Write down your dehumidifying________________________________
dryer serial numbers________________________________
here for future reference________________________________
________________________________
Performance figures stated in this manual are based on a standard atmosphere of 59°F
(15°C) at 29.92” Hg (1,014 millibars) at sea level, using 60 hz power. Altitude is an
important consideration when specifying dehumidifying dryers. Sterling can advise you
on proper selection and sizing of systems for your operating environment.
Sterling is committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual
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.
To avoid possible personnel injury or equipment damage when
installing, operating, or maintaining this equipment, use good
judgment and follow these safe practices:
; Follow all SAFETY CODES.
; Wear SAFETY GLASSES and WORK GLOVES.
; Disconnect and/or lock out power before servicing or
maintaining the dryer.
; Use care when LOADING, UNLOADING, RIGGING, or
MOVING this equipment.
; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before
working on this equipment. It is a good idea to remove the
fuses and carry them with you
; Make sure the dryer and components are properly
GROUNDED before switching on power.
; Do not jump or bypass any electrical safety control.
; Do not restore power until all tools, test equipment, etc. have
been removed and the dryer and allied equipment are fully
reassembled.
; Only PROPERLY TRAINED personnel familiar with the
information within this manual should work on this equipment.
SMD Series Dehumidifying DryersPage 5
STERLING
“SMD” Series
Membrane Dryers
This dryer is manufactured by ACS, Inc. at the ACS-Wood Dale facility:
ACS, Inc.
800 N. Wood Dale Rd.
Wood Dale, IL 60191
Phone: 630.595.1060
Fax: 630.595.6641
The equipment is distributed in Europe by our European facility:
ACS-EUROPE
Daniels Industrial Estate
BATH ROAD
Stroud, Gloucestershire, England
GL5 3TJ
Phone: (44) 1453 768980
Fax: (44) 1453 768990
Page 6SMD Series Dehumidifying Dryers
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
9. Allowable frequency fluctuation:Continuous+/- 1%
Intermittent+/- 2%
10. Nominal supply voltage:460/3/60 (Verify on serial number tag)
11. Earth ground type:TN (system has one point directly earthed through
a protective conductor)
12. Power supply should include a ground connection.
13. Over-current protection is supplied in the dryer, but additional protection should be
supplied by the user.
14. The door-mounted disconnect serves as the electrical disconnect device.
15. Dryer is not equipped with local lighting.
16. Functional identification
17. Dryer is equipped with a CE mark
18. Dryer is supplied with an operating manual in the language of the destination country.
19. Cable support may be required for power cord, depending on final installation.
20. No one is required to be in the interior of the electrical enclosure during the normal
operation of the unit. Only skilled electricians should be inside the enclosure for
maintenance.
21. Doors can be opened with a screwdriver, but no keys are required.
22. Two-hand control is not required or provided.
23. All dryers should be moved around and set in a place with a lift truck or equivalent.
24. There are no frequent repetitive cycles that require manual controlrepetitive functions
are automatic while the dryer is operating.
25. An inspection report detailing the functional test is included with the dryer.
26. The machine is not equipped with cableless controls.
27. Color-coded (harmonized) power cord is sufficient for proper installation.
SMD Series Dehumidifying DryersPage 7
Charts and Figures
1
Typical SMD Dryer Components11
2
Typical Dryer Air Flow Schematic12
3
SMD Series Floor-Mount Dimensions13
4
Suggested Lift Rigging for SMD Dryers (Floor Mount)25
5
Dryer Hose Connections to Hopper26
6
Typical Control Panel30
7
Typical Temperature Controller31
8
Setting List for Process Temperature Controller36
9
Typical Dew Point Display Monitor37
10
11
12
13
14
Typical Redundant Safety Controller Display38
Setting List for Redundant Safety Controller (WATLOW)40
Process Heater Location & Disassembly51
Level 1 Spare Parts List (Electrical & Mechanical)57
Level 2 & 3 Spare Parts List (Electrical & Mechanical)58
Page 8SMD Series Dehumidifying Dryers
General Information1
1-1Models 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.
1-2Equipment Function
Sterling membrane mini dryers are designed to generate heated,
dehumidified air at carefully controlled temperatures for use in
plastic drying systems. Drying systems are sized to meet the
specific requirements stated by the purchaser at the time of
purchase.
Moisture removal from hygroscopic (moisture attracting) plastic
pellets is an essential step in the manufacture of high-quality
plastic products.
Sterling dehumidifying dryers are used to generate very low dew
point air heated to a controlled temperature for drying plastic
pellets and regrind.
1-3Necessary Documents
The documents listed below are necessary for the operation, installation, and maintenance of Sterling SMD30 through SMD60
dryers. Additional copies are available from Sterling.
Familiarize the appropriate personnel with these documents:
; This manual.
; The schematic and assembly drawings included in the customer
information packet.
; The Customer Parts List included in the information packet.
; Operation and installation manuals for any optional controls or
auxiliary equipment in the drying system.
SMD Series Dehumidifying DryersPage 9
1-4Standard 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.
; Nema 12 control enclosure
• NFPA79 machinery electrical standards
• Non-fused electrical disconnect
• Branch fusing
• Mercury process heater contactor
• Regeneration temperature control
• Process high temperature alarm light
• Process/regeneration heater box
1-5Options
• High temperature safety system (Process/Regeneration)
Options can tailor your Sterling dehumidifying dryer to meet the
exact requirements of the drying task being performed.
; Process temperature up to 400ºF (or below 160ºF), including
pyrex sight glass and silicone insulated delivery hose.
; Drawer magnet, stainless steel construction.
; Casters, two (2) fixed and two (2) swivel.
Page 10SMD Series Dehumidifying Dryers
Figure 1
Typical SMD Dryer Components
Standard Air
Filter
High
Temperature
Switch
Heater Box
Optional Dust
Collector
Membrane
Dryer
Coalescing
0.01 Micron
Filter
Pressure
Switch
Pressure
Gage
Large Particle
Filter
Solenoid
Valve
Compressed
Air Inlet
SMD Series Dehumidifying DryersPage 11
1-6The 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.
The Moisture Vent Compressed Air Dryer, consists of thousands
of hollow-fiber membranes made of tough temperature and
pressure resistant plastic. The inside surface of these hollow fibers
is coated with an ultra-thin layer of a second plastic that performs
the actual water-vapor from air separation. This second coating
allows air to pass through it over 20,000 times easier than it allows
water to pass. As a result, moisture is expelled rapidly with very
little air loss. Two-stage drying provides the option of using the
Moisture Vent directly at the point-of-use in combination with a
refrigerated air dryer.
As a single stage unit, the dryer provides consistent performance
from 60°F to -20°F outlet dew point. When combined with a
refrigerated air dryer, the Moisture Vent system will suppress or
reduce the inlet pressure dew point to below -40°F with very low
sweep requirements.
Humid Air
Purge
Figure 2
Typical Dryer Air Flow Schematic
Dry Air
Water
Air
Dry Air
Page 12SMD Series Dehumidifying Dryers
Figure 3
SMD Series Floor-Mount Dimensions
ON
OFF
B
PROCESS
TEMPERATURE
CONTROL POWER
ON OFF
ALARM
DEW POINT
ALARM HORN
ALARM
Silencer
A
C
SMD30 and SMD60 floor-mount dimensions in inches/cm
Many variables were considered in the selection of your drying
system, including type of materials, residence time, throughput of
the extruder or injection molding machine. Should your operating
environment change, Sterling can advise you on necessary
equipment and process time and temperature modifications
required for your system.
SMD Series Dehumidifying DryersPage 13
Safety2
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. Obey these specific work rules:
Read and follow the instructions in this manual before
installing, operating, or maintaining any equipment.
Additional copies are available from Sterling.
Only qualified persons should work on, or with, this
equipment.
Work only with approved tools and devices.
Disconnect and lock out power while working on this
equipment.
2-2Tools and Equipment Needed
You’ll need the following:
• Hand tools
• Fork lift or overhead lift
• Wire, conduit, and fittings for wiring runs (if receptacle is not
already in place)
• Mounting bolts with nuts and washers
2-3 Mechanical Installation
Dryers may be mounted on a stand, or a mezzanine. Be sure it is
securely attached and additional bracing is used if necessary. The
sections on the following pages explain general installation rules.
Read manual thoroughly before installing dryer.
Use approved safety straps or chains to lift the
dryer at the marked lifting points.
Page 14SMD Series Dehumidifying Dryers
2-4Safety Considerations
The terms NOTICE, CAUTION, WARNING, and DANGER
have specific meanings in this manual. See Section 13 for a
complete list of specific safety warning information.
A NOTICE is used to indicate a statement of company policy
directly or indirectly related to the safety of personnel or protection
of property.
A CAUTION indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury.
A WARNING indicates a potentially hazardous situation which, if
not avoided could result in death or serious injury.
A DANGER indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury. This word will
be limited to the most serious situation(s).
The term IMPORTANT emphasizes areas where equipment
damage could result, or provides additional information to make a
step or procedure easier to understand. Disregarding information
marked IMPORTANT would not be likely to cause personal
injury.
REPORTING A SAFETY DEFECT
NOTE: If you believe that your equipment has a defect which could cause
injury, you should immediately discontinue its use and inform
Sterling, at our address listed in this manual.
The principle factors which can result in injury are:
1. Failure to follow proper operating and clean-out
procedures, i.e. lockout/tagout.
2. Failure to maintain a clean and safe working environment.
SMD Series Dehumidifying DryersPage 15
2-5General Responsibility
NO MATTER WHO YOU ARE…
Safety is important. Owners, operators, and maintenance
personnel must realize that every day, safety is a vital aspect of
their jobs.
If your main concern is loss of productivity, remember this:
Production is always affected in a negative way following an
accident. The following are some of the reasons, which can affect
your production:
• Loss of a skilled operator (temporarily or permanently)
• Breakdown of shop morale
• Costly damage to equipment
• Down-time
An effective safety program is responsible and economically
sound.
Organize a safety committee or group, and hold regular meetings.
Promote this group from the management level. Through this
group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the
meetings.
Hold daily equipment inspections in addition to regular
maintenance checks. You will keep your equipment safe for
production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety.
This manual contains safety warnings throughout, specific to each
function and point of operation.
2-6Operator Responsibility
The operator’s responsibility does not end with efficient
production. The operator usually has the most daily contact with
the dryer and intimately knows its capabilities and limitations.
Plant and personnel safety is sometimes forgotten in the desire to
meet incentive rates, or through a casual attitude toward machinery
formed over a period of months or years. Your 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.
Page 16SMD Series Dehumidifying Dryers
REMEMBER:
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.
Learn and always use safe operation. Cooperate with co-workers
to promote safe practices. Immediately report any potentially
dangerous situation to your supervisor or appropriate person.
•NEVER place your hands or any part of your body in any
dangerous location.
•NEVER operate, service, or adjust the dryer without
appropriate training and first reading and understanding this
manual.
•NEVER try to pull material out of the dryer with your hands
while it is running!
• Before you start the dryer check the following:
• Remove all tools from the dryer;
• Be sure no objects (tools, nuts, bolts, clamps, bars) are
laying in the hopper area;
• If your dryer has been inoperative or unattended, check all
settings before starting the unit.
• At the beginning of your shift and after breaks, verify that the
controls and other auxiliary equipment are functioning properly.
• Keep all safety guards in place and in good repair. NEVER
attempt to bypass, modify, or remove safety guards. Such
alteration is not only unsafe, but will void the warranty on your
equipment.
• When changing control settings to perform a different mode of
operation, be sure selector switches are correctly positioned.
Locking selector switches should only be adjusted by authorized
personnel and the keys removed after setting.
• Report the following occurrences IMMEDIATELY:
• unsafe operation or condition
• unusual dryer action
• leakage
• improper maintenance
• NEVER stand or sit where you could slip or stumble
into the dryer while working on it.
•DO NOT wear loose clothing or jewelry, which can be caught
while working on a dryer. In addition, cover or tie back long
hair.
SMD Series Dehumidifying DryersPage 17
• 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.
2-7Maintenance Responsibility
Safety is essential to the good health of both operator and machine.
If you are a maintenance worker, you must make safety a priority
in order to effectively repair and maintain equipment.
BEFORE REMOVING, ADJUSTING, OR REPLACING
PARTS ON A MACHINE, REMEMBER TO DO THE
FOLLOWING:
•TURN OFF all air and electric supplies and all accessory
equipment at the machine.
•DISCONNECT AND LOCK OUT electrical and pneumatic
power, and attach warning tags to the disconnect switch and air
shutoff valve.
When you need to perform maintenance or repair work on a 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 place for tools and
parts. DO NOT climb on dryers, machines, or work from ladders.
If you need to repair a large component, use appropriate handling
equipment. Before you use handling equipment (portable “A”
frames, electric boom trucks, fork trucks, overhead cranes) be sure
the load does not exceed the capacity of the handling equipment or
cause it to become unstable.
Carefully test the condition of lifting cables, chains, ropes, slings,
and hooks before using them to lift a load.
Be sure that all non-current carrying parts of electrical apparatus,
electrical component enclosures, and the dryer frame are correctly
connected to earth ground with an electrical conductor that
complies with current codes. Install in accordance with national
and local codes, which apply.
When you have completed the repair or maintenance procedure,
check your work, remove your tools, rigging, and handling
equipment.
Page 18SMD Series Dehumidifying Dryers
2-8Safety
2-8-1 Description and Objectives
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.
BEFORE you turn the dryer over to the operator for production,
verify all dryer enclosure panels, guards and safety devices are in
place and functioning properly.
This section includes information on safety devices and procedures
that are inherent to the SMD Dryer. This manual is not intended to
supersede or alter safety standards established by the user of this
equipment. Instead, the material contained in this section is
recommended to supplement these procedures in order to provide a
safer working environment.
At the completion of this section, the operator and maintenance
personnel will be able to:
• Identify and locate specific safety devices.
• Understand the proper use of the safety devices provided.
• Describe the function of the safety devices.
2-8-2 Safety Circuit Standards
Safety circuits used in industrial systems protect the operator and
maintenance personnel from dangerous energy. They also provide
a means of locking out or isolating the energy for servicing
equipment.
Various agencies have contributed to the establishment of safety
standards that apply to the design and the manufacture of
automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial Council (JIC) are
just a few of the organizations that have joined with the plastics
industry to develop safety standards.
Every effort has been made to incorporate these standards into the
design of the SMD Dryer; however, it is the responsibility of the
personnel operating and maintaining the equipment to familiarize
themselves with the safety procedures and the proper use of any
safety devices.
SMD Series Dehumidifying DryersPage 19
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. If the switch fails, it will go
to the open condition, tripping out the safety circuit.
At no time should the safety device fail and allow the operation
to continue. For example, if a safety switch is guarding a motor,
and the safety switch fails, the motor should not be able to run.
2-8-4 Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit.
The safety devices that are utilized on SMD models are primarily
concerned with the pneumatics and electrical power disconnection,
and the disabling of moving parts that may need to be accessed
during the normal operation of the machine.
Some of the safety devices utilize a manual activator. This is the
method of initiating the safety lock out. This may be in the form of
a plug, disconnect plug, lever or a handle. Within this lockable
handle, there may be a location for a padlock. Personnel servicing
the equipment should place a padlock in the lockout handle.
WARNING! Always disconnect and lockout all electrical power and pneumatic
(i.e. compressed air) sources prior to servicing or cleaning any
Dryer, including all SMD units. Failure to do so may result in
serious injury.
At no time must anyone remove the lockout or reconnect the twist
plug, other than the person who installed the lockout or who
unplugged the twist plug.
2-8-5 Lock-Outs, Plugs, and Other Safety Devices
The SMD Dryer utilizes several types of safety devices.
The Line Cord Plug
This line cord plug allows the operator or maintenance personnel
to unplug the dryer from its power source and tag it out. This plug
may be tagged with any number of approved electrical lockout
tags. These tags are available at most electrical supply stores.
WARNING!
Disconnect both of these items to ensure optimum maintenance
personnel safety when cleaning or servicing this equipment.
Page 20SMD Series Dehumidifying Dryers
-Notes-
SMD Series Dehumidifying DryersPage 21
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