Page 4 - Table of contents
SDF 250/400/500 4 Table of contents 1. General Information ............................................................................................. 1-1 1.1. Warnings and symbols....................................................................................... 1-21.2. Explanations and infor...
Page 6 - General Information 1-1; General Information
SDF 250/400/500 General Information 1-1 1. General Information These operating instructions are addressed to all users of thedevice.These operating instructions must be used by every personcharged with work on the unit.
Page 7 - General Information 1-2
SDF 250/400/500 General Information 1-2 1.1. Warnings and symbols The following warnings and symbols are used in these operating instructions: This symbol indicates danger to life! Fatal or serious injury ispossible if the corresponding instructions, regulations orwarnings are not observed. L This s...
Page 8 - General Information 1-3
SDF 250/400/500 General Information 1-3 When disposing of drying agents / batteries / oil, observe allofficial rules. Caution: High noise pollution !For all work on the equipment, hearing protection should beworn.Avoids impairment of hearing! Caution: Danger of crushing !Disconnect the equipment fro...
Page 9 - General Information 1-4
SDF 250/400/500 General Information 1-4 1.2. Explanations and information Various terms and designations are used in these operating instructions to ensure clarity.Therefore please note that the terms used in the text stand for the corresponding explanationslisted below. • Equipment: ”Equipment” can...
Page 10 - Safety instructions 2-1; Safety instructions
SDF 250/400/500 Safety instructions 2-1 2. Safety instructions These safety instructions apply to all persons within the range ofaction of the equipment.Please inform all persons within the range of action of theequipment of the direct and indirect hazards connected with theequipment.These operating...
Page 11 - Safety instructions 2-2
SDF 250/400/500 Safety instructions 2-2 2.1. General The operating personnel of this equipment must be at least 16 years old. Please read these operating instructions carefully before taking into operation for the first time.Contact us should questions arise. This avoids injury and damage to equipme...
Page 12 - Safety instructions 2-3; Assembly
SDF 250/400/500 Safety instructions 2-3 2.1.1. Assembly Compare the connected loads with those of the mains supply. Danger of injury through electricalshock! When using lifting gear, please observe the pertaining regulations. Caution: Danger of accidents! Do not modify, add other equipment or change...
Page 13 - Safety instructions 2-4; Maintenance
SDF 250/400/500 Safety instructions 2-4 to people and material! 2.1.3. Maintenance Before starting maintenance work, appoint a supervisor. Inform the responsible personnel before maintenance work on the system is started. Caution:Danger of accidents! Disconnect the equipment from mains supply before...
Page 14 - Safety instructions 2-5
SDF 250/400/500 Safety instructions 2-5 2.2. For the safety of the devices Never change settings without carefully assessing the consequences. Use only original Sterling spare parts. Observe the maintenance instructions. Keep a record of all maintenance works and repairs. Please note that electronic...
Page 15 - Start up
SDF 250/400/500 Start up 3-1 3. Start up This chapter is addressed to the operators of the machine.This chapter assumes general skills with drying systems and SPS(PLC) control units.This chapter assumes that the functional description has beenread and understood.It must be ensured that the operators...
Page 16 - Touch Screen
SDF 250/400/500 Start up 3-2 3.1. Control Unit The control system is switched on at the main switch. The control system is operated via the ”Touch Screen and the keyboard of the operator panel. The facility’s control system is factory-programmed. Nevertheless, you have to set specific values(basic p...
Page 18 - Basic parameters; Entering Dryer Values; Target value
SDF 250/400/500 Start up 3-4 Basic parameters 3.3.1. Entering Dryer Values Return air cooler on/orr“I”: enabling the return air cooler“O” disabling the return air cooler Target value Actual value Status Dryer Back to “Start-Screen”
Page 19 - Temperature
SDF 250/400/500 Start up 3-5 Heater Reg. Act. The regenerated heat temperature will be displayed. Exit air Act. The current temperature of the used air will bedisplayed. & If the unit is operates with “dewpoint controlled changeoverpoint with dew point display”(optional): Dew point max. Enter th...
Page 20 - Entering hopper values; Enter hopper name
SDF 250/400/500 Start up 3-6 3.3.2. Entering hopper values Return air cooler on/orr“I”: enabling the return air cooler“O” disabling the return air cooler Enter hopper name Status Hopper Back to “Start-Screen” STT 1
Page 22 - Setting the timer
SDF 250/400/500 Start up 3-8 3.3.3. Setting the timer
Page 24 - Observing processing status
SDF 250/400/500 Start up 3-10 3.3.4. Observing processing status Actual operation status: The following operation statuses can be displayed: • system is off • system is on • blower runs on • valve block • regeneration will be finished in x min. Actual hopper temperature displayed in °C Status dryer ...
Page 25 - Setting date and time
SDF 250/400/500 Start up 3-11 3.3.5. Setting date and time Date/Time Enter the desired day and time.
Page 26 - Changing language
SDF 250/400/500 Start up 3-12 3.3.6. Changing language & This function is passwordprotected. Enter the password (password: 792154) ****** ******
Page 30 - Never switch off the dryer directly at the main switch
SDF 250/400/500 Start up 3-16 3.5. Switching the dryer/hopper heater off Switch off the hopper heater: Switch off the dryer: L Wait until the regeneration phase is finished and the blower hascome to a standstill.Switch off the dryer at the main switch.Disconnect the power supply. F Never switch off ...
Page 31 - Error and error correction 4-1; Error and error correction
SDF 250/400/500 Error and error correction 4-1 4. Error and error correction This chapter is directed at the operators of the equipment.This chapter assumes general skills in dealing with dryingsystems and SPS (PLC) control units.This chapter assumes that the “start-up” description has beenread and ...
Page 32 - Error and error correction 4-2; Failures must be repaired immediately.
SDF 250/400/500 Error and error correction 4-2 F Failures must be repaired immediately. & Alarm messages are displayed in plain language on the screen ofthe operator device. An alarm is given by flashing of the LED“alarm”.The display of alarm messages in the operator device can only beerased by ...
Page 33 - Error and error correction 4-3
SDF 250/400/500 Error and error correction 4-3 4.1. Actual messages Following alarm messages can be displayed: PLC (= SPS) Battery is Empty Replace the SPS battery. The Safety Switch Regeneration Blower Has Been Actuated Check the blower. Check the fuses. Short circuit check of the blower. Vacuum Re...
Page 34 - Error and error correction 4-4
SDF 250/400/500 Error and error correction 4-4 Error Bypass Flap The bypass flap does not close or closes too slowly. Check the bypass flap. Error Valve Block The valve block has not reached the proper position. The main switch is placed in the off position. Check the position of the valve block. Pr...
Page 35 - Error and error correction 4-5
SDF 250/400/500 Error and error correction 4-5 Excess Temperature Heater Hopper X (X = number of the drying hopper) The temperature of the hopper heater is too high. Check the safety temperature limiter. Sterling Service. Insufficient Temperature Heater Hopper X (X = number of the drying hopper) The...
Page 36 - Error and error correction 4-6
SDF 250/400/500 Error and error correction 4-6 Overload Regeneration Heater - STB has been activated Check the safety temperature limiter (= STB). Check regeneration heater. Short circuit check. Overload Drying Heater - STB has been activated Check the safety temperature limiter (= STB). Check dryin...
Page 37 - Error and error correction 4-7
SDF 250/400/500 Error and error correction 4-7 4.2. Alarm protocol & Alarm messagesare displayed inplain languagewith date and timein the alarmprotocol.
Page 40 - The service intervals refer to a 3-shift operation.
SDF 250/400/500 Maintenance 5-3 5.1. Maintenance schedule Daily: Check warning signs on equipment for good legibility and completenessClean return air filters and casing (depending on dust build-up) Weekly: Check main switch for proper functionCheck the signal lamps for proper functioning Every thre...
Page 41 - Cleaning or Replacing the Air Filter; when operating with return air cooler:
SDF 250/400/500 Maintenance 5-4 5.2. Cleaning or Replacing the Air Filter Switch off the hopper heater: And the dryer: L Wait until the regeneration phase is finishedand the blower has come to a standstill.Switch off the main switch of the dryer.Interrupt the mains supply so that the device cannot b...
Page 42 - Cleaning or Replacing the Return Air Filter
SDF 250/400/500 Maintenance 5-5 5.2.1. Cleaning or Replacing the Return Air Filter Open the panel (A) by means of the providedswitch cabinet key. Open the tension ring on the housing of thereturn air filter (B) and remove the housingcover. Remove the nut of the filter cartridge. Remove the filter ca...
Page 43 - Cleaning or Replacing the Regeneration air filter; Never operate the dryer without regeneration air filter
SDF 250/400/500 Maintenance 5-6 5.2.2. Cleaning or Replacing the Regeneration air filter Open the back panel. Slide the air filter (A) off the nozzle. Blow compressed air through the cloggedair filter from the inside out or replace theair filter. Install the cleaned/new air filter (A). Mount the bac...
Page 44 - Filter of the electrical cabinet; Never operate the dryer without filter mat.
SDF 250/400/500 Maintenance 5-7 5.2.3. Filter of the electrical cabinet Remove the lid of the filter. Remove the filter mat. Blow through the filter mat with compressed air from inside to outside or renew the filter mat. Clean the filter housing. Use lint-free cleaning rags. Re-install the cleaned/n...
Page 45 - When disposing of drying agents, observe all official rules.
SDF 250/400/500 Maintenance 5-8 5.3. Disposing of Drying Agents Please note that drying cells are replaced or refilled by Sterling only if they are empty. When disposing of drying agents, observe all official rules. Since used drying agents may contain impurities from the driedmaterials, treat them ...
Page 47 - Remove any granules remaining in the cleaning opening.
SDF 250/400/500 Maintenance 5-10 STT 25 Open the toggle-type fasteners (A) at the hopper lidand fold the hopper lid upwards (if in use: removebefore the single conveyor).Clean the drying hopper.Close the hopper lid and close the toggle-typefasteners (A) (if in use: re-mount the singleconveyor). F Re...
Page 49 - Changing the battery of the control system; The notch on the battery connector must point to the left!
SDF 250/400/500 Maintenance 5-12 5.5. Changing the battery of the control system This work may be carried through only by qualified personneltrained in the field of electrical engineering. F The battery may be changed only with the control systemswitched on. Open the control box by means of the cont...
Page 50 - Order number battery:
SDF 250/400/500 Maintenance 5-13 Close the control box. L Store backup batteries in a dry and cool place.Backup batteries can be stored for approx. 5 years.If backup batteries are not treated properly, they can ignite,explode and cause severe burning. & Order number battery: ID 83809 Batteries m...
Page 51 - Resetting the control values
SDF 250/400/500 Maintenance 5-14 5.5.1. Resetting the control values This electrical work is intended to be carried out only by trainedpersonnel. After changing the battery or the PLC the control values should be resetted. All control values are set back to the standard settings. Open the control bo...
Page 52 - Functional description 6-15; Functional description
SDF 250/400/500 Functional description 6-15 6. Functional description This functional description is addressed to the operators of theequipment. This functional description assumes general familiarity withdrying equipment. It should be verified that the operators do indeed have theappropriate skills...
Page 53 - Functional description 6-16; The dryer is rated for continuous operation.
SDF 250/400/500 Functional description 6-16 6.1. General Information The dryers work according to the dehumidified air principle, i.e., the air is not only heated but alsodehumidified before it flows through the drying hopper. In this manner, plastic granules can be dried down to a very small residu...
Page 54 - Functional description 6-17; Figure 3: Drying Hopper
SDF 250/400/500 Functional description 6-17 6.2. Drying Hopper (Optional) The material is dried in the drying hopper. Thedehumidified air is conducted through the materialin the drying hopper and takes up moisture. Dryinghoppers must have the appropriate dimensions fortheir specific use so that the ...
Page 55 - Functional description 6-18; Figure 4: Suction Box
SDF 250/400/500 Functional description 6-18 6.3. Connection to a Pneumatic Conveying System (Optional) Your drying facility works best in combinationwith a pneumatic conveying system. In thisway, your drying hopper will always besupplied with sufficient material.The facility will only take as much m...
Page 56 - Transport, Assembly and Storage
SDF 250/400/500 Transport, Assembly and Storage 7-1 7. Transport, Assembly and Storage This chapter is intended for all operating personnel of theequipment. Personnel using these instructions must be instructed in theregulations for the prevention of accidents, the operatingconditions and safety reg...
Page 57 - The machine must not be tilted or laid on its side.; Figure 5: Transport with a fork lift truck
SDF 250/400/500 Transport, Assembly and Storage 7-2 7.1. Tansport and Packing Please ensure adequate carrying capacity of the liftingequipment.Note that the dryer system is top-heavy. Risc of toppling! F The machine must not be tilted or laid on its side. The equipment pass a rigorous operating test...
Page 58 - Figure 6: Transport with a workshop crane
SDF 250/400/500 Transport, Assembly and Storage 7-3 with a workshop crane Check if the eyelets are installed on the dryer housing. If this condition is met, fasten the transport cables to the eyelets. If this condition is not met, mount the eyelets and then fasten the transport cables to the eyelets...
Page 60 - Assembly instructions 8-1; Assembly instructions; Ensure in each case that the personnel are informed.
SDF 250/400/500 Assembly instructions 8-1 8. Assembly instructions These installation instructions are intended for persons withskills in electrical and mechanical areas due to their training,experience and received instructions. Personnel using these installation instructions must be instructedin t...
Page 61 - Assembly instructions 8-2
SDF 250/400/500 Assembly instructions 8-2 8.1. Installation of the exhauster fan for regeneration of exhaustair When plastics are being dried that release harmful gases during the drying process, care must betaken that the regeneration exhaust air is disposed of in an environmentally sound way. At t...
Page 62 - Assembly instructions 8-3
SDF 250/400/500 Assembly instructions 8-3 8.3. Electrical Connection Observe the rules of the local electricity board.Check that the supply voltage and the power frequency are inaccordance with the data on the nameplate of the device.The electrical connection may only be carried through orassigned b...
Page 63 - Assembly instructions 8-4
SDF 250/400/500 Assembly instructions 8-4 8.4. Compressed Air Supply A compressed air supply is needed to operate the valve stem. Check whether the compressed air piping has been installed and connected properly. Check whether fittings, length and quality of the hose assemblies are in accordance wit...
Page 64 - Technical data
SDF 250/400/500 Technical data 9-1 9. Technical data Basic Version Central control unit for operating the dryer and the drying hoppers. Drying temperature adjustment for all connected hoppers • SPS-S7 PLC • Touch-screen • Timer clock • Regeneration heater with safety temperature limiter • Isolated a...
Page 66 - Accessories
STT 25 – STT 6400 Accessories 10-1 10. Accessories o Spare parts list Drying Hoppers STT 25 – STT 6400 o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _...
Page 67 - Sterling Material Processing
Sterling Material Processing Accessories Spare parts listDrying HoppersSTT 25 – STT 6400
