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Manual Sterling 822.00292.00

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  • Sterling 822.00292.00 - page 1

    SDA 1000-5100 Large Dehumidifying Dryers with AP0 Controls Part Number: 882.00292.0 0 Bulletin Number: DH1-605-1 Effective: 04/28/2008 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ W ...

  • Sterling 822.00292.00 - page 2

    Large Dehumidifying Dryers ii Shipping Info Unpacking and Inspection You should inspect the large dehumidifying 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 Dam ...

  • Sterling 822.00292.00 - page 3

    Large Dehumidifying Dryers iii Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping departme nt. 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 retu ...

  • Sterling 822.00292.00 - page 4

    Large Dehumidifying Dryers iv Table of Contents CHAPTER 1: SAFETY ................................................................ 7 1-1 How to Use This Manual ............................................................................................. 7 Safety Symbols Used in this Manual ........................................................... ...

  • Sterling 822.00292.00 - page 5

    Large Dehumidifying Dryers v 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 Poi ...

  • Sterling 822.00292.00 - page 6

    Large Dehumidifying Dryers vi 8-4 8-5 Dryer Identification (Serial Number) Tag ............................................................. 58 8-5 Technical Assistance................................................................................................. 59 Parts Department ................................................................ ...

  • Sterling 822.00292.00 - page 7

    Large Dehumidifying Dryers Safety 7 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for in stalling, operating, and maintaining the large dehumidifying dryer. The purpose is to assist you in applying effici ent, proven techniques that enhance equipment productivity. This manual covers only light corrective main ...

  • Sterling 822.00292.00 - page 8

    Large Dehumidifying Dryers Safety 8 Dryer Safety Tags Tag Description Tag Description Read Operation & Installation Manual High Voltage Inside Enclosure Hot! Lifting Point PE Protected Earth Ground Earth Ground 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design ...

  • Sterling 822.00292.00 - page 9

    Large Dehumidifying Dryers Safety 9 ; Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment. We have long recognized the importance of saf ety and have designed and m anufactured our equipment with operator safety as a prime consid eration. We expect you, as a user, to abide by the foregoing reco ...

  • Sterling 822.00292.00 - page 10

    Large Dehumidifying Dryers Safety 10 employer probably has established a set of safet y 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 a ...

  • Sterling 822.00292.00 - page 11

    Large Dehumidifying Dryers Safety 11 When you need to perform maintenance or repa ir work on a dehumidifying dr yer above floor level, use a solid platform or a hydraulic elevat or. If there is a permanently installed catwalk on your dryer, use it. The work platfor m should have secure footing and a place for tools and parts. DO NOT climb on the de ...

  • Sterling 822.00292.00 - page 12

    Large Dehumidifying Dry ers Functional Description 12 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d maintenance instructions for 6 00-3000 cfm Large Dehumidifying Dry ers with AP0 contro l. These dryers are available with el ectric heaters or gas burners. Gas dryers are indica ...

  • Sterling 822.00292.00 - page 13

    Large Dehumidifying Dry ers Functional Description 13 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 dr y material again. This system is a "closed loop", because ambien t (outside) air is never introduced into the process air. The closed loop syste ...

  • Sterling 822.00292.00 - page 14

    Large Dehumidifying Dry ers Functional Description 14 Regeneration Filter Regeneration Blower Process Blower Regeneration Exhaust Process Heater Process Filter Insulated Drying Hopper Right Desiccant Regeneration Heaters Dryer Valve Left Desiccant AD600-AD1500 Dryer Flow Schematic Left Desiccant in Regeneration Sequence of Operation When the dryer ...

  • Sterling 822.00292.00 - page 15

    Large Dehumidifying Dry ers Functional Description 15 2-3 Controller Description The AP0 control package uses a relay logic cont roller 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 ...

  • Sterling 822.00292.00 - page 16

    Large Dehumidifying Dry ers Functional Description 16 2-4 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 Featu ...

  • Sterling 822.00292.00 - page 17

    Large Dehumidifying Dry ers Functional Description 17 2-5 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 th e atmosphere until the heating porti ...

  • Sterling 822.00292.00 - page 18

    Large Dehumidifying Dry ers Functional Description 18 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 filte ...

  • Sterling 822.00292.00 - page 19

    Large Dehumidifying Dry ers Functional Description 19 Figure 6: Material Miser/Air Balance Valve Coupling Temperature Probe Drying Hopper Valve Proofing Switch Mechanical Options ; Low temperature operation (120°F to 250°F) ; High temperature operation (180°F to 400°F) ; Precooler (Required for temperatures be low 180°F, used with low temperat ...

  • Sterling 822.00292.00 - page 20

    Large Dehumidifying Dry ers Functional Description 20 2-6 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 in tended to supersede or alter safety standards established by the user of this equipment. Instead, the material contained ...

  • Sterling 822.00292.00 - page 21

    Large Dehumidifying Dry ers Functional Description 21 In addition to the safety devices listed above, th ese 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 num ber of approved electrical lockout ...

  • Sterling 822.00292.00 - page 22

    Large Dehumidifying Dry ers Mechanical Installation 22 Chapter 3: Mechanical Inst allation 3-1 Uncrating the Equipment The large dehumidifying dryers are shipped mounted on a skid, encl osed 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 ...

  • Sterling 822.00292.00 - page 23

    Large Dehumidifying Dry ers Mechanical Installation 23 ; The power drop must include a ground wire. ; Make sure all electrical connections are tight. 3-4 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 proc ...

  • Sterling 822.00292.00 - page 24

    Large Dehumidifying Dry ers Mechanical Installation 24 3-5 Making Dryer/Drying Hopper Process Air C onnections When making process air connections to your drye r, ensure that you take into consideration and make arrangements for the following: ; Use high-temperature flexible dryer hose or rigid tubing to co nnect the dryer to the drying hopper. ; K ...

  • Sterling 822.00292.00 - page 25

    Large Dehumidifying Dry ers Mechanical Installation 25 After cooler Model Water Flow ( GPM ) AD600 10 AD850 10 AD1000 15 AD1250 15 AD1500 20 AD2000 25 AD2500 30 AD3000 35 High Temperature Gasket Stainless Steel Cooler Housing Cooling Coil Cooling Coil Pipe Gasket Cooling Coil Cover Plate Mounting Brackets High Temperature Gasket Cooling Coil Coolin ...

  • Sterling 822.00292.00 - page 26

    Large Dehumidifying Dry ers Mechanical Installation 26 3-7 Using the Drying Hopper Air Trap Our exclusive air trap assembly in the top of the drying hopper prevents am bient air from contaminating the material being dried . To en sure that air does not enter the drying system, do the following (See Figure 10): ; Keep the material level above the bo ...

  • Sterling 822.00292.00 - page 27

    Large Dehumidifying Dryers Controls 27 Chapter 4: Controls 4-1 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 ...

  • Sterling 822.00292.00 - page 28

    Large Dehumidifying Dryers Controls 28 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 ...

  • Sterling 822.00292.00 - page 29

    Large Dehumidifying Dryers Controls 29 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 para ...

  • Sterling 822.00292.00 - page 30

    Large Dehumidifying Dryers Controls 30 Available E5CN Modes Operation Level Indicator Name Description Run/Stop Mode (r-S) When “RUN” is selected, the control is running. 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 Mode (AL-1) This sett ...

  • Sterling 822.00292.00 - page 31

    Large Dehumidifying Dryers Controls 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 and 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 ...

  • Sterling 822.00292.00 - page 32

    Large Dehumidifying Dryers Controls 32 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 hous ...

  • Sterling 822.00292.00 - page 33

    Large Dehumidifying Dryers Controls 33 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 ...

  • Sterling 822.00292.00 - page 34

    Large Dehumidifying Dryers Controls 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. 2. Press the Advance Key to move through the param eter prompts. 3. Press the Up ...

  • Sterling 822.00292.00 - page 35

    Large Dehumidifying Dryers Operation 35 Chapter 5: Operation 5-1 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 dryer electrical connections are tight. Auto-Tuning the ...

  • Sterling 822.00292.00 - page 36

    Large Dehumidifying Dryers Operation 36 5-2 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. 2. Turn the control power switc ...

  • Sterling 822.00292.00 - page 37

    Large Dehumidifying Dryers Operation 37 5. If the Regen E5CN controller faults, a re gen 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 an ...

  • Sterling 822.00292.00 - page 38

    Large Dehumidifying Dryers Operation 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. Press the OK k ...

  • Sterling 822.00292.00 - page 39

    Large Dehumidifying Dryers Operation 39 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 alar ms are enabled 5 seconds after startup. Dew Point al ...

  • Sterling 822.00292.00 - page 40

    Large Dehumidifying Dryers Operation 40 PF - PROCESS FILTER RF - REGEN FILTER CV - CLOSED LOOP VALVE BV - BED SWITCH VALVE PS - PROCESS TEMP SWITCH RS - REGEN TEMP SWITCH PH - PROCESS HI TEMP Screen 6. PL - PROCESS LOW TEMP RH - REGEN HI TEMP DP - DEWPOINT PR - REDUNDANT SAFETY 5-4 Auto-Tuning the Dryer 1. For Auto-tuning, press the beige button on ...

  • Sterling 822.00292.00 - page 41

    Large Dehumidifying Dryers Maintenance 41 Chapter 6: Maintenance 6-1 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 # EVERY WEEK Date/ By ...

  • Sterling 822.00292.00 - page 42

    Large Dehumidifying Dryers Maintenance 42 6-2 Preventative Maintenance Cleaning or Replacing the Process Air Filters Regular filter cleaning will keep your dryer op erating at peak efficiency. The process air filters protect the centrifugal blowers from pl astic fines being drawn in from the dr ying hopper. Filters should be cleaned when airflow re ...

  • Sterling 822.00292.00 - page 43

    Large Dehumidifying Dryers Maintenance 43 Use the following procedure to clean or replace the filter cartridges: 1. Turn off and/or lock out el ectrical power to the dryer. 2. Remove the hand knobs or clamps securi ng the filter a ccess cover and remove the cover. 3. Remove the nut on the center-retaining rod to remove a filter cartridge. 4. Vacuum ...

  • Sterling 822.00292.00 - page 44

    Large Dehumidifying Dryers Maintenance 44 5. Remove the restricted filter cartridge from the housing again. The alarm light should stay off when the process blower operate s 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. 7. Fine tune the swi ...

  • Sterling 822.00292.00 - page 45

    Large Dehumidifying Dryers Maintenance 45 6-3 Corrective Maintenance Symptoms of Worn Out Desiccant The moisture adsorption capacity of the desi ccant used in Large Dehumidifying Dryers degrades after an indefinite period of time. Us eful life depends on variables such as material moisture content, plasticizer vapors in the re turn air and number o ...

  • Sterling 822.00292.00 - page 46

    Large Dehumidifying Dryers Maintenance 46 6. Inspect the gaskets on each of the covers. Replace if necessary. 7. Re-install the covers. Figure 17: Desiccant Tower Assembly Regeneration Heater Cover. High Temperature Gaskets. Heater Element Mounting Plate. Access cover can be removed in order to replace desiccant. Viewing Glass, for checking the sta ...

  • Sterling 822.00292.00 - page 47

    Large Dehumidifying Dryers Maintenance 47 High Temperature Gasket Double Wall Stainless Steel Heater Housing Heater Elements Heater Element Mounting Plate Stainless Steel Heater Housing Cover High Temperature Gasket Heater Assembly Gude Bars 1. Remove the bolts securing the process heater access cover. 2. Sketch the heater wiring configuration so t ...

  • Sterling 822.00292.00 - page 48

    Large Dehumidifying Dryers Maintenance 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, taki ng care to not damage the gaskets. 5. Unscrew the heater loops that need to be replaced. ...

  • Sterling 822.00292.00 - page 49

    Large Dehumidifying Dryers Troubleshooting 49 Chapter 7: T roubleshooting 7-1 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 ...

  • Sterling 822.00292.00 - page 50

    Large Dehumidifying Dryers Troubleshooting 50 Problem Possible Cause Corrective Action Process heaters are faulty. Replace. Desiccant beds are contam i nated. Replace desiccant . Material being dried differs from material specified at the time of purchase. Drying systems are designed for the material that was originally specified. Different materia ...

  • Sterling 822.00292.00 - page 51

    Large Dehumidifying Dryers Troubleshooting 51 7-3 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. 7-4 Alarm Descriptions Alarm Code Alarm Description Alarm Effect BV The Main Air Valve did not maintain or find position. Possible Motor or Limit Switch Fail ...

  • Sterling 822.00292.00 - page 52

    Large Dehumidifying Dryers Troubleshooting 52 7-5 Determining Temperature Contro ller 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 control ler is normal and the sensor is probably broken, short-circuited, o ...

  • Sterling 822.00292.00 - page 53

    Large Dehumidifying Dryers Appendix 53 Chapter 8: Appendix 8-1 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 compliance 2. Ambient temperature: 0 degrees Celsius – Maximum (104 degrees Fahrenheit) 3. Humidity ...

  • Sterling 822.00292.00 - page 54

    Large Dehumidifying Dryers Appendix 54 8-2 Drawings and Diagrams Regen. Filter Regeneration Blower Process Blower Optional After-cooler Process Air Filter Insulated Drying Hopper Left Desiccants Right Desiccants Process Heater Optional Regeneration Closed Loop Cooler Optional Regeneration Closed Loop Valve Regen. Exhaust Dryer Valve Airflow Schemat ...

  • Sterling 822.00292.00 - page 55

    Large Dehumidifying Dryers Appendix 55 PS Differential Pressure Switch Filter Check Gage E F Dust Level Indicator Slide Gate Clamp Dust Pan Filter Retainer Dust Shroud Cartridge Filter Thumb Screws Optional dryer dust collector ...

  • Sterling 822.00292.00 - page 56

    Large Dehumidifying Dryers Appendix 56 8-3 Spare Parts List 600CFM 600CFM 600CFM 600CFM 600CFM 850CFM 850CFM 850CFM 850CFM 850CFM 1000CFM 1000CFM 1000CFM 1000CFM 1000CFM 1250CFM 1250CFM 1250CFM 1250CFM 1250CFM 1500CFM 1500CFM 1500CFM 1500CFM 1500CFM 2000CFM 2000CFM 2000CFM 2500CFM 2500CFM 2500CFM 3000CFM 3000CFM 3000CFM LEVEL 1 ( Electrical Compone ...

  • Sterling 822.00292.00 - page 57

    Large Dehumidifying Dryers Appendix 57 8-4 LEVEL 3 ( Electrical Components ) 600CFM 600CFM 600CFM 600CFM 600CFM 850CFM 850CFM 850CFM 850CFM 850CFM 1000CFM 1000CFM 1000CFM 1000CFM 1000CFM 1250CFM 1250CFM 1250CFM 1250CFM 1250CFM 1500CFM 1500CFM 1500CFM 1500CFM 1500CFM 2000CFM 2000CFM 2000CFM 2500CFM 2500CFM 2500CFM 3000CFM 3000CFM 3000CFM PART # SIZE ...

  • Sterling 822.00292.00 - page 58

    Large Dehumidifying Dryers Appendix 58 8-5 Dryer Identificatio n (Serial Number) Tag (Located on back of Dryer) XXX Series Dryer Model Number XXX-15 Max Drying Capacity HR 460V Serial Number 060701R 1 Date of Manufacture 06/2003 4.5A Over-current Protec tion Device (s) 4.5A Total Frequency 50/60Hz Compressed air supply None Dryer Mass 400 lbs/(180 ...

  • Sterling 822.00292.00 - page 59

    Large Dehumidifying Dryers Appendix 59 8-5 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 262 ] 641-861 0 Fax: [262] 641-8653 The ACS Customer Service Group will provide your compan y with genuine OEM quality p arts manufactured to engi neering desig n specifications, which will maximize your equipmen ...

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