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Operation and Installation Manual SMD Series Dehumidifying Dryers Important! Read Carefully Before Attempting to Install or Operate Equipment Part No. A0570029 Revision NEW Bulletin No.
Page 2 SMD Series Dehumidifying Dryers Write down your dehumidifying ________________ ________________ dryer serial numbers ________________ ________________ here for future reference ________________.
SMD Series Dehumidifying Dryers Page 3 Table of Contents 1 General Information ............................................................ 9 1-1 Models Covered ..........................................................................................
Page 4 SMD Series Dehumidifying Dryers Table of Contents 6 Control Operation .............................................................. 41 6-1 Controller Operation ...................................................................................
SMD Series Dehumidifying Dryers Page 5 Safety Considerations Sterling SMD Series membrane dryers are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes.
Page 6 SMD Series Dehumidifying Dryers STERLING “SMD” Series Membrane Dryers This dryer is manufactured by ACS, Inc. at the ACS-Wood Dale facility: ACS, Inc.
SMD Series Dehumidifying Dryers Page 7 Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this eq uipment that could alter the CE compliance 2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit) 3.
Page 8 SMD Series Dehumidifying Dryers Charts and Figures 1 Typical SMD Dryer Components 11 2 Typical Dryer Air Flow Schematic 12 3 SMD Series Floor-Mount Dimensions 13 4 Suggested Lift Rigging for SM.
SMD Series Dehumidifying Dryers Page 9 General Information 1 1-1 Models Covered This manual provides instructions for installing and operating Sterling SMD30 and SMD60 membrane dryers. The number designation represents air flow capacity. SMD30 models have a 30 cfm air flow capacity, and SMD60 models have a 60 cfm capacity.
Page 10 SMD Series Dehumidifying Dryers 1-4 Standard Features ; Electrical solenoid valve ; Drying temperature range of 160ºF to 400ºF. ; Mitsubishi programmable relay controller ; Display of process temperature set point and actual settings ; Process thermocouple to be connected to drying hopper air inlet.
SMD Series Dehumidifying Dryers Page 11 Figure 1 Typical SMD Dryer Components Large Particle Filter Coalescing Filter 0.01 Micron Solenoid Valve Heater Box Membrane Dryer High Temperature Switch Compr.
Page 12 SMD Series Dehumidifying Dryers 1-6 The Drying System Sterling Membrane Compressed air dryers, take a small percentage of the dried gas and direct it back in a sweeping pattern through the module shell. This provides a driving force to remove the moisture with the minimum purge required.
SMD Series Dehumidifying Dryers Page 13 Figure 3 SMD Series Floor-Mount Dimensions SMD30 and SMD60 floor-mount dimensions in inches/cm SMD30 SMD60 Dimension in.
Page 14 SMD Series Dehumidifying Dryers Safety 2 2-1 Work Rules Install, operate, and maintain this equipment according to applicable work and safety codes for your location. This includes OSHA, CE, NEC, CSA, SPI, and many other local, national, and international regulations.
SMD Series Dehumidifying Dryers Page 15 2-4 Safety Considerations The terms NOTICE, CAUTION, WARNING , and DANGER have specific meanings in this manual.
Page 16 SMD Series Dehumidifying Dryers 2-5 General Responsibility NO MA TTER WHO YOU ARE… Safety is important. Owners, operators, and maintenance personnel must realize that every day, safety is a vital aspect of their jobs.
SMD Series Dehumidifying Dryers Page 17 ONLY YOU can make safety work for you by constantly thinking about what is safe and what is not. It is often the “just once” that an operator reaches into a dryer to remove material and it results in serious injury.
Page 18 SMD Series Dehumidifying Dryers • 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.
SMD Series Dehumidifying Dryers Page 19 Do not restore power to the dryer until all persons are clear of the area. DO NOT start and run the dryer until you are sure all parts are functioning correctly.
Page 20 SMD Series Dehumidifying Dryers 2-8-3 Fail Safe Operation If a safety device or circuit should fail, the design must be such that the failure causes a “Safe” condition. As an example, a safety switch must be a normally open switch. The switch must be held closed with the device it is to protect.
SMD Series Dehumidifying Dryers Page 21 -Notes-.
Page 22 SMD Series Dehumidifying Dryers Shipping Information 3 3-1 Unpacking and Inspection You should inspect your Sterling dehumidifying dryer for possible shipping damage. If the container and packing materials are in re- usable condition, save them for reshipment, if necessary.
SMD Series Dehumidifying Dryers Page 23 3-3 If the Shipment is Not Complete Check the packing list. The apparent shortage may be intentional. Back-ordered items are noted on the packing list.
Page 24 SMD Series Dehumidifying Dryers Installation 4 4-1 Work Rules The installation, operation, and maintenance of this equipment must be conducted in accordance with all applicable work and safety codes for the installation location.
SMD Series Dehumidifying Dryers Page 25 CAUTION! • Use caution and observe safety rules when lifting and placing your dryer! Figure 4 Suggested Lift Rigging for SMD Dryers (Floor Mount) Note: Floor Mounted Dryers can be lifted by hoist or fork lift.
Page 26 SMD Series Dehumidifying Dryers SMD30 and SMD60 Electrical Schematics Refer to your Customer Information Packet on actual drawings for your specific dryer. 4-4 Making Dryer/Drying Hopper Process Air Connections Floor Mount Models ; Use high-temperature flexible dryer hose or rigid tubing to connect the dryer to the drying hopper.
SMD Series Dehumidifying Dryers Page 27 4-5 Drying Hopper Air Trap Considerations Sterling’s exclusive air trap assembly on the top of the drying hopper prevents ambient air from contaminating the material being dried. ; Keep the material level at the mid point of the air trap for the dryer to operate efficiency.
Page 28 SMD Series Dehumidifying Dryers - Notes -.
SMD Series Dehumidifying Dryers Page 29 Controls 5 5-1 Identifying Control Panel Indicator Lights and Switches for Standard Controller Switches System OFF/ON/START Switch The OFF/ON/START switch energizes or de-energizes control power to the indicator panel and starts the dryer.
Page 30 SMD Series Dehumidifying Dryers Figure 6 Typical Control Panel.
SMD Series Dehumidifying Dryers Page 31 5-2 Process Air Temperature Controller Sterling 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.
Page 32 SMD Series Dehumidifying Dryers 5-3 Identifying Process Air Temperature Controller LED Indicators Process Value Numeric LED During normal operation, the process value ( PV ) numeric LED indicator displays the process temperature at the To Process thermocouple.
SMD Series Dehumidifying Dryers Page 33 5-4 Identifying Temperature Controller Keys 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.
Page 34 SMD Series Dehumidifying Dryers 5-6 Restoring the E5CN Temperature Controller to Factory Setup 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.
SMD Series Dehumidifying Dryers Page 35 Proportional Band Mode(P) This setting controls the amount in which the manipulated variable ( MV ) is proportionate to the deviated value or controller error. Integral Time Mode (I) Setting this feature, gives the control an action that is proportionate to the time integral of the control error.
Page 36 SMD Series Dehumidifying Dryers Figure 8 Setting List for Process Temperature Controller (E5CN), Part No. A0555757 Mode Parameter Setting range Default Sterling setting Operation Run/Stop Run/.
SMD Series Dehumidifying Dryers Page 37 Figure 9 Typical Dew Point Display Monitor PV SV OUT1 OUT2 MANU STOP RMT AT SUB 1 AT E5CK OMRON ( Note: The only functional buttons on this contoller are the up and down keys.
Page 38 SMD Series Dehumidifying Dryers 5-10 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 Sterling dryers use a microprocessor-based controller for limiting the process air temperature.
SMD Series Dehumidifying Dryers Page 39 W A TLOW Operating Parameters The WATLOW controller has only one mode selection; ALARM. The factory at Sterling sets the security level to protect the critical parameters from being accidentally changed. Below is an explanation of the modes you will have access to and the Sterling default settings.
Page 40 SMD Series Dehumidifying Dryers Figure 11 Setting List for Redundant Safety Controller (WATLOW), Part No. A0555757 Mode Parameter Setting range Default Sterling setting SEn Sensor Type 0-3 0 - Lin Thermocouple Linearization 0-10 0 H (1) C-F Temperature Units Fahrenheit / Celsius F - S.
SMD Series Dehumidifying Dryers Page 41 Control Operation 6 6-1 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 42 SMD Series Dehumidifying Dryers 6.) When no fault conditions exist, the display reads “ SYSTEM NORMAL ”. 7.) When a dew point fault is generated by the optional dew point controller, the alarm horn and light will activate. The alarm light will flash, indicating a non-critical fault.
SMD Series Dehumidifying Dryers Page 43 4.) 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.
Page 44 SMD Series Dehumidifying Dryers 6-3 Alarm Display Messages Note: The relay screen which contains the Alarm Display Messages is located inside the controller enclosure.
SMD Series Dehumidifying Dryers Page 45 Startup, Shutdown, and Operation 7 7-1 Pre-Startup Checks ; Check the process hose for tight connections. ; Check hopper exhaust filter for tight connection. ; Check all companion equipment, such as the drying hopper; verify that the loading system is ready for operation.
Page 46 SMD Series Dehumidifying Dryers 7-3 Shutting Down the Dryer 1. When processing is complete, close the hopper slide gate and shut down any in-line companion equipment. 2. Turn the Dryer ON/OFF selector switch to OFF . 3. Turn the system ON/OFF switch to OFF .
SMD Series Dehumidifying Dryers Page 47 Maintenance 8 8-1 Work Rules The installation, operation, and maintenance of this equipment is to be conducted in accordance with all applicable work and safety codes for the installation location.
Page 48 SMD Series Dehumidifying Dryers Recommendations for Cleaning and Replacing Filters 1. Turn off and/or lock out electrical power to the dryer. 2. Remove the back access cover. 3. Locate the 2 compressed air hoses and filter bowls connected to the filters.
SMD Series Dehumidifying Dryers Page 49 5. Locate filters. 6. Remove the filters. 7. Replace particulate filter with new element. 8. Replace coalescing filter with new element.
Page 50 SMD Series Dehumidifying Dryers After each cleaning: • Inspect the filter element. Briefly hold a light bulb behind the element and look for any fatigued paper or residual dirt. Inspect for holes and tears by looking though the filter toward a bright light.
SMD Series Dehumidifying Dryers Page 51 Figure 12 Process Heater Location and Disassembly Procedures 1. Remove the four (4) 10-32 button head screws securing the process heater access cover using a 1/8” Allen wrench. 2. Sketch the heater wiring configuration so you can properly re- wire the heater.
Page 52 SMD Series Dehumidifying Dryers Preventive Maintenance Checklist Sterling SMD Dehumidifying Dryers System model # Serial # Every week Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Date/ By Inspect all filters for wear, replace/ clean if dirty or worn.
SMD Series Dehumidifying Dryers Page 53 Troubleshooting 9 Problem Possible cause Corrective action Process heaters are faulty. Check for open heaters. Replace if required. Solid-state temperature controller faulty. Replace. Loss or reduction of process air temperature.
Page 54 SMD Series Dehumidifying Dryers Problem Possible cause Corrective action Process temperature set too high due to operator error. Check resin manufacturer’s data sheet for proper drying temperature. Make sure plant personnel are aware of the correct process temperature set point.
SMD Series Dehumidifying Dryers Page 55 Problem Possible cause Corrective action Input polarity on thermo-couple is wrong or connection is wrong. Properly wire the terminals. Input-type setting is incorrect. Properly set the input with the input-type selector rotary switch.
Page 56 SMD Series Dehumidifying Dryers Dryer Options 10 The following is a list of options, which your Dryer may have been equipped with: • Dew Point Monitor • Audible Alarm with Silence Button .
SMD Series Dehumidifying Dryers Page 57 11 Spare Parts 11-1 Spare Parts List SMD Series Dehumidifying Dryers Figure 13 Level 1 Spare Parts List (Electrical & Mechanical) MINI DRYER SPA RE PA RTS L.
Page 58 SMD Series Dehumidifying Dryers Figure 14 Level 2 & 3 Spare Parts List (Electrical & Mechanical) MINI DRY ER SPA RE PA RTS LIST ACM30, ACM60 30CFM 30CFM 30CFM 30CFM 30CFM 30CFM 60CFM 6.
SMD Series Dehumidifying Dryers Page 59 Technical Assistance 12 12-1 Contact Information for Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423-3183 or call [414] 354-0970,.
Page 60 SMD Series Dehumidifying Dryers 12-2 Returned Material Policy 12-2-1 Credit Returns 1. Prior to the return of any material authorization must be given by Sterling. A RMA number will be assigned for the equipment to be returned. 2. Reason for requesting the return must be given.
SMD Series Dehumidifying Dryers Page 61 12-3 Warranty Sterling warrants all equipment manufactured by it to be free from defects in workmanship and material when us ed under recommended conditions.
Page 62 SMD Series Dehumidifying Dryers -Notes-.
SMD Series Dehumidifying Dryers Page 63 Safety Tag Information 13 13-1 SMD Dryer Safety Tags Hot! Read Operation and Installation Manual High Voltage Earth Ground Inside Enclosure PE Protected Earth L.
Page 64 SMD Series Dehumidifying Dryers 13-2 Dryer Identification (Serial Number) Tag (Located on back of Dryer) SMD Series Dryer Model Number SMD-030 Max Drying Capacity HR 460V Serial Number 060701R 1 Ǿ Date of Manufacture 06/2003 4.5A Over-current Protection Device (s) 4.
SMD Series Dehumidifying Dryers Page 65 Service Notes.
Page 66 SMD Series Dehumidifying Dryers Service Notes.
Sterling warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. T he Company’s obligation is limited to repair or repla.
Service Department Call Toll Free (800) 783-7835 Auxiliary Equipment for the Process Industries PO Box 245018 5200 West Clinton Avenue • Milwaukee, WI 53224-9518 (414) 354-0970 • Fax (414) 354-642.
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