation mode: ”internal” = operation with internal timer, “external” = operation with external timer (if present), ”off” = operation without timer. &...

  • Page 24: Observing Processing Status

    3.3.4. Observing processing status Actual operation status: The following operation statuses can be displayed: system is off • system is on • blower runs on • valve block • regeneration will be finished in x min. • Actual hopper temperature displayed in °C Status dryer LED grey - dryer off LED green - dryer on...

  • Page 25: Setting Date And Time

    SDF 250/400/500 3.3.5. Setting date and time Date/Time Enter the desired day and time. Start up 3-11...

  • Page 26: Changing Language

    3.3.6. Changing language & This function is password protected. Enter the password (password: 792154) SDF 250/400/500 ****** ****** Start up 3-12...
  • Page 27 SDF 250/400/500 & If the password has been entered correctly, the language can be changed. Start up 3-13...

  • Page 28: Continuous Operation

    3.4. Continuous operation When you have carried through all basic settings, you can start with continuous operation. Make sure that hoppers which are not in use are separated from the dehumidified air supply. Make sure that the set drying temperatures are suited for the materials in the hoppers.
  • Page 29 SDF 250/400/500 Start up 3-15...

  • Page 30: Switching The Dryer/Hopper Heater Off

    3.5. Switching the dryer/hopper heater off Switch off the hopper heater: Switch off the dryer: Wait until the regeneration phase is finished and the blower has come to a standstill. Switch off the dryer at the main switch. Disconnect the power supply. Never switch off the dryer directly at the main switch SDF 250/400/500 Start up 3-16...

  • Page 31: Error And Error Correction

    4. Error and error correction This chapter is directed at the operators of the equipment. This chapter assumes general skills in dealing with drying systems and SPS (PLC) control units. This chapter assumes that the “start-up” description has been read and understood. It should be ensured in each and every case that the operators have the relevant skills.
  • Page 32 Failures must be repaired immediately. & Alarm messages are displayed in plain language on the screen of the operator device. An alarm is given by flashing of the LED “alarm”. The display of alarm messages in the operator device can only be erased by pressing the “ACK”...

  • Page 33: Actual Messages

    Check the power supply. Short circuit check. Excess Temperature Regeneration Heater The regeneration temperature is too high. Check the safety temperature limiter. Sterling Service. Insufficient Temperature Regeneration Heater The regeneration temperature is too low. Check the regeneration heater. Error and error correction 4-3...
  • Page 34 Check the position of the valve block. Press the “ACK” key and put the main switch in the on position immediately. If the valve block has not reached the correct position within 1 minute, the main switch is again placed in the off position. Sterling Service. Temperature Measurement Outgoing Air Defective Check cables and sensor.
  • Page 35 (X = number of the drying hopper) The temperature of the hopper heater is too high. Check the safety temperature limiter. Sterling Service. Insufficient Temperature Heater Hopper X (X = number of the drying hopper) The temperature of the hopper heater is too low.
  • Page 36 SDF 250/400/500 Overload Regeneration Heater - STB has been activated Check the safety temperature limiter (= STB). Check regeneration heater. Short circuit check. Overload Drying Heater - STB has been activated Check the safety temperature limiter (= STB). Check drying heater. Short circuit check.

  • Page 37: Alarm Protocol

    4.2. Alarm protocol & Alarm messages are displayed in plain language with date and time in the alarm protocol. SDF 250/400/500 Error and error correction 4-7...

  • Page 38: Maintenance

    Never operate the equipment when partially dismantled. Any maintenance and repair work NOT described here may only be carried out by Sterling service personnel or by specialised staff authorized by Sterling. Disconnect the equipment from mains supply before starting maintenance procedures to ensure that it cannot be switched on unintentionally.
  • Page 39 Ensure that materials and incidentals required for operation as well as spare parts are disposed of properly and in an environmentally sound manner. Use only original Sterling spare parts. Keep record of all maintenance and repair procedures. Maintenance 5-2...

  • Page 40: Maintenance Schedule

    Clean air filter of the suction box All electrical and mechanical connections should be checked to see if they fit securely Annually: Dewpoint should be checked (only by Sterling service personnel) Whenever the material is changed: The drying hopper and suction box must be cleaned &...

  • Page 41: Cleaning Or Replacing The Air Filter

    5.2. Cleaning or Replacing the Air Filter Switch off the hopper heater: And the dryer: Wait until the regeneration phase is finished and the blower has come to a standstill. Switch off the main switch of the dryer. Interrupt the mains supply so that the device cannot be switched on unintentionally.

  • Page 42: Cleaning Or Replacing The Return Air Filter

    5.2.1. Cleaning or Replacing the Return Air Filter Open the panel (A) by means of the provided switch cabinet key. Open the tension ring on the housing of the return air filter (B) and remove the housing cover. Remove the nut of the filter cartridge. Remove the filter cartridge.

  • Page 43: Cleaning Or Replacing The Regeneration Air Filter

    SDF 250/400/500 5.2.2. Cleaning or Replacing the Regeneration air filter Open the back panel. Slide the air filter (A) off the nozzle. Blow compressed air through the clogged air filter from the inside out or replace the air filter. Install the cleaned/new air filter (A). Mount the back panel.

  • Page 44: Filter Of The Electrical Cabinet

    5.2.3. Filter of the electrical cabinet Remove the lid of the filter. Remove the filter mat. Blow through the filter mat with compressed air from inside to outside or renew the filter mat. Clean the filter housing. Use lint-free cleaning rags. Re-install the cleaned/new filter mat.

  • Page 45: Disposing Of Drying Agents

    5.3. Disposing of Drying Agents Please note that drying cells are replaced or refilled by Sterling only if they are empty. When disposing of drying agents, observe all official rules. Since used drying agents may contain impurities from the dried materials, treat them as special waste.

  • Page 46: Cleaning The Drying Hopper

    5.4. Cleaning the Drying Hopper Switch off the hopper heater and the dryer: Wait until the regeneration phase is finished and the blower has come to a standstill. Switch off the main switch of the dryer. Interrupt the mains supply so that the device cannot be switched on unintentionally.
  • Page 47 SDF 250/400/500 STT 25 Open the toggle-type fasteners (A) at the hopper lid and fold the hopper lid upwards (if in use: remove before the single conveyor). Clean the drying hopper. Close the hopper lid and close the toggle-type fasteners (A) (if in use: re-mount the single conveyor).
  • Page 48 STT 60 - 1600 Open the cleaning opening of the drying hopper: Lift and turn the handle (A) to open the lock, if in use: remove before the single conveyor (STT 400 - STT 1600: 2 handles). Clean the drying hopper. Close the cleaning opening of the drying hopper: Turn the handle (A) until the cleaning opening is locked and then close the handle (if in use: re-mount the single conveyor).

  • Page 49: Changing The Battery Of The Control System

    5.5. Changing the battery of the control system This work may be carried through only by qualified personnel trained in the field of electrical engineering. The battery may be changed only with the control system switched on. Open the control box by means of the control box key which is part of the supply. Open the front door of the CPU.
  • Page 50 Close the control box. Store backup batteries in a dry and cool place. Backup batteries can be stored for approx. 5 years. If backup batteries are not treated properly, they can ignite, explode and cause severe burning. & Order number battery: Batteries must be disposed of in keeping with the relevant national environment protection regulations/guidelines.

  • Page 51: Resetting The Control Values

    5.5.1. Resetting the control values This electrical work is intended to be carried out only by trained personnel. After changing the battery or the PLC the control values should be resetted. All control values are set back to the standard settings. Open the control box with the switch box key which is part of the supply.

  • Page 52: Functional Description

    SDF 250/400/500 6. Functional description This functional description is addressed to the operators of the equipment. This functional description assumes general familiarity with drying equipment. It should be verified that the operators do indeed have the appropriate skills. Functional description 6-15...

  • Page 53: General Information

    SDF 250/400/500 6.1. General Information The dryers work according to the dehumidified air principle, i.e., the air is not only heated but also dehumidified before it flows through the drying hopper. In this manner, plastic granules can be dried down to a very small residual moisture content. The drying takes place continuously, i.e., there are no rest periods due to regeneration of the drying agent.

  • Page 54: Drying Hopper (Optional)

    SDF 250/400/500 6.2. Drying Hopper (Optional) The material is dried in the drying hopper. The dehumidified air is conducted through the material in the drying hopper and takes up moisture. Drying hoppers must have the appropriate dimensions for their specific use so that the desired final moisture content is reached.

  • Page 55: Connection To A Pneumatic Conveying System (Optional)

    The facility will only take as much material as is required by the processing machines. Therefore, the drying result will always be the same. Sterling drying hoppers are equipped with a suitable flange for adding a Sterling pneumatic conveyor. Suction boxes with one or three suction tubes can be supplied as well (optional).

  • Page 56: Transport, Assembly And Storage

    SDF 250/400/500 7. Transport, Assembly and Storage This chapter is intended for all operating personnel of the equipment. Personnel using these instructions must be instructed in the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation. Ensure in each case that the operating personnel are sufficiently informed.

  • Page 57: Tansport And Packing

    7.1. Tansport and Packing Please ensure adequate carrying capacity of the lifting equipment. Note that the dryer system is top-heavy. Risc of toppling! The machine must not be tilted or laid on its side. The equipment pass a rigorous operating test in the factory and are packed carefully to avoid transport damage.
  • Page 58 SDF 250/400/500 with a workshop crane Check if the eyelets are installed on the dryer housing. If this condition is met, fasten the transport cables to the eyelets. If this condition is not met, mount the eyelets and then fasten the transport cables to the eyelets. Disassemble the eyelets after set-up.

  • Page 59: Assembly

    7.2. Assembly Please ensure adequate carrying capacity of the lifting equipment. Check the carrying capacity of the point of installation, particularly if installed on a platform. The place selected for installation should be as free of vibrations as possible. The main switch must be freely accessible. Ground the equipment against electrostatic charging.

  • Page 60: Assembly Instructions

    8. Assembly instructions These installation instructions are intended for persons with skills in electrical and mechanical areas due to their training, experience and received instructions. Personnel using these installation instructions must be instructed in the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation.

  • Page 61: Installation Of The Exhauster Fan For Regeneration Of Exhaust Air

    8.1. Installation of the exhauster fan for regeneration of exhaust When plastics are being dried that release harmful gases during the drying process, care must be taken that the regeneration exhaust air is disposed of in an environmentally sound way. At the same time the throughput of the regeneration blower must not be altered.

  • Page 62: Electrical Connection

    The electrical connection may only be carried through or assigned by Sterling service staff or by qualified staff authorized by Sterling. Other persons are not permitted to carry through the electrical connection.

  • Page 63: Compressed Air Supply

    8.4. Compressed Air Supply A compressed air supply is needed to operate the valve stem. Check whether the compressed air piping has been installed and connected properly. Check whether fittings, length and quality of the hose assemblies are in accordance with the requirements.

  • Page 64: Technical Data

    Throughput control at the drying hopper for automatic dwell time monitoring (only available • when used in conjunction with Sterling Central Conveyor System) -Optimum protection for changing service conditions -Alarm or removal stop if dwell time has not been reached...
  • Page 65 SDF 250/400/500 Dimension Sheet Dimensions and data without obligation. Dimensions in mm. Specifications may be subject to alterations. Technical data 9-2...

  • Page 66: Accessories

    STT 25 – STT 6400 10. Accessories o Spare parts list Drying Hoppers STT 25 – STT 6400 o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...
  • Page 67 Accessories Spare parts list Drying Hoppers STT 25 – STT 6400 Sterling Material Processing...
  • Page 68 STT 25 – STT 6400 Sterling Material Processing 5200 West Clinton Ave. Milwaukee, WI 53223 Telephone: (414) 354-0970 Fax: (414) 354-6421 www.sterlco.com Technical service: Service department Telephone: (800) 423-3183 Edition: 07/03 These operating instructions are for*: (* please fill in personally)
  • Page 69 STT 25 – STT 6400 Sterling Material Processing retains all rights to change the information in these operating instructions at any time without notice. We assume no liability for any errors or direct or indirect damage resulting in context with these operating instructions.
  • Page 70 STT 25 – STT 6400...
  • Page 71 Pos. Description Radiator hopper heater 85343 1.5 kW 85338 3.0 kW 85363 6.0 kW 85651 9.0 kW 95828 18.0 kW, 27.0 kW, 36.0 kW, 63.0 kW 87094 27.0 kW, 48.0 kW, 63.0 kW 18232 Hand flap Ø 80 92241 Tension ring 16523 Hand flap Ø...
  • Page 72 Pos. Description 18232 Hand flap 92241 Tension ring 94233 Sealing ring 30306 Lid 92241 Tension ring 94233 Sealing ring (optional, if flap in use) 30350 Grounding set Multiplier PT 100: Description 86371 Pt 100 (3 m) 89846 Pt 100 (6 m) 93303 PT 100 (9 m) 86387 PT 100 (12 m) 83015 PT 100 (15 m)

This manual is also suitable for:

Sdf 250Sdf 400

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