Benutzeranleitung / Produktwartung 882.00295.00 des Produzenten Sterling
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SDA 1000-5100 Series Large Dehumidifying Dryer AP-1 Control Part Number: 882.00295.0 0 Bulletin Number: DH1-615 Effective: 12/01/05 Write Down Your Serial Numbers Here For Future Reference: __________.
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.
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.
Large Dehumidifying Dryers iv Table of Contents CHAPTER 1: SAFETY ................................................................ 7 1-1 How to Use This Manual ...........................................................................................
Large Dehumidifying Dryers v 3-7 Connecting Aftercooler/Precooler Cooling Water (Optional) ..................................... 32 3-8 Using the Drying Hopper Air Trap ............................................................................. 33 CHAPTER 4: CONTROLS .
Large Dehumidifying Dryers vi Parts Department ................................................................................................ 72 Service Department .....................................................................................
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.
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 Groun.
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.
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.
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.
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 AP1 contro l.
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.
Large Dehumidifying Dry ers Functional Description 14 Once the main air valve and closed loop regeneration valve are in place, the process air blower starts. The system monitors the process ai r blower’s overload, starter auxiliary contact feedback and air pressure.
Large Dehumidifying Dry ers Functional Description 15 • Sequence shutdown switch ; NFPA86, UL, AGA & CGA machinery electrical stan dards (Gas Dryers) ; Available supply voltages of 208, 230, 460.
Large Dehumidifying Dry ers Functional Description 16 2-5 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.
Large Dehumidifying Dry ers Functional Description 17 PS Differential Pressure Switch Filter Check Gage E F Dust Level Indicator Slide Gate Clamp Dust Pan Filter Retainer Dust Shroud Cartridge Filter .
Large Dehumidifying Dry ers Functional Description 18 Process Aftercooler The optional aftercooler cools the moist air returning to the dryer from the drying hopper. The aftercooler can cool the return air from 250º F to about 150ºF. This maintains the dr yer’s efficiency and condenses the unwanted plasticizer from the air stream.
Large Dehumidifying Dry ers Functional Description 19 Figure 4: Process Air Dust Collector PS Differential Pressure Switch Filter Check Gage E F Dust Level Indicator Slide Gate Clamp Dust Pan Filter R.
Large Dehumidifying Dry ers Functional Description 20 Material Overdrying Protection Material Overdrying Protection is an automatic system used to reduce the chance of over- drying, and possibly melting, the resin i n the drying hopper.
Large Dehumidifying Dry ers Functional Description 21 Mechanical Options ; Low temperature operation (120°F to 250°F) ; High temperature operation (250°F to 400°F) ; Precooler (Required for temper.
Large Dehumidifying Dry ers Functional Description 22 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.
Large Dehumidifying Dry ers Functional Description 23 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.
Large Dehumidifying Dry ers Functional Description 24 Dimensions and Specifications 9 Denotes availability CFM 600 850 1000 1250 1500 2000 2500 3000 (Electric Dryer w/ Basic Control) 9 9 9 9 9 9 9 9 (.
Large Dehumidifying Dry ers Functional Description 25 Electrical Features CFM Drye r AMP Draw 600 850 1000 1250 1500 2000 2500 3000 Standard voltage Low Heat (Electric Dryers) Full load Amps 208v/3/60Hz. 152 217 249 314 378 230v/3/60Hz. 137 196 225 284 342 N/A 400v/3/50Hz.
Large Dehumidifying Dry ers Mechanical I nstallation 26 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.
Large Dehumidifying Dry ers Mechanical Installation 27 ; Make sure all electrical connections are tight. 3-4 Making Gas Line Connections (Gas-Fired Models Only) Connect a gas line to the dryer’ s gas inlet. See Figure 6 for a detailed sche matic of the gas system.
Large Dehumidifying Dry ers Mechanical I nstallation 28 3-5 Checking for Proper Blower Rotation After the electrical connections have been made, check the process and regeneration blowers for proper blower rotation.
Large Dehumidifying Dry ers Mechanical Installation 29 3-6 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.
Large Dehumidifying Dry ers Mechanical I nstallation 30 Process Air Heater on Dry ing Hopper Return air thermocouple location.
Large Dehumidifying Dry ers Mechanical Installation 31 Drying System with Dust Collector and Proc ess Air H eater on Dryer Return air thermocouple location.
Large Dehumidifying Dry ers Mechanical I nstallation 32 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 Stai.
Large Dehumidifying Dry ers Mechanical Installation 33 3-8 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 .
Large Dehumidifying Dryers Controls 34 Chapter 4: Controls 4-1 Controller Description The AP1 control package uses a PLC with a touc h screen interface to control the operation of the dryer. See for descriptions of each screen. Figure 11: Controller Screen Descriptions Main Menu.
Large Dehumidifying Dryers Controls 35 4-2 Identifying Control Panel Comp onents for the AP-1 Optional Controller Disconnect Switch The Disconnect Switch is located in the front upper right hand corner of the control enclosure. It allows the user to disconnect power to the dryer for emergency shutdown, service or long periods of inactivity.
Large Dehumidifying Dryers Controls 36 • Copyright Information • PLC Version • Display Version After approximately 10-12 seconds the controller will flash to the Dryer Status Screen shown on the previous page.
Large Dehumidifying Dryers Controls 37 The DEW POINT value will give you a reading of what the actu al process air dew point is . The area in the lower lef t portion of the touch screen conveys two lines of information relat ing to th e over all operation of the dryer.
Large Dehumidifying Dryers Controls 38 Enter the values you would like to set in the screen by pressing the number keys. Press ENT (Enter) when you are finished to set the new values or CLR (Clear) to erase the current values and reenter new ones. To set the values in the next field, press ENT (Enter) to close the screen shown above.
Large Dehumidifying Dryers Controls 39 By pressing the LOW TEMP or HIGH TEMP alarm buttons, the operator can enter the desired values to enable the alarm to go off at a specific deviation from setpoint (on the high or low side).
Large Dehumidifying Dryers Controls 40 OVERDRY PROTECTION (Overdry Protection Screen - 1 of 2) This feature is used to prevent the overdryi ng of the plastic resin in the drying hopper. RETURN TEMP provides the actual temperature of the process air leaving the drying hopper.
Large Dehumidifying Dryers Controls 41 ALARMS (Alarm History Screen) This screen allows the operator to review the number and type of issues that the dryer has encountered during its operation. Problems can be viewed by Date, Hour, and Comment. Because of the size of the screen, only th ree (3) comments/alar ms can be viewed at a time.
Large Dehumidifying Dryers Controls 42 DEW POINT SETUP (Dew Point Setup Screen) This screen allows the operator to set the dew point. The HIGH DEW PT ALARM is an audible/visual alarm that will sound when the process air dewpoint rises to this value. Values can be set between –40 through +30 degrees.
Large Dehumidifying Dryers Controls 43 This button enab les and disables t he AutoStart Ti mer. HELP MENU (Help Menu Screen) The DRYER ALARMS button shows Help menus for Dryer Alarms. MAIN MENU (Main Menu Screen) This screen allows you to jump to the different areas of the controller to set, monitor, and operate different features of the dryer.
Large Dehumidifying Dryers Controls 44 • SYSTEM BACKUP • SERVICE MENU • MAIN MENU SYSTEM SETUP (System Setup Screen) This screen allows the operator to set alarm and password features. ALARM OFF DUR is the amo unt of time (0-99 m inutes) that the a larm and horn will stay off after the alarm silence button is pushed.
Large Dehumidifying Dryers Controls 45 The AP1 control system can detect and alarm a lo w material level condition in up to three (3) material hoppers. The material hopper assignments on the display are “Machine Hopper 1,” “Machine Hopper 2,” and “Drying Hopper.
Large Dehumidifying Dryers Controls 46 Press the SYSTEM MENU button to return back to the sy stem menu screen and the next set of programmable features. HOUR METERS (Hour Meter Sc reen) This screen monitors the number of hours that the dryer has operated.
Large Dehumidifying Dryers Controls 47 (System Backup Screen) ACS Dryer control version 2.000 introduces a system backup feature. Pressing SAVE SETTINGS will save the s ystem variables for la ter recall. Pressing RESTORE SETTINGS will restore previously saved values.
Large Dehumidifying Dryers Controls 48 This service menu screen is PASSWORD PROTECTED and meant for ACS personnel use only. Press the RETURN key to go back to the SYSTEM MENU . Touching the MAIN MENU button in the SYSTEM MENU screen, will return the operator back to the overall menu screen.
Large Dehumidifying Dryers Controls 49 Alarm Screen Example This is an example of what a typical Alarm screen looks like. The user will see the message causing the alarm in the top half of the display with an ALARM SILENCE button in the lower half. To turn off the alarm, the user must press the ALARM SILE NCE button.
Large Dehumidifying Dryers Controls 50 4-6 Setting the Redunda nt Safety Controller The Redundant Safety Controller alarm setting is changed by pressing the up and down keys to input the alarm value. The upper display reading indicates the Pr ocess Value, while the lower display indicates the High Point Setting al arm value.
Large Dehumidifying Dryers Controls 51.
Large Dehumidifying Dryers Operation 52 Chapter 5: Operation 5-1 Start-up There are two possible methods of starting the dryer system: manually, by pressing the Start button on the Dryer Status screens, and automatic ally through use of the Auto Start Timer built into the dryer control system.
Large Dehumidifying Dryers Operation 53 5-2 Using the Dryer Status Screen From the Main Menu screen, press the DRYER button to access the Dryer Status screen. The Dryer Status screen displays the set point and actual process temperature as well as the actual dewpoint.
Large Dehumidifying Dryers Operation 54 5-3 Alarms Use the Alarm History screen to monitor syst em alarms. Fro m the Main Menu screen, press the Alarms button to access the Alarm History screen . The three most recent alarms appear at the top of the Alarm History screen.
Large Dehumidifying Dryers Operation 55 Alarm Comment Alarm Description Alarm Effect REGEN LOW TEMP Regeneration air temperature deviation is below low limit value. Possible heater failure. Alert Only DEWPOINT SENSOR The dew point sensor is out of range.
Large Dehumidifying Dryers Maintenance 56 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.
Large Dehumidifying Dryers Maintenance 57 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.
Large Dehumidifying Dryers Maintenance 58 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.
Large Dehumidifying Dryers Maintenance 59 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.
Large Dehumidifying Dryers Maintenance 60 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.
Large Dehumidifying Dryers Maintenance 61 6. Inspect the gaskets on each of the covers. Replace if necessary. 7. Re-install the covers. Figure 14: Desiccant Tower Assembly Regeneration Heater Cover. High Temperature Gaskets. Heater Element Mounting Plate.
Large Dehumidifying Dryers Maintenance 62 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.
Large Dehumidifying Dryers Maintenance 63 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.
Large Dehumidifying Dryers Troubleshooting 64 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.
Large Dehumidifying Dryers Troubleshooting 65 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.
Large Dehumidifying Dryers Troubleshooting 66 7-3 Determining Temperature Cont roller Errors or Sensor Errors Using a Thermocouple If the controller displays a temperature that is close to room temper.
Large Dehumidifying Dryers Appendix 67 Chapter 8: Appendix 8-1 Warranty The manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used un der recommended conditions.
Large Dehumidifying Dryers Appendix 68 8-2 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.
Large Dehumidifying Dryers Appendix 69 8-3 Spare Parts List 600CFM 600CFM 600CFM 600CFM 600CFM 850CFM 850CFM 850CFM 850CFM 850CFM 1000CFM 1000CFM 1000CFM 1000CFM 1000CFM 1250CFM 1250CFM 1250CFM 1250CF.
Large Dehumidifying Dryers Appendix 70 8-4 LEVEL 3 ( Electrical Components ) 600CFM 600CFM 600CFM 600CFM 600CFM 850CFM 850CFM 850CFM 850CFM 850CFM 1000CFM 1000CFM 1000CFM 1000CFM 1000CFM 1250CFM 1250C.
Large Dehumidifying Dryers Appendix 71 8-5 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 1 Date of Manufacture 06/2003 4.5A Over-current Protec tion Device (s) 4.
Large Dehumidifying Dryers Appendix 72 8-5 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 G.
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