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Sterling SDAA 25-100 User Manual

15-60 cfm dehumidifying dryers
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SDAA 25-100 (15-60 cfm)
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 2005
All rights reserved.
Dehumidifying Dryers
Part Number: 882.00290.00
Bulletin Number: DH1-640
Effective: 12/06/05
_________________________
_________________________
_________________________

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Summary of Contents for Sterling SDAA 25-100

  • Page 1 SDAA 25-100 (15-60 cfm) Dehumidifying Dryers Part Number: 882.00290.00 Bulletin Number: DH1-640 Effective: 12/06/05 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.
  • Page 2 Shipping Information Unpacking and Inspection You should inspect your 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: Table Of Contents

    Table of Contents CHAPTER 1: SAFETY..............V How to Use This Manual ..................... v Safety Symbols Used in this Manual ..............v Warnings and Precautions ..................vi Responsibility ......................vii General Responsibility..................vii Operator Responsibility ..................viii Maintenance Responsibility.................. ix Reporting a Safety Defect ..................ix CHAPTER 2: FUNCTIONAL DESCRIPTION ......
  • Page 4 Restoring the Process Air Temperature Controller (E5CN) to Factory Settings..28 Process Air Dew Point Display ................31 Setting the High Dew Point Alarm ...............31 Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup ....31 Redundant Safety Controller Display ..............32 Setting the Redundant Safety Controller .............32 Restoring the WATLOW Redundant Safety Controller to Factory Setup ....32 Dryer Operation Procedures ..................
  • Page 5 Service Department.....................59 Sales Department....................59 Contract Department ...................59 Dehumidifying Dryers...

  • Page 6: Chapter 1: Safety

    Chapter 1: Safety How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your dehumidifying dryer. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer.

  • Page 7: Warnings And Precautions

    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 8: Responsibility

    Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machine should become familiar with its operation as described in this manual.

  • Page 9: Operator Responsibility

    Operator Responsibility The operator’s responsibility does not end with efficient 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 formed over a period of months or years.

  • Page 10: Maintenance Responsibility

    • Clean the dryer and surrounding area DAILY, and inspect the machine for loose, missing or broken parts. • Shut off power to the dryer when it is not in use. Turn the switch to the OFF position, or unplug it from the power source. Maintenance Responsibility Proper maintenance is essential to safety.
  • Page 11 Dehumidifying Dryers Chapter 1: Safety...

  • Page 12: Chapter 2: Functional Description

    Chapter 2: Functional Description Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 15, 30, and 60 cfm dehumidifying dryers. Model numbers 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 service.

  • Page 13: What Is Desiccant

    A small amount of ambient air is introduced into the process air stream to make up for the air lost during the bed regeneration. Because the process air is typically much drier than the ambient air, the air mixture maintains drying efficiency at a consistently high level. This air is heated to 500°...

  • Page 14: Controller Features

    • NFPA79 machinery electrical standards • Non-fused electrical disconnect • Branch fusing • Mercury process heater contactor • Regeneration temperature control • Process high temperature alarm light • Process/regeneration heater box • High temperature safety system (Process/Regeneration) • Dew point monitor with digital read-out Controller Features •...
  • Page 15 • Identify and locate specific safety devices. • Understand the proper use of the safety devices provided. • Describe the function of the safety device. Safety Circuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy.

  • Page 16: Chapter 3: Installation

    Chapter 3: Installation 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;...
  • Page 17 Figure 16: Machine-Mount Dryer Dimensions Mounting flange Diameter hole: Notes: Hopper mounting flanges on 0.75 and PROCESS DEW POINT TEMPERATURE and 1.5 cu. ft. (20 & 40 liter) hoppers are supplied blank so the customer CONTROL POWER ALARM HORN ALARM ALARM Silencer can drill to match existing machine throat.
  • Page 18 Figure 17: Floor-Mount Dryer Dimensions PROCESS DEW POINT TEMPERATURE CONTROL POWER ALARM HORN ALARM ALARM Silencer 15, 30, 60 cfm floor-mount dimensions in inches/cm 15 cfm 30 cfm 60 cfm Dimension 32.5 32.5 32.5 23.75 23.75 Dehumidifying Dryers Chapter 3: Installation 17 of 59...

  • Page 19: Recommended Dryer Lifting Hardware

    Figure 1: Suggested Lift Rigging for Cart Mounted Dryers DO NOT PROCESS DEW POINT TEMPERATURE CONTROL POWER ALARM HOR N ALARM ALARM Silencer FORK LIFT TRUCK Caution! Do not use a hoist to move or rig your Dryer when it is mounted on a cart! Moving the Dryer with a hoist will cause it to become unstable and may cause damage to the Dryer and/or injury to personnel! Recommended Dryer Lifting Hardware...

  • Page 20: Electrical Connections

    Figure 3: Suggested Lift Rigging for Machine Mounted Dryers PROCESS TEMPERATURE DEW POINT CONTROL POWER ALARM HORN ALARM ALARM Silencer Caution! When using a hoist to move a machine mounted dryer, ALWAYS attach chains to the three (3) locations/lifting points on the unit! Moving the Dryer without the chains attached to all of the lifting points will cause the unit to become unstable and may cause damage to the Dryer and/or injury to personnel!

  • Page 21: Setup Procedures

    Setup Procedures This section provides the procedures necessary for configuring your Dehumidifying Dryer. Configuration of your dryer includes checking for proper blower rotation, making dryer/drying hopper process air connections and the optional aftercooler (on 60 cfm models). We recommend that you carry out these procedures in the order given here. Note: Before carrying out these procedures, install all equipment as described in this section.

  • Page 22: Drying Hopper Air Trap Considerations

    Drying Hopper Air Trap Considerations Our exclusive air trap assembly on the top of the drying hopper prevents ambient 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 •...

  • Page 23: Initial Start-Up

    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. Starting Up the Dryer 1.

  • Page 24: Shutting Down The Dryer

    Shutting Down the Dryer 1. Turn off the conveying system supplying the drying hopper. 2. When processing is complete, close the hopper slide gate and shut down any in-line companion equipment, such as the aftercooler. 3. Turn the Dryer ON/OFF selector switch to OFF. 4.

  • Page 25: Chapter 4: Operation

    Chapter 4: Operation Start-up 1. Turn on (energize) the disconnect switch in your power drop, 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 slidegate at the bottom of the drying hopper. Make sure that the blowers turn in the right direction.

  • Page 26: Controller Description And Operation

    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.) Optional Alarm Silence Switch.

  • Page 27: Process Air Temperature Controller

    Process Air Temperature Controller Our dryers use a microprocessor-based PID temperature controller for maintaining process air temperature. The controller is a modular, self-contained unit you can remove from the mounting housing. All parameters except for the process air set point are factory set and adjusted;...

  • Page 28: Setting The Process Air Temperature

    Indicator Name Description ALARM1 ALARM 1 LED Lights in the Operation Indicator Section when the output function assigned to auxiliary output 1 turns on. The ALARM1 indicator lights when the process temperature exceeds the set point temperature by more than the alarm deviation value.

  • Page 29: Restoring The Process Air Temperature Controller (E5Cn) To Factory Settings

    Restoring the Process Air Temperature Controller (E5CN) to Factory Settings If the preset parameters on the controller have been tampered with and it no longer properly controls temperature and displays dew point, you can restore the controllers to the factory setup.
  • Page 30 Adjustment Level Indicator Name Description Auto-Tune Mode See Page 19 of Chapter 3 for instructions on how (At) 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 This setting is used to offset an error between the Shift Mode (TnS)
  • 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. 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: 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 36 3. Once the control power is on and no fault conditions exist, turning the OFF-ON- START switch to the START position will start the dryer as follows: a. The process heater is turned on and controlled by the E5CN controller. b.
  • Page 37 11. When a dew point fault is generated by the optional dew point controller, the alarm light will activate. The alarm light will flash, indicating a non-critical fault. Press Alarm Reset to deactivate the alarm until the next dew point fault occurs. 12.

  • Page 38: Controller Operation (With Optional Alarm Horn & Reset Button)

    Controller Operation (With 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.
  • Page 39 5. If the OMRON controller faults, the optional redundant high temperature safety device opens, or the process heater safety switch opens, a process heater fault is generated. “HIGH TEMP” is displayed on the relay screen. The alarm horn and light are activated. The process heater, regen heater, and process/regen blower are turned off.

  • Page 40: Alarm Display Messages

    Alarm Display Messages Note: The relay screen which contains the Alarm Display Messages is located inside the controller enclosure. WARNING! Do not attempt to check the Alarms on the Controller located within the unit enclosure unless you are a qualified electrician! The following is a list of Alarm Display Messages which can be found on the relay screen: Temperature Controller Alarm and/or HIGH TEMP...

  • Page 41: Auto-Tuning The Dryer

    Auto-Tuning the Dryer 1. For Auto-tuning, press the beige button once. The AT screen will show with the setting OFF. 2. Press the UP arrow to change the setting to ON. 3. Press the beige button again to go back to the Temperature Screen. Your actual temperature will start to flash for about 10-20 minutes with the temperature fluctuating up and down during that period.

  • Page 42: Chapter 5: Maintenance

    Chapter 5: Maintenance Preventative Maintenance Schedule The checklist below contains a list of items which should be inspected and/or replaced to keep your Dehumidifying Dryer operating at peak efficiency. Perform each inspection at the regular intervals listed below. System model # Serial # Date/ Date/...

  • Page 43: Preventative Maintenance

    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 process air filter installed voids your warranty! Filter cleaning is an important part of your dryer maintenance program.

  • Page 44: Servicing The Dew Point Monitor

    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 from the filter with compressed air or vaccum from the outside. Caution! DO NOT clean/wash filter with water! After each cleaning: •...

  • Page 45: Corrective Maintenance

    Dew point sensor life depends on: • Air temperature and flow passing over the sensor. • The amount of fines (dust) in the process air. • The amount of plasticizer vapor in the process air. Once every six months, the dryer operator should monitor the initial dew point sensor readings and establish a periodic replacement schedule as needed.

  • Page 46: Replacing Worn Desiccant

    WARNING! Handling desiccant material is HAZARDOUS. 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. ✚...
  • Page 47 Figure 11: Desiccant Bed Location and Disassembly Undo (4) 10-32 Button Desiccant Cap Head Screws using 1/8 Allen Wrench 1" Wide x 1/8" Thick Silicon 13X Molecular Sieve Strip and Stick Gasket 8x12 Beads Regeneration Heater Regeneration Thermocouple 16 Mesh 0.028 Diameter Wire (2) 4-40 screws Stainless Steel Screen Hi Temperature...

  • Page 48: Replacing The Process Heater

    Replacing the Process Heater The dehumidifying dryers utilize a single-phase Calrod-type heater element. This heater element is mounted in the center compartment below the desiccant beds. Although the replacement procedure is the same for each heater, the wattage varies by model, voltage, temperature range, etc.

  • Page 49: Chapter 6: Troubleshooting

    Chapter 6: 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 Check for open heaters. Replace Process heaters are faulty. if required. Solid-state temperature Replace. controller faulty. Loss or reduction of process air Make sure that plant personnel temperature. Process temperature was are aware of the proper adjusted in error by plant temperature set point.
  • Page 51 Problem Possible cause Corrective action Check resin manufacturer’s data sheet for proper drying Process temperature set too high temperature. Make sure plant due to operator error. personnel are aware of the correct process temperature set point. High temperature alarm not set Reset high temperature alarm.

  • Page 52: Determining Temperature Controller Errors Or Sensor Errors

    Problem Possible cause Corrective action No setting change possible on The key protection switch is set Set the key protection switch to temperature controller. to ON. OFF. Input polarity on thermo-couple Properly wire the terminals. is wrong or connection is wrong. Properly set the input with the Input-type setting is incorrect.

  • Page 53: Chapter 7: Appendix

    Chapter 7: Appendix Warranty Unless otherwise specified, this product includes a Standard ONE YEAR PARTS WARRANTY. Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions, as set forth in the operating manuals for such equipment.

  • Page 54: Warranty Liabilities

    Warranty Liabilities THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT RESULT FROM THE USE OF THIS PRODUCT. Some states do not allow the exclusion or limitation of special, consequential or incidental damages, so the above limitation may not apply to you.

  • Page 55: Technical Specifications

    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. Humidity range: 50% relative humidity 4.

  • Page 56: Aftercooler Design Specifications

    Aftercooler Design Specifications Entering water temp. ºF ºC 85ºF 29ºC Drawings and Diagrams Spare Parts List Figure 18: Level 1 Spare Parts List (Electrical & Mechanical) MINI DRYER SPARE PARTS LIST AD15, AD30, AD60 LEVEL 1 ( Electrical Components ) PART # SIZE Description A0568932...
  • Page 57 Figure 19: Level 2 & 3 Spare Parts List (Electrical & Mechanical) MINI DRYER SPARE PARTS LIST AD15, AD30, AD60 LEVEL 2 ( Electrical Components ) PART # SIZE Description A0558000 Motor Starter A0530042 Mercury Heater Contactor A0567917 Process Air Temperature Controller A0544089 Regeneration Air Temperature Controller A0558065...

  • Page 58: Returned Material Policy

    Returned Material Policy 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. ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00 minimum) restocking charge.

  • Page 59: Dryer Identification (Serial Number) Tag

    Dryer Identification (Serial Number) Tag (Located on back of Dryer) Company Logo XXX Series Dryer Model Number XXX-15 Max Drying Capacity HR 460V Serial Number 060701R 1Ǿ 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 60: Technical Assistance

    Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423-3183 or call [ 630 ] 595-1060, Fax [630] 475-7005 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency.

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