Sterling SMD User Manual

$30
Operation and Installation Manual
SMD Series
Dehumidifying Dryers
Important! Read Carefully Before Attempting to Install or Operate Equipment
00
Part No. A0570029 Revision NEW Bulletin No. SM1-620
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
are subject to change without notice.
© Copyright Sterling/Sterling Material Processing 2003
All rights reserved. Effective 8/21/2003
Part No. A0570029 Revision NEW Bulletin No. SM1-620
Page 2 SMD Series Dehumidifying Dryers
Table of Contents
1 General Information ............................................................9
1-1 Models Covered .......................................................................................................... 9
1-2 Equipment Function .................................................................................................... 9
1-3 Necessary Documents ................................................................................................ 9
1-4 Standard Features..................................................................................................... 10
1-5 Options......................................................................................................................10
1-6 The Drying System.................................................................................................... 12
1-7 Specifying a Drying System ...................................................................................... 13
2 Safety.................................................................................. 14
2-1 Work Rules................................................................................................................14
2-2 Tools and Equipment Needed................................................................................... 14
2-3 Mechanical Installation .............................................................................................. 14
2-4 Safety Considerations ............................................................................................... 15
2-5 General Responsibility .............................................................................................. 16
2-6 Operator Responsibility ............................................................................................. 16
2-7 Maintenance Responsibility....................................................................................... 18
2-8 Safety ........................................................................................................................ 19
3 Shipping Information ........................................................22
3-1 Unpacking and Inspection ......................................................................................... 22
3-2 In the Event of Shipping Damages............................................................................ 22
3-3 If the Shipment is Not Complete................................................................................ 23
3-4 If the Shipment is Not Correct ................................................................................... 23
3-5 Returns......................................................................................................................23
4 Installation .........................................................................24
4-1 Work Rules................................................................................................................ 24
4-2 Rigging and Placing the Dryer................................................................................... 24
4-3 Making Electrical Connections .................................................................................. 25
4-4 Making Dryer/Drying Hopper Process Air Connections............................................. 26
4-5 Drying Hopper Air Trap Considerations .................................................................... 27
5 Controls.............................................................................. 29
5-1 Identifying Control Panel Indicator Lights and Switches for Standard Controller ...... 29
5-2 Process Air Temperature Controller.......................................................................... 31
5-3 Identifying Process Air Temperature Controller LED Indicators ................................ 32
5-4 Identifying Temperature Controller Keys................................................................... 33
5-5 Setting the Process Air Temperature ........................................................................ 33
5-6 Restoring the E5CN Temperature Controller to Factory Setup ................................. 34
5-7 Process Air Dew Point Display.................................................................................. 36
5-8 Setting the High Dew Point Alarm ............................................................................. 37
5-9 Restoring the E5CK Dew Point Meter to Factory Setup............................................ 37
5-10 Redundant Safety Controller Display ........................................................................ 38
5-11 Setting the Redundant Safety Controller................................................................... 38
5-12 Restoring the WATLOW Redundant Safety Controller to Factory Setup .................. 38
SMD Series Dehumidifying Dryers Page 3
Table of Contents
6 Control Operation.............................................................. 41
6-1 Controller Operation .................................................................................................. 41
(Without Optional Alarm Horn & Reset Button) ......................................................... 41
6-2 Controller Operation .................................................................................................. 42
(With Optional Alarm Horn & Reset Button) .............................................................. 42
6-3 Alarm Display Messages........................................................................................... 44
7 Startup, Shutdown, and Operation .................................. 45
7-1 Pre-Startup Checks ................................................................................................... 45
7-2 Starting Up the Dryer................................................................................................. 45
7-3 Shutting Down the Dryer ........................................................................................... 46
8 Maintenance....................................................................... 47
8-1 Work Rules................................................................................................................ 47
8-2 Servicing Process Air Filters ..................................................................................... 47
8-3 Servicing the Dew Point Monitor ............................................................................... 50
8-4 Replacing the Process Heater................................................................................... 50
9 Troubleshooting ................................................................ 53
10 Dryer Options ....................................................................56
11 Spare Parts ........................................................................57
11-1 Spare Parts List......................................................................................................... 57
12 Technical Assistance........................................................59
12-1 Contact Information for Technical Assistance ........................................................... 59
12-2 Returned Material Policy ........................................................................................... 60
12-3 Warranty.................................................................................................................... 61
13 Safety Tag Information .....................................................63
13-1 SMD Dryer Safety Tags ............................................................................................ 63
13-2 Dryer Identification (Serial Number) Tag................................................................... 64
Page 4 SMD Series Dehumidifying Dryers
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.
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 Dryers Page 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 6 SMD 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
2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit)
3. Humidity range: 50% relative humidity
4. Altitude: Sea level
5. Environment: Clean, dust-free and non-explosive
6. Radiation: None
7. Vibration: Minimal, i.e. machine mounting
8. Allowable voltage fluctuation: +/- 10%
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 controlrepetitive 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 Dryers Page 7
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 SMD Dryers (Floor Mount) 25
5
Dryer Hose Connections to Hopper 26
6
Typical Control Panel 30
7
Typical Temperature Controller 31
8
Setting List for Process Temperature Controller 36
9
Typical Dew Point Display Monitor 37
10 11 12 13 14
Typical Redundant Safety Controller Display 38
Setting List for Redundant Safety Controller (WATLOW) 40
Process Heater Location & Disassembly 51
Level 1 Spare Parts List (Electrical & Mechanical) 57
Level 2 & 3 Spare Parts List (Electrical & Mechanical) 58
Page 8 SMD Series Dehumidifying Dryers
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.

1-2 Equipment 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.

1-3 Necessary 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 Dryers Page 9
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.
; 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

1-5 Options

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 10 SMD 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 Dryers Page 11
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.
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 12 SMD 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
SMD30 SMD60
Dimension in. cm in. cm
A22 562564 B 12.75 32 12.75 32 C 15.5 39 15.5 39 D28 7128 71
D
1-7 Specifying a Drying System
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 Dryers Page 13
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. 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.
2-2 Tools 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 14 SMD Series Dehumidifying Dryers
2-4 Safety 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 Dryers Page 15
2-5 General 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.

2-6 Operator 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 16 SMD 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 Dryers Page 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.
2-7 Maintenance 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 18 SMD Series Dehumidifying Dryers
2-8 Safety
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 Dryers Page 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 20 SMD Series Dehumidifying Dryers
-Notes-
SMD Series Dehumidifying Dryers Page 21
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