Sterling SDA AP-1 - Manuals

Large Dehumidifying Dryers Safety 7 Chapter 1: Safety 1-1 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 productivit...

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 o...

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 safety and have designed and manufactured our equipment with operator safety as a prime consideration. We expect...

Large Dehumidifying Dryers Safety 10 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-worker...

Large Dehumidifying Dryers Safety 11 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 pla...

Large Dehumidifying Dryers Functional Description 12 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 600-3000 cfm Large Dehumidifying Dryers with AP1 control. These dryers are available with electric h...

Large Dehumidifying Dryers 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 dry material again. This system is a "closed loop", because ambient (outside) air is never introduce...

Large Dehumidifying Dryers 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 air blower’s overload, starter auxiliary contact feedback and air pressure. Loss of any of these items when the...

Large Dehumidifying Dryers Functional Description 15 • Sequence shutdown switch ; NFPA86, UL, AGA & CGA machinery electrical standards (Gas Dryers) ; Available supply voltages of 208, 230, 460, 575/3/60 and 400/3/60 2-4 Options Dewpoint Extend The Dewpoint Extend option measures the temperature ...

Large Dehumidifying Dryers 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 Regenerat...

Large Dehumidifying Dryers 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 Thumb Screws Optional dryer dust collector

Large Dehumidifying Dryers 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 250ºF to about 150ºF. This maintains the dryer’s efficiency and condenses the unwanted pla...

Large Dehumidifying Dryers 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 Retainer Dust Shroud Cartridge Filter Thumb Screws

Large Dehumidifying Dryers 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 in the drying hopper. Material Overdrying Protection activates when the return temperatu...

Large Dehumidifying Dryers 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 intended to supersede or alter safety standards established by the user of ...

Large Dehumidifying Dryers 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 (Electric Dryer High Performance) 9 9 9 9 9 9 9 9 (Gas Dryer option in lieu of Electric- 180°F to 250°...

Large Dehumidifying Dryers Functional Description 25 Electrical Features CFM Dryer 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. 79 113 129 163 197 270 339 4...

Large Dehumidifying Dryers Mechanical Installation 26 Chapter 3: Mechanical Installation 3-1 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 ...

Large Dehumidifying Dryers 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 schematic of the gas system. Figure 6: Gas Flow Schematic PS Fume E...

Large Dehumidifying Dryers Mechanical Installation 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. Check blower rotation before making process air connections between the dryer and hopp...

Large Dehumidifying Dryers Mechanical Installation 29 3-6 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 ...

Large Dehumidifying Dryers Mechanical Installation 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 Stainless Steel Cooler Housing Cooling Coil Cooling Coil Pipe Gasket Cooling Coil Cover Plate Mounting Bra...

Large Dehumidifying Dryers Mechanical Installation 33 3-8 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 Figu...

Large Dehumidifying Dryers Controls 34 Chapter 4: Controls 4-1 Controller Description The AP1 control package uses a PLC with a touch screen interface to control the operation of the dryer. See for descriptions of each screen. Figure 11: Controller Screen Descriptions Main Menu. The main navigationa...

Large Dehumidifying Dryers Controls 35 4-2 Identifying Control Panel Components 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 shutdow...

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. 4-4 Identifying Controller Screens Main Menu Screen (Main Menu Screen) The MAIN MENU provi...

Large Dehumidifying Dryers Controls 37 The DEW POINT value will give you a reading of what the actual process air dew point is. The area in the lower left portion of the touch screen conveys two lines of information relating to the overall operation of the dryer. The following is a list of typical m...

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 (Ente...

Large Dehumidifying Dryers Controls 40 OVERDRY PROTECTION (Overdry Protection Screen - 1 of 2) This feature is used to prevent the overdrying of the plastic resin in the drying hopper. RETURN TEMP provides the actual temperature of the process air leaving the drying hopper. Press the MORE button loc...

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 three (3) comme...

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 enables and disables the AutoStart Timer. 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, a...

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 amount of time (0-99 minutes) that the alarm and horn will stay off after the alarm silence bu...

Large Dehumidifying Dryers Controls 45 The AP1 control system can detect and alarm a low 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.” Although your naming conventions may ...

Large Dehumidifying Dryers Controls 46 Press the SYSTEM MENU button to return back to the system menu screen and the next set of programmable features. HOUR METERS (Hour Meter Screen) This screen monitors the number of hours that the dryer has operated. In addition to monitoring the total number of ...

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 system variables for later recall. Pressing RESTORE SETTINGS will restore previously saved values. Pressing RESTORE FACTORY DEFAULTS ...

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. In this ...

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 ALAR...

Large Dehumidifying Dryers Controls 50 4-6 Setting the Redundant 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 Process Value, while the lower display indicates the High Poi...

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 automatically through use of the Auto Start Timer built into the dryer control system. Before...

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. (Dryer Status Screen) The area ...

Large Dehumidifying Dryers Operation 54 5-3 Alarms Use the Alarm History screen to monitor system alarms. From 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. Use the DOWN and UP buttons to ...

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. Possible transducer or electronics failure. D...

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...

Large Dehumidifying Dryers Maintenance 57 6-2 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 ho...

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 operates if the switch is adjusted correctly. 6. Re-install the obstructed cartridge filter. The alarm light should go on again if the s...

Large Dehumidifying Dryers Maintenance 60 6-3 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, pl...

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. Access cover can be removed in order to repl...

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 cov...

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, taking care to not damage the gaskets. 5. Un...

Large Dehumidifying Dryers Troubleshooting 64 Chapter 7: Troubleshooting 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 must be accomplished with the power off, line fu...

Large Dehumidifying Dryers Troubleshooting 66 7-3 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...

Large Dehumidifying Dryers Appendix 67 Chapter 8: Appendix 8-1 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. ...

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 equipment that could alter the CE compliance 2. Ambient temperature: 0 degrees Celsius – Maximum (104 degre...

Large Dehumidifying Dryers Appendix 69 8-3 Spare Parts List 600CFM 600CFM 600CFM 600CFM 600CFM 850CFM 850CFM 850CFM 850CFM 850CFM 1000C F M 1000C F M 1000C F M 1000C F M 1000C F M 1250C F M 1250C F M 1250C F M 1250C F M 1250C F M 1500C F M 1500C F M 1500C F M 1500C F M 1500C F M 2000C F M 2000C F M ...

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 Protection Device (s) 4.5A Total Frequency 50/60Hz Com...

Large Dehumidifying Dryers Appendix 72 8-5 Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610; Fax: [262] 641-8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specificat...