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Sterling SDA 1000-5100 Manual

Large dehumidifying dryers with ap0 controls
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Write Down Your Serial Numbers Here For Future Reference:
_________________________
_________________________
_________________________
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2008
All rights reserved.
SDA 1000-5100 Large
Dehumidifying Dryers
with AP0 Controls
Part Number: 882.00292.00
Bulletin Number: DH1-605-1
Effective: 04/28/2008
_________________________
_________________________
_________________________

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  • Page 1 SDA 1000-5100 Large Dehumidifying Dryers with AP0 Controls Part Number: 882.00292.00 Bulletin Number: DH1-605-1 Effective: 04/28/2008 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement.
  • Page 2 Shipping Info Unpacking and Inspection You should inspect the large dehumidifying dryer for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
  • Page 3 Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department. Credit 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.

  • Page 4: Table Of Contents

    Table of Contents CHAPTER 1: SAFETY..............7 How to Use This Manual ..................... 7 Safety Symbols Used in this Manual ..............7 Warnings and Precautions ..................8 Responsibility ......................9 General Responsibility...................9 Operator Responsibility ..................9 Maintenance Responsibility.................10 Reporting a Safety Defect ...................11 CHAPTER 2: FUNCTIONAL DESCRIPTION ......
  • Page 5 Setting the Process Air Temperature ..............29 Restoring the Process Air Temperature Controller (E5CN) to Factory Settings..29 Process Air Dew Point Display ................32 Setting the High Dew Point Alarm ...............32 Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup ....32 Redundant Safety Controller Display ..............33 Setting the Redundant Safety Controller .............33 Restoring the WATLOW Redundant Safety Controller to Factory Setup ....33...
  • Page 6 8-5 Dryer Identification (Serial Number) Tag............. 58 Technical Assistance....................59 Parts Department ....................59 Service Department.....................59 Sales Department....................59 Contract Department ...................59 Large Dehumidifying Dryers...

  • Page 7: Chapter 1: Safety

    Chapter 1: Safety How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining the large dehumidifying dryer. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance.

  • Page 8: Warnings And Precautions

    Dryer Safety Tags Description Description Read Operation & High Voltage Inside Installation Manual Enclosure Hot! Lifting Point Protected Earth Earth Ground Ground Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations.

  • Page 9: Responsibility

    Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment. We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration. We expect you, as a user, to abide by the foregoing recommendations in order to make operator safety a reality.

  • Page 10: Maintenance Responsibility

    employer probably has established a set of safety 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 any potentially dangerous situation to your supervisor.

  • Page 11: Reporting A Safety Defect

    When you need to perform maintenance or repair work on a dehumidifying dryer above floor level, use a solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your dryer, use it. The work platform should have secure footing and a place for tools and parts.

  • Page 12: Chapter 2: Functional Description

    Chapter 2: Functional Description Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 600-3000 cfm Large Dehumidifying Dryers with AP0 control. These dryers are available with electric heaters or gas burners. Gas dryers are indicated with a “G” in the model number. Model numbers are listed on the serial tag.

  • Page 13: The Process/Regeneration Cycle

    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 dry material again. This system is a "closed loop", because ambient (outside) air is never introduced into the process air.

  • Page 14: Sequence Of Operation

    AD600-AD1500 Dryer Flow Schematic Left Desiccant in Regeneration Regeneration Blower Dryer Valve Regeneration Filter Insulated Drying Hopper Regeneration Heaters Process Heater Regeneration Process Exhaust Filter Left Desiccant Right Desiccant Process Blower Sequence of Operation When the dryer is started, the main air valve rotates 360º and then moves to place the last successfully regenerated desiccant bed online.

  • Page 15: Controller Description

    Controller Description The AP0 control package uses a relay logic controller to control the operation of the dryer. See below for descriptions of each screen. Figure 2: Controller Screen Descriptions Regen Set Screen. Displays heating and cooling times for regeneration. Also used to change times if necessary.

  • Page 16: Standard Features

    Standard Features Mechanical Features 180ºF – 250ºF Drying temperature range High regeneration temperature control safeties 13X desiccant (molecular sieve) Easy to access process and regeneration High pressure centrifugal blower Dew point +15º F to –40º F Electrical Features Electrically-actuated air valve NFPA79, UL &...

  • Page 17: Options

    Options Closed-Loop Regeneration An optional regeneration closed-loop valve and heat exchanger can be used to close the regeneration loop during the cooling portion of the regeneration cycle. If this option is enabled on the dryer, air will be bled to the atmosphere until the heating portion of the regeneration cycle is finished.

  • Page 18: Process Air Dust Collector

    Process Air Dust Collector The optional process air dust collector consists of a filter, dust can, pressure gauge, and optional pressure switch (see Figure 5). The gauge will let you know whether it is time to clean out your filters. The optional dirty filter alarm will be activated if the filter is dirty. Figure 5: Process Air Dust Collector Filter Check Gage...

  • Page 19: Mechanical Options

    Figure 6: Material Miser/Air Balance Valve Temperature Probe Valve Coupling Proofing Switch Drying Hopper Mechanical Options Low temperature operation (120°F to 250°F) High temperature operation (180°F to 400°F) Precooler (Required for temperatures below 180°F, used with low temperature operation) Aftercooler (Required for temperatures above 250°F, used with high temperature operation) Plasticizer trap / Aftercooler w/filter Automatic airflow reduction valve 13X desiccant...

  • Page 20: Safety Devices And Interlocks

    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 intended to supersede or alter safety standards established by the user of this equipment. Instead, the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment.
  • Page 21 In addition to the safety devices listed above, these 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 number of approved electrical lockout tags available at most electrical supply stores.

  • Page 22: Chapter 3: Mechanical Installation

    Chapter 3: Mechanical Installation Uncrating the Equipment The large 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’...

  • Page 23: Checking For Proper Blower Rotation

    The power drop must include a ground wire. Make sure all electrical connections are tight. 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 optional aftercooler).

  • Page 24: Making Dryer/Drying Hopper Process Air Connections

    Making Dryer/Drying Hopper Process Air Connections When making process air connections to your dryer, ensure that you take into consideration and make arrangements for the following: Use high-temperature flexible dryer hose or rigid tubing to connect the dryer to the drying hopper.

  • Page 25: Connecting Aftercooler/Precooler Cooling Water (Optional)

    Connecting Aftercooler/Precooler Cooling Water (Optional) Support both sides of the fitting when making the cooling water connections to prevent damage to the aftercooler coil. See Figure 9. Connect 85°F water to the inlet closest to the exiting air side of the aftercooler coil. This will cool the process air about 100°F and raise the water-out temperature about 10°F.

  • Page 26: Using The Drying Hopper Air Trap

    Using the Drying Hopper Air Trap Our exclusive air trap assembly in the top of the drying hopper prevents ambient air from contaminating the material being dried. To ensure that air does not enter the drying system, do the following (See Figure 10): Keep the material level above the bottom edge of the air trap for maximum efficiency.

  • Page 27: Chapter 4: Controls

    Chapter 4: Controls Controller Description and Operation Identifying Control Panel Indicator Lights and Switches for the Standard Controller Switches System OFF/ON/START Switch. This switch energizes or de-energizes control power to the indicator panel and starts the dryer. (The controller can be energized without the dryer running.) Indicator Lights Alarm Light.
  • Page 28 Identifying Process Air Temperature Controller LED Indicators Indicator Name Description Process Value During normal operation, the process value (PV) Numeric LED numeric LED indicator displays the process 8.8.8.8 temperature at the To Process thermocouple. It also lists parameters during setup and error messages if any errors occur.

  • Page 29: Setting The Process Air Temperature

    Identifying Temperature Controller Keys Indicator Name Description Mode Key Press the Mode key to shift the display to the next set of parameters. The menu screen displays. Down Key Press the Down arrow key to lower the process air set point temperature. During setup, it lets you decrease the value of the parameter displayed on the set point LED readout.
  • Page 30 Available E5CN Modes Operation Level Indicator Name Description Run/Stop Mode When “RUN” is selected, the control is running. (r-S) When “STOP” is selected, the control is stopped. When the control is stopped, the STOP display lights. The default is set to “RUN.” Alarm Value 1 This setting is used to indicate how many degrees Mode (AL-1)
  • Page 31 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 to set the higher or lower the values of the parameter or turn that function On or Off. The SV readout displays the different values for the parameter within a mode.

  • Page 32: Process Air Dew Point Display

    Process Air Dew Point Display Optional The Process Air Dew Point meter indicates the current 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 mounting housing.

  • Page 33: Redundant Safety Controller Display

    Redundant Safety Controller Display Optional The Redundant Safety Controller limits the process 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 from the mounting housing.
  • Page 34 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.

  • Page 35: Chapter 5: Operation

    Chapter 5: Operation Initial Start-up Pre-Startup Checks Check the process and return hoses for tight connections. Check all companion equipment, such as the drying hopper; verify that the loading system is ready for operation. Verify that all dryer electrical connections are tight. Auto-Tuning the Dryer 1.

  • Page 36: Dryer Operation Procedures

    Dryer 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.
  • Page 37 5. If the Regen E5CN controller faults, a regen high heat fault is generated. “RH” 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-START switch to the START position to deactivate the alarm light and restart the dryer.
  • Page 38 on the relay screen. Press ALARM RESET to deactivate the alarm until the next dew point fault occurs. 15. Use the right arrow key to display the REGEN SET screen (Screen 1). Use the up & down arrow keys to select the parameter to change. Use the + & - keys to change the parameter value.

  • Page 39: Alarm Display Messages

    18. Turn selector switch to START position to start the dryer. The bed switch valve will cycle to a known good position. The process & regen blowers will start. Process & Regen heaters are enabled. A new regen heat/cool cycle is started. Blower alarms are enabled 5 seconds after startup.

  • Page 40: Auto-Tuning The Dryer

    PF - PROCESS FILTER RF - REGEN FILTER ALARMS : CV - CLOSED LOOP VALVE PB RB BV - BED SWITCH VALVE BV PS RS PS - PROCESS TEMP SWITCH PH PL RH RS - REGEN TEMP SWITCH PH - PROCESS HI TEMP Screen 6.

  • Page 41: Chapter 6: Maintenance

    Chapter 6: Maintenance 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 # Date/ Date/...

  • Page 42: Preventative Maintenance

    Preventative Maintenance Cleaning or Replacing the Process Air Filters Regular filter cleaning will keep your dryer operating at peak efficiency. The process air filters protect the centrifugal blowers from plastic fines being drawn in from the drying hopper. Filters should be cleaned when airflow restriction trips the dirty filter alarm. Filters should be replaced at least once a year.

  • Page 43: Cleaning Or Replacing The Regeneration Filter

    Use the following procedure to clean or replace the filter cartridges: Turn off and/or lock out electrical power to the dryer. Remove the hand knobs or clamps securing the filter access cover and remove the cover. Remove the nut on the center-retaining rod to remove a filter cartridge. Vacuum, blow out, or wash the filter.

  • Page 44: Checking The Dewpoint Control System

    5. Remove the restricted filter cartridge from the housing again. The alarm light should stay off when the process blower operates 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.

  • Page 45: Corrective Maintenance

    Corrective Maintenance Symptoms of Worn Out Desiccant The moisture adsorption capacity of the desiccant used in Large Dehumidifying Dryers degrades after an indefinite period of time. Useful life depends on variables such as material moisture content, plasticizer vapors in the return air and number of regeneration cycles. Your dryer may need new desiccant if it exhibits any of the following symptoms: •...

  • Page 46: Replacing The Process Heater (Electric Dryers)

    6. Inspect the gaskets on each of the covers. Replace if necessary. 7. Re-install the covers. Figure 17: Desiccant Tower Assembly High Regeneration Heater Cover. Temperature Gaskets. Regeneration Heaters Heater Element Mounting Plate. Viewing Glass, for Access cover can be checking the status of removed in order to the desiccant inside.

  • Page 47: Replacing The Regeneration Heater (Electric Dryers)

    1. Remove the bolts securing the process heater access cover. 2. Sketch the heater wiring configuration so the heaters may be re-wired properly. Heaters are mounted on a common plate of three or six for easy maintenance. 3. Remove the jumper bars and wires for the heater plate assembly(ies) being removed or replaced.
  • Page 48 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, taking care to not damage the gaskets. 5.

  • Page 49: Chapter 7: Troubleshooting

    Chapter 7: Troubleshooting 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 must be accomplished with the power off, line fuses removed, and with the machine tagged as out of service.
  • Page 50 Problem Possible Cause Corrective Action Loss or reduction in Process heaters are faulty. Replace. drying capacity. Desiccant beds are contaminated. Replace desiccant. Material being dried differs from Drying systems are designed for material specified at the time of the material that was originally purchase.

  • Page 51: Alarms

    Alarms The Alarm Screen will pop up to show what alarm the dryer is having that moment. Look through the window on the door to see the screen. Alarm Descriptions Alarm Alarm Description Alarm Effect Code The Main Air Valve did not maintain or find Immediate position.

  • Page 52: Determining Temperature Controller Errors Or Sensor Errors

    Determining Temperature Controller 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 controller is normal and the sensor is probably broken, short-circuited, or incorrectly wired. Using a Platinum Resistance Thermometer If the controller displays a temperature of about 0.0°C (32ºF) when you insert a 100-ohm resistor between terminals A and –B of the controller, and you short-circuit controller...

  • Page 53: Chapter 8: Appendix

    Chapter 8: Appendix Technical Specifications Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equipment that could alter the CE compliance 2. Ambient temperature: 0 degrees Celsius – Maximum (104 degrees Fahrenheit) 3.

  • Page 54: Drawings And Diagrams

    Drawings and Diagrams Regeneration Blower Insulated Drying Hopper Regen. Filter Process Air Filter Process Heater Optional Regeneration Closed Loop Cooler Regen. Optional Exhaust Regeneration Closed Loop Valve Optional After-cooler Right Desiccants Left Desiccants Dryer Valve Process Blower Airflow Schematic: 2000-3000 cfm dryers (4 desiccant beds). Left desiccant beds are regenerating—closed loop regeneration is activated.
  • Page 55 Filter Check Gage Differential Pressure Switch Thumb Screws Cartridge Filter Dust Shroud Filter Retainer Slide Gate Clamp Dust Pan Dust Level Indicator Optional dryer dust collector Large Dehumidifying Dryers Appendix...

  • Page 56: Spare Parts List

    Spare Parts List LARGE DRYER SPARE PARTS LIST 600,850,1000, 1250,1500,2000,2500, AND 3000 LEVEL 1 ( Electrical Components ) PART # SIZE Description A0536474 Fuse, Process Heater Elements A0536471 Fuse, Regen Heater Elements A0534846 Fuse, Process Blower A0545343 Fuse, Regen Blower A0538001 Transformer, Control Primary A0538017...
  • Page 57 LARGE DRYER SPARE PARTS LIST 600,850,1000,1250, 1500,2000,2500, AND 3000 LEVEL 3 ( Electrical Components ) PART # SIZE Description A0567930 PLC, Controller A0567932 PLC, Temperature Control Module A0569896 PLC, Analog Input Module A0567933 PLC, Touch Screen A0563932 Power Supply, 24VDC A0568961 Redundant Temperature Safety Controller LEVEL 3 ( Mechanical Components )

  • Page 58: Dryer Identification (Serial Number) Tag

    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 Date of Manufacture 06/2003 4.5A Over-current Protection Device (s) 4.5A Total Frequency 50/60Hz Compressed air supply None Dryer Mass 400 lbs/(180 KG) Electrical Diagrams &...
  • Page 59 Let us install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or non- union installations. Sterling, Inc. 2900 S. 160 Street New Berlin, WI 53151 www.sterlco.com...

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